Table of Content

15 October 2021, Volume 41 Issue s1

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Quality management of HL-2M tokamak assembly and installation 

CAI Li-jun, SONG Bin-bin, LI Lian-cai, XU Hong-bin, YANG Hong, LIN Chen, MAO Wei-cheng, HL-M Development Team

2021, 41(s1):  289-294.  DOI: 10.16568/j.0254-6086.2021s1001

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The main components of HL-2M tokamak have the characteristics of large scale, complex 
structure, compact internal space, and complex integrated assembly process and high assembly precision 
requirements. The assembly and installation of the main components are the final key process in the development 
and construction of the main components of HL-2M tokamak, which has a direct impact on the project quality and 
the total construction period. Based on the practice of HL-2M tokamak assembly and installation, taking risk 
control and process management as the general idea of quality management, quality management was carried out 
from the aspects of project planning, implementation and acceptance to effectively ensure the smooth 
implementation of the project. Through the implementation of quality management activities, the quality 
objectives for the HL-2M tokamak assembly and installation project were achieved, and HL-2M tokamak passed 
the acceptance of the expert group and the quality management experience of large scale scientific engineering 
project was accumulated. The HL-2M first discharge was successful on December 4, 2020. 


Analysis and research on the assembly process of HL-2M tokamak 

LI Lian-cai, CAI Li-jun, LIU Kuan-cheng, ZHANG Long, LIU De-quan MAO Wei-cheng, LI Qiang, HL-M Development Team

2021, 41(s1):  295-299.  DOI: 10.16568/j.0254-6086.2021s1002

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 During the HL-2M tokamak installation plan formulation period and the project construction 
process, CAD&CAE design analysis method was adopted to optimize the assembly plan for many times according 
to the requirements of system function and installation schedule. The position relationship between each system 
was checked and the installation scheme was simulated by computer. Finally, a complete and implementable 
installation process and technical scheme were formed. The assembly plan was analyzed and studied 
comprehensively, and the construction of the three-dimensional datum network, the measurement of key 
components, the insulation and cushion process plan, and the magnetic permeability control of the key 
components of device are summarized and discussed in this work, to provide valuable design and assembly 
reference for the construction and development of the fusion reactor in the future. 


Research of the assembly and installation schedule control for HL-2M tokamak 

LI Lian-cai, CAI Li-jun, MAO Wei-cheng, YANG Qing-wei, LI Qiang, WANG Quan-ming, FENG Yong-jin, LI Yong-ge, LIN Chen, ZHANG Long, HL-M Development Team

2021, 41(s1):  300-306.  DOI: 10.16568/j.0254-6086.2021s1003

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The assembly and installation work for large tokamak device features lots of sub-projects, many 
interfaces, small working space, complex systems and many joining personals highlighting the importance of a 
good control of the overall schedule. Based on the risk management of project schedule, this paper makes a 
thorough analysis of the risk factors in the assembly and installation schedule control for HL-2M tokamak and 
explores an effective operating mode for the schedule control system. It is expected that this operating mode can 
provide guarantee to the controllable schedule risk factors and achievable schedule control objectives, and offer 
some experiences to standardized and industrialized development for the assembly and installation of China’s 
large magnetic confinement fusion devices. 


Structural design and fabrication of HL-2M poloidal field coils

ZOU Hui, LI Guang-sheng, QIU Yin, LIU Xiao-long, LIU Jian, SHAN Ya-nong, LI Qiang, HL-M Development Team

2021, 41(s1):  307-311.  DOI: 10.16568/j.0254-6086.2021s1004

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The structure design and fabrication of HL-2M poloidal field (PF) coils were introduced. Sixteen 
PF coils are situated between the toroidal field coils and the vacuum vessel, and symmetrically with respect to the 
mid-plane. The PF coils were wound with hollow rectangular copper conductor, among which PF1~PF4 coils are 
of double-layer spiral winding structure and the maximum running current is 14.5kA, PF5~PF8 coils are of 
multi-layer disc winding structure and the maximum running current is 38~42kA. 


Engineering development and commissioning of HL-2M toroidal field coils 

LIU Xiao-long, LI Guang-sheng, ZOU Hui, QIU-Yin, SHAN Ya-nong, CAI Li-jun, LIU Jian, HL-M Development Team

2021, 41(s1):  312-315.  DOI: 10.16568/j.0254-6086.2021s1005

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The design, key manufacturing process and commissioning results of HL-2M toroidal field (TF) 
coils were introduced. The toroidal magnetic field of 0.66T was generated by TF coils at the maximum current 
42kA, which meets the requirement of the first plasma discharge on HL-2M tokamak. 


Overview of the structure and manufacturing process of the central solenoid coil in HL-2M tokamak

QIU Yin, LI Guang-sheng, ZOU Hui, LIU Xiao-long, SHAN Ya-nong, LIU Jian, CAI Li-jun, LI Qiang, HL-M Development Team

2021, 41(s1):  316-320.  DOI: 10.16568/j.0254-6086.2021s1006

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The central solenoid (CS) coils of HL-2M tokamak are divided into alternately wound two groups, 
i.e., groups A and B, the inner and outer layers in each group are axially reversely wound, and the leads of the two 
groups are drawn out symmetrically. During the manufacturing process of the CS coils, brazing process of the 
hollow copper wire, insulation wrapping process, winding process, jumper connection of inner and outer layer 
process, heating and curing process and other tests were carried out. The made coils meet the design requirements 
of the main insulation withstand voltage of 60kV and the inter-turn withstand voltage of A/B group of 1kV. 


Research on the positioning measurement technology for the installation of the HL-2M magnet system

ZHANG Long, LIU Jian, LAI Chun-lin, LIU Kuan-cheng, ZA Fang-zheng, CAI Li-jun, LU Yong, HUANG Wen-yu, HL-M Development Team

2021, 41(s1):  321-326.  DOI: 10.16568/j.0254-6086.2021s1007

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 To improve the magnet system installation accuracy, 63 reference points were installed in the 
HL-2M hall to form a measurement reference network. The local coordinates of the characteristic points on every 
coil were measured with the established local coordinate system and the high-precision measuring equipment such 
as the laser tracker. And then the coordinates of these points were converted to the installation coordinate system 
through the reference network and the best fit, which could be used for the positioning of the coils. When the 
integration of these coils was completed, the coaxality between the center column of toroidal field (TF) coils and 
the supporting foundation was ∅2.03mm. The elevation deviation of the PF1~4 coils was±0.5mm, and the 
coaxality with the center column was ∅2.60mm. The coaxality between the PF5~8 coils and the center column 
was below ∅3.00mm, and the elevation deviation of these coils was within the interval of [−1mm, 1mm]. So, the 
installation accuracy of these coils meet the installation requirements. 


Structure design of HL-2M tokamak vacuum vessel 

RAN Hong, CAO Zen, TANG Le, SONG Bin-bin, HOU Ji-lai, HUANG Yun-cong, CAI Li-jun, LI Yong

2021, 41(s1):  327-331.  DOI: 10.16568/j.0254-6086.2021s1008

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HL-2M tokamak vacuum vessel (VV) is designed with a D-shaped, double thin-wall structure. The 
whole torus is welded with 20 sectors and is supported by 5 trunnions locating in the equatorial plane to absorb 
thermal displacement at the baking. There are 121 ports to meet the demands of pumping、diagnosis、heating and 
installing. Inconel 625 is selected as the main material of the VV. Design analyses have be done. The results show 
that vacuum vessel structure can meet the design requirements of the machine. 


Difficulty analysis and optimization of manufacturing process of HL-2M vacuum vessel

SONG Bin-bin, RAN Hong, HUANG Yun-cong, HOU Ji-lai, TANG Le, HL-M Development Team

2021, 41(s1):  332-336.  DOI: 10.16568/j.0254-6086.2021s1009

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According to the structure and operating conditions of HL-2M vacuum vessel, the technical 
difficulties in the manufacturing process of HL-2M vacuum vessel are analyzed in depth. Combined with the 
manufacturing experience of the earlier test section, the manufacturing process of the vacuum chamber was 
optimized and the manufacturing process scheme of the vacuum chamber products was refined. Through the 
implementation of the optimized process measures, the manufacturing quality of the vacuum vessel is improved, 
and accumulated a lot of experience for the subsequent manufacturing of tokamak vacuum vessel. 


Welding and permeability control technology in HL-2M vacuum vessel manufacturing

HOU Ji-lai, RAN Hong, SONG Bin-bin, HUANG Yun-cong, CAO Zeng, TANG Le

2021, 41(s1):  337-340.  DOI: 10.16568/j.0254-6086.2021s1010

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Based on the development practice of HL-2M vacuum vessel, this paper introduces the high air 
tightness welding process of Inconel625, which can effectively reduce the occurrence of weld leakage and ensure 
that the ultimate vacuum of the vacuum vessel can reach 10⁻⁶Pa. In addition, the permeability control technology 
of 316L in the manufacturing process is introduced, so that the relative permeability of parts after processing is 
kept at μ< 1.04. 


Research and implementation of stud welding process in HL-2M vacuum vessel 

LAI Chun-lin, LIU Yu-xiang, CAI Li-jun, LIU Xiao-yu, GU Hong-gang, LIU Jian, LU Yong, HUANG Yun-cong

2021, 41(s1):  341-345.  DOI: 10.16568/j.0254-6086.2021s1011

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For the in-vessel stud welding of HL-2M vacuum vessel, this paper introduces a detailed study on 
the structure design of welding stud, welding process scheme, welding process test, welding quality evaluation, 
etc. Finally, the welding parameters including welding current, welding time, extension length, lifting height, total 
lifting height and other welding parameters, as well as the position of grounding and the direction of welding 
torch are determined. Through a large number of process tests, the welding problem of HL-2M vacuum vessel 
wall (5mm, Inconel625 material) - large diameter stud (∅12mm, 316L) has been solved effectively. The weld has 
uniform shape, less spatter and weld bead, and the surface blackening is obviously improved, which meets the 
requirements of vacuum cleanliness; moreover, the welding stability and yield are relatively high, and the tensile 
test and fatigue test also meet the design requirements.


Study of installation for the first wall of HL-2M first plasma

HUANG Wen-yu , LI Lian-cai, CAI Li-Jun, LIU Yu-xiang, LAI Chun-lin, LIU Xiao-yu, LIU Kuan-cheng, SONG Bin-bin, HL-M Development Team

2021, 41(s1):  346-350.  DOI: 10.16568/j.0254-6086.2021s1012

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The first wall for the HL-2M first plasmas is mainly composed of 2mm thick guard plates and 
affiliated supports, which together with the limiters form the protection layer for inner wall of HL-2M vacuum 
vessel. According to the structural design of the first wall and the overall installation specifications of HL-2M 
tokamak, the overall installation process plan of the first wall was proposed. The supports of the first wall were 
fixed by stud welding and argon arc welding. The assistant tools that can adjust the positioning accuracy of the 
parts by the use of studs were applied, and the laser tracker is used to adjust the installation accuracy in real time 
throughout the process. Finally, the overall installation of the first wall of the HL-2M initial plasma is completed. 
The component installation accuracy reaches ±2mm, the weld quality meets the requirements of the first level 
weld, and the structure can withstand a tensile force of more than 3675N.The first wall works well during the 
HL-2M first plasma discharges. 


Structure design and process analysis of limiter system for the HL-2M tokamak 

LU Yong, CAI Li-jun, HUANG Wen-yu, LIU Yu-xiang, LAI Chun-lin, LIU Jian, ZHANG Wei, LI Zai-xin

2021, 41(s1):  351-354.  DOI: 10.16568/j.0254-6086.2021s1013

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There are 8 sets of the unmovable limiter and 1 set of the moveable limiter in HL-2M tokamak, in 
order to protect the vacuum vessel and its in-vessel components. Besides, the moveable limiter would also provide 
the different plasma configurations for HL-2M physics experiments. Based on the operation requirements of 
HL-2M device, the moving distance of the moveable limiter must be larger than 120 mm, and its moving 
precision need to below 0.1mm. During the assembly of HL-2M limiter system, the laser tracker was used to meet 
the high accuracy requirement, and its assembly results show that the installation tolerance of the plasma facing 
components on the limiter is less than 0.5mm. The first plasma operation experiment results of HL-2M tokamak 
show that all of the limiter components operate well. 


Development of HL-2M vacuum pre-pumping system 

CAI Xiao, CAO Zeng, ZHANG Wei, LI Rui-jun, RAN Hong, CAI Li-jun

2021, 41(s1):  355-359.  DOI: 10.16568/j.0254-6086.2021s1014

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HL-2M vacuum pre-pumping system is composed of four turbo molecular pump units and four 
cryo-pump units. Vacuum degree of 2.3×10⁻⁶Pa was achieved, after 100℃ baking of the vacuum chamber, which 
exceeded the design requirement and satisfied HL-2M plasma discharges. 


Engineering commissioning of HL-2M vacuum system

CAO Cheng-zhi, CAO Zeng, RAN Hong, XIE Yan-feng, CAI Xiao, JI Xiao-quan, ZHONG Wu-lü, YANG Qing-wei, MAO Wei-cheng, HL-M Development Team

2021, 41(s1):  360-365.  DOI: 10.16568/j.0254-6086.2021s1015

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In the phase of initial completion of the device, the clarification on the items of engineering 
commissioning of vacuum and the development of reasonable commissioning scheme are conducive to the 
functional confirmation, troubleshooting, and the efficient coordinated operation of various systems. And it can 
prepare discharge conditions for the initial plasma discharge of HL-2M tokamak. The vacuum system of device 
consists of the ultra-high vacuum pumping system, the wall conditions and the gas injection system. Based on the 
defined objective, the interface sheets are sorted out, and the commissioning schemes and schedules are 
formulated for each subsystem and integrated system. The preparation of the vacuum environment, first wall and 
fueling of the device has been completed, and it provides essential conditions for the first plasma of HL-2M 
tokamak. 


Development of the DC glow discharge cleaning system for HL-2M first plasma discharges

CAO Cheng-zhi, CAO Zeng, CUI Cheng-he, GAO Xiao-yan, HE Yi, HUANG Xiang-mei, ZHOU Jun, LI Bin-bin, , HL-M Development Team

2021, 41(s1):  366-370.  DOI: 10.16568/j.0254-6086.2021s1016

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Based on the engineering requirements of the first plasma discharge of HL-2M, a DC glow 
discharge cleaning (GDC) system was designed and developed, including electrode, feed through, power supply, 
control and monitoring etc. components and auxiliary sub-system. In addition, the manufactured components are 
assembled, the system engineering commissioning has been completed, and it was implemented for the first 
discharge. The results show that the DC GDC system is stable and reliable, and the GDC cleaning notably reduce 
the main impurities in vacuum chamber. This system can meet the wall condition requirements of HL-2M first 
plasma discharge. 


Design and assembly process for the thermal insulation of the HL-2M vacuum vessel 

HUANG Yun-cong, RAN Hong, TANG Le, HOU Ji-lai, SONG Bin-bin, CAI Li-jun, CAO Zeng

2021, 41(s1):  371-376.  DOI: 10.16568/j.0254-6086.2021s1017

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Based on the requirements of HL-2M baking insulation requirement, it was determined that 
ceramic fiber and nanoscale microporous material were used as insulation material for HL-2M vacuum vessel 
through finite element analysis and prototype test. It is found that the thermal conductivity of the insulation layer 
is less than 0.027W⋅m−1·℃⁻¹ at 30℃ and less than 0.038W⋅m⁻¹·℃⁻¹ at 300℃. For the chosen insulation layer of 
25mm thick, when the temperature of the hot surface is 300℃ and reaches a steady state, the cold surface can be 
controlled below 85℃, the temperature of the coil side is lower than 60℃, and the overall heat loss is less than 
12kW, which meets the baking requirements of the HL-2M vacuum vessel. 


Design of HL-2M vacuum baking system

CAI Qiang, JIA Rui-bao, MENG Jian-peng, QIU Li-yuan, XIE Yan-feng

2021, 41(s1):  377-382.  DOI: 10.16568/j.0254-6086.2021s1018

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The HL-2M vacuum baking system use two PLCs (Programmable logic Controller) to form an 
automatic control system, and compile the corresponding logic program according to the process requirements to 
control each actuator, realize the program adjustment of the system heater electric power, heat exchanger heat load 
and valve opening, and achieve the purpose of baking with a temperature rise gradient of ±2℃. The PLC 
establishes the profinet communication protocol with the valve island, and controls the on-off valves in and out of 
the vacuum chamber and the divertor through address mapping and adjusts the load input of the baking system. 


Engineering design and flow analysis of HL-2M vacuum baking system 

JIA Rui-bao, MENG Jian-peng, CAO Cheng-zhi, CAI Qiang, QIU Li-yuan, XIE Yan-feng

2021, 41(s1):  383-387.  DOI: 10.16568/j.0254-6086.2021s1019

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The HL-2M vacuum baking system is designed from the aspects of process, structure and 
equipment. Simulation analysis is carried out for constant flow condition. At the total flow rate of 2.5kg⋅s⁻¹, the 
vacuum vessel flow rate of 2.1kg⋅s⁻¹ and the divertor flow rate of 0.21kg⋅s⁻¹, the baking effect of the system was 
verified. 


Simulation analysis and optimization of piping stress in baking system of HL-2M tokamak 

MENG Jian-peng, JIR Riu-bao, CAI Qiang, QIU Li-yuan, XIE Yan-feng

2021, 41(s1):  388-391.  DOI: 10.16568/j.0254-6086.2021s1020

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According to pipeline design of baking system in HL-2M tokamak, the piping stress calculation 
model of baking system is established. The pipeline initial support of baking system is designed, and the 
maximum temperature distribution in the system is used to calculate the thermal stress of baking system, and 
analyze the pipeline stress and the load of equipment nozzle. Based on the results of thermal stress calculation, the 
pipeline layout was optimized, the design of support was improved, the stress of baking system was checked, the 
reliability of baking system was verified, the calculation of nozzle displacement was complete. 


Introduction of the HL-2M cooling water system 

MENG Jian-peng, JIA Rui-bao, CAI Qiang, QIU Li-yuan, XIE Yan-feng, HL-M Development Team

2021, 41(s1):  392-396.  DOI: 10.16568/j.0254-6086.2021s1021

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The HL-2M cooling water system, the circulation flow, operating principle and parameters of each 
subsystem were introduced. 


Design of support structure of HL-2M tokamak 

LIU De-quan, QIAO Tao, LIN Tao, CAO Cheng-zhi, CAI Li-jun, LI Qiang

2021, 41(s1):  397-401.  DOI: 10.16568/j.0254-6086.2021s1022

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The support structure system of HL-2M tokamak consists of the machine basic and gravity support 
structure, poloidal field coils and vacuum vessel support structure, and the toroidal field coil anti-torque and 
preload structure. The engineering design of the support structure is introduced. 


Evaluation of the electromagnetic behavior of HL-2M poloidal field coils and the mechanical performance of the supporting structure

ZHANG Long, YUAN Ying-long, CAI Li-jun, LIU Jian, LU Yong, LIU Yu-xiang, LIU Kuan-cheng, LI Yun-feng, HL-M Development Team

2021, 41(s1):  402-408.  DOI: 10.16568/j.0254-6086.2021s1023

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Based on the two-dimensional axisymmetric model, the electromagnetic (EM) response of the PF 
coils at the discharge initial time, climbing phase, flat top and current drop phase under various plasma 
configuration is researched. At the same time, the mechanical performance under the extreme conditions is also 
evaluated. The study shows that at the discharge initial time, the vertical EM force of the PF6 coils is the largest 
and reaches 1.9MN. At the end of the discharge top phase, the vertical EM force of the PF5L coil is the largest and 
can be up to 2.6MN in the tripod configuration and 2.06MN in the snowflake and double null configurations. 
Under such extreme conditions, the structural mechanical evaluation of the support shows that it has the local 
plastic deformation. Using ASME VIII.2 as the criterion to evaluate the local high-stress area, the evaluation 
shows that there is no plastic collapse and local failure of the structure. In addition, the axial force of the bolt at 
the inner support near the upper main beam is the largest, and a pre-tightening force must be greater than 50kN. 


Analysis of anti-torsion structure of HL-2M tokamak 

LIN Tao, LIU De-quan, CAI Li-jun, LI Qiang, QIAO Tao

2021, 41(s1):  409-414.  DOI: 10.16568/j.0254-6086.2021s1024

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According to the lateral force and radial force produced by the toroidal field coils, an anti-torsion 
support structure is proposed. This scheme can reduce the influence of these two forces on TF coil, and ensure the 
close contact of coil interface and the relative dislocation of insulation layer. In this paper, the anti-torsion 
structure is calculated and analyzed to determine the stress mode and force transmission path of the structure. The 
results show that the stress and displacement of the structure can meet the design requirements under the 
experimental operation and extreme conditions. Through fatigue calculation, it is concluded that the anti torsion 
support structure can meet the experimental operation for more than 20 years, and ultimately ensure the safe, 
stable and reliable operation of HL-2M tokamak. 


Design of the toroidal field coil preloading system on HL-2M tokamak

LIN Tao, LIU De-quan, CAI Li-jun, LI Qiang, QIAO Tao

2021, 41(s1):  415-419.  DOI: 10.16568/j.0254-6086.2021s1025

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According to the detachable toroidal field (TF) coil structure of HL-2M tokamak, horizontal 
preloading mechanism is adopted to preload the TF coil at the upper and lower ends of the "D" shaped coil. When 
the TF coil carries large current and endures large electromagnetic force, the preload and prestress of TF coil 
connecting bolts can ensure that the connection surface does not separate. Due to the requirements of 
synchronization and consistency, the system adopts hydraulic synchronous lifting mechanism, and uses pressure 
sensor to monitor the preload value in real time. The system ensures the safety of TF coil in the whole discharge 
experiment stage and provides the overall safety of HL-2M tokamak. 


Manufacturing technology of HL-2M support system

QIAO Tao, LIU De-quan, LIN Tao, ZHENG Xiao-zhou, HL-M Development Team

2021, 41(s1):  420-424.  DOI: 10.16568/j.0254-6086.2021s1026

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The magnetic permeability of HL-2M support system was controlled within the design value, i.e. 
≤1.03, when the special nitrogen control stainless steel was adopted, the GMS310 welding wire and Ar (96%) + 
N2 (4%) shielding gas were employed in welding, and the scheme of low speed and large feed rate in machining 
process was performed. In order to ensure the precise positioning of the coil system during assembly, it was 
necessary to preinstall the poloidal field coils support subsystem in development stage. 


Installation and location of magnetic measurement sensors  on the HL-2M tokamak 

LIANG Shao-yong, ZHANG Jun-Zhao, SUN Teng-fei, JI Xiao-quan, LIU Jian, HL-M Development Team

2021, 41(s1):  425-430.  DOI: 10.16568/j.0254-6086.2021s1027

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The installation precision order of magnetic sensors is analyzed by numerical evaluation. The R 
and Z coordinate error of the flux loops is within ±2.0mm, and the R, Z error of the magnetic probes is within 
±1.0mm and θ error ±0.1°. The locator devices adopt the high-precision laser tracker and the arm-measuring 
machine, which have a positioning accuracy of 0.3mm. According to the installation characteristics of different 
kinds of magnetic sensors, the location structures of sensors including the flux loops, magnetic probe arrays, 
diamagnetic loops, are optimized and designed. The installation accuracy of magnetic measurement sensors on the 
HL-2M tokamak is controlled within 0.5mm. 


Development of safety interlock system for the first plasma operation on HL-2M tokamak

SUN Jiang, XIA Fan, LI Bo, SONG Xiao, WANG Shuo, CHEN Yu-hong, HU Hao-tian, SONG Xian-ming

2021, 41(s1):  431-436.  DOI: 10.16568/j.0254-6086.2021s1028

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A central safety interlock system based on PLC slow control is established to make sure the safety 
performance of the first plasma on HL-2M tokamak. The system is referred to the safety interlock design of ITER. 
A gigabit fiber star network is adopted to realize the communication between the systems. The central safety 
interlock system coordinates with its subsystems to carry out the protection actions according to the failure risk 
level and the preset failure handling mechanism. The WINCC monitor screen displays the operating status and 
fault information of each subsystem. The EPICS CA protocol and S7 nodave driver are used to realize the soft 
IOC reading PLC variables, and combined with C# programming to realize the control of the access system of the 
HL-2M hall. The central safety interlock system has been deployed, with an average scanning period of 1~3ms, 
which meets the safety interlock protection requirements in the first plasma discharge of HL-2M tokamak.