The HL-3 tokamak has achieved plasma currents exceeding 1 MA in high-confinement H-mode operations, pushing the boundaries of fusion research and offering new scientific insights. However, this advancement poses significant engineering challenges related to machine safety due to increased thermal loads and electromagnetic forces. To address these challenges, an integrated real-time machine monitoring and safe operation system has been developed, featuring real-time monitoring, interlock protection, data analysis, and centralized control. This system oversees critical components such as coils, vacuum vessel, plasma-facing elements, and auxiliary systems like cooling and gas injection. A hydraulic preload system optimizes preload forces on the toroidal field coils, reducing mechanical stresses and enhancing structural integrity. To mitigate risks from uncontrolled plasma disruptions, a Shattered Pellet Injection (SPI) system has been implemented. This system injects pellets composed of hydrogen, deuterium, neon, or argon to rapidly dissipate plasma energy, significantly reducing mechanical stresses and potential damage. Operational results at plasma currents up to 1.6 MA demonstrate the effectiveness of these measures, with successful monitoring and control of displacements and accelerations in vital components. These advancements have effectively addressed safety challenges, allowing high-performance operation without compromising machine integrity. Future work will focus on safely increasing plasma currents beyond 1 MA and achieving higher toroidal magnetic fields, addressing new engineering challenges while maintaining safety as the paramount priority.
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