Introduction to W7-X Coil Testing at CEA – Saclay, France G.Croari – March 2008

2 1.Test facility description 2.Coil test procedure 3.Main difficulties 4.Conclusion Outline

3 G.Croari – March Test facility description 2.Coil test procedure 3.Main difficulties 4.Conclusion Outline a.Cryostats, valve boxes, satellite b.Power supply c.Pumping system d.Cryogenic part (Refrigerator/liquifier) e.Data acquisition system

4 G.Croari – March Test facility description 2.Coil test procedure 3.Main difficulties 4.Conclusion Outline a.Cryostats, valve boxes, satellite b.Power supply c.Pumping system d.Cryogenic part (Refrigerator/liquifier) e.Data acquisition system a.Documentation b.Incoming Inspection tests c.Coils into cryostat d.Outgoing check

5 G.Croari – March Test facility description 2.Coil test procedure 3.Main difficulties 4.Conclusion Outline a.Cryostats, valve boxes, satellite b.Power supply c.Pumping system d.Cryogenic part (Refrigerator/liquifier) e.Data acquisition system a.Documentation b.Incoming Inspection tests c.Coils into cryostat d.Outgoing check a.DC test b.Leaks c.Detail of some coils

6 G.Croari – March Test facility description 2.Coil test procedure 3.Main difficulties 4.Conclusion Outline a.Cryostats, valve boxes, satellite b.Power supply c.Pumping system d.Cryogenic part (Refrigerator/liquifier) e.Data acquisition system a.Documentation b.Incoming Inspection tests c.Coils into cryostat d.Outgoing check a.DC test b.Leaks c.Detail of some coils a.My contribution

7 G.Croari – March 2008 a)Cryostats, valve boxes, satellite b)Power supply c)Pumping system d)Cryogenic part (Refrigerator/liquifier) e)Data acquisition system Test Facility Description 1. Test Facility Description

8 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Cryostat 1 Test Frames Satellite Valve box C 2 Valve box C 1 Cryostat 2

9 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Valve box C 1 Valve box C 2 Satellite Power Supply terminals

10 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Connections for Coil A Nitrogen Shield Connections for Coil B Cryostat detail

11 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Current leads Valve box detail

12 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Valves Valve box detail

13 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Safety Valves Calibration Leak Cablings Valve box detail

14 G.Croari – March 2008 Test Facility Description Power Supply Test Facility Description Power Supply Simplified schematicInput: 380 Vac 3-phase IoutTransformerThristorsLoad

15 G.Croari – March 2008 Test Facility Description Power Supply Test Facility Description Power Supply Input: Max absorption 980 A Nominal Power 700 KVA Water cooled Output: Max current 25KA Max Voltage 10V Regulation: <+-10 E-4 on inductive Loads <+-10 E-3 on resistive Loads

16 G.Croari – March 2008 Test Facility Description Pumping System Test Facility Description Pumping System

17 G.Croari – March 2008 Test Facility Description Pumping System Test Facility Description Pumping System Primary system

18 G.Croari – March 2008 Test Facility Description Pumping System Test Facility Description Pumping System Secondary system

19 G.Croari – March 2008 Test Facility Description Pumping System Test Facility Description Pumping System Diffusion pump Vane pump Secondary systemPrimary system Root pumps

20 G.Croari – March 2008 Test Facility Description Cryogenic part: Refrigerator / Liquifier Test Facility Description Cryogenic part: Refrigerator / Liquifier Cold Box Nitrogen Exchanger Heat Exchanger Turbine Cold Helium

21 G.Croari – March 2008 Test Facility Description Cryogenic part Refrigerator / Liquifier Test Facility Description Cryogenic part Refrigerator / Liquifier Specifications of cold part: Total mass flow rate gr/sec 300 K Refrigerating power = 4,2 K LHe production = 70 Lt / hour 5000 Litres LHe tank

22 G.Croari – March 2008 Test Facility Description Data Acquisition System Test Facility Description Data Acquisition System Signals: Voltage drops Mass flow meters Current of Power Supply Pressure drops Temperature Strain gauges Extensometer Coils Coils & Test Facility

23 G.Croari – March 2008 Test Facility Description Data Acquisition System Test Facility Description Data Acquisition System Measurement on coils: Temperature sensors Strain Gauges Extensometer

24 G.Croari – March 2008 Test Facility Description Data Acquisition System Test Facility Description Data Acquisition System Sensors VoltageCurrentOthers Condition Cool down / Warm up (phase 1)0.025Hz Cold Test day (phase 2)1Hz Quench / Fast Discharge (quench)5kHz 100Hz

25 G.Croari – March 2008 a)Documentation b)Incoming Inspection tests c)Coils into cryostat d)Outgoing check Coil Test Procedure 2. Coil Test Procedure

26 G.Croari – March 2008 Coil test procedure Documentation Scope and Requirements

27 G.Croari – March 2008 Coil test procedure Documentation Scope and Requirements Documentation

28 G.Croari – March 2008 Coil test procedure Documentation Scope and Requirements Documentation Non Conformrmity Report

29 G.Croari – March 2008 Coil test procedure Incoming Inspection Tests Unloading from the lorry

30 G.Croari – March 2008 Coil test procedure Incoming Inspection Tests Unloading from the lorry Installation under a test frame

31 G.Croari – March 2008 Coil test procedure Incoming Inspection Tests Unloading from the lorry Installation under a test frame Bending and Joint box installation

32 G.Croari – March 2008 Coil test procedure Incoming Inspection Tests Unloading from the lorry Installation under a test frame Bending and Joint box installation Cablings and tests: Temperature sensors, Strain gauges, Extensometers

33 G.Croari – March 2008 Coil test procedure Incoming Inspection Tests Unloading from the lorry Installation under a test frame Bending and Joint box installation Cablings and tests: Temperature sensors, Strain gauges, Extensometers QD Wire check, DC insulation test

34 G.Croari – March 2008 Coil test procedure Coils Into Cryostat Coil at open cryostat: QD wire check, DC test

35 G.Croari – March 2008 Coil test procedure Coils Into Cryostat Coil at open cryostat: QD wire check, DC test Under Vacuum: Leak test Calibration leak Coil leak

36 G.Croari – March 2008 Coil test procedure Coils Into Cryostat At open cryostat: QD wire check, DC test Under Vacuum: Leak test Coils at cryogenic temperature: Current test, AC test, DC test

37 G.Croari – March 2008 Coil test procedure Coils Into Cryostat At open cryostat: QD wire check, DC test Under Vacuum: Leak test Coils at cryogenic temperature: Current test, AC test, DC test AC test is to test the interlayer insulation

38 G.Croari – March 2008 Coil test procedure Coils Into Cryostat At open cryostat: QD wire check, DC test Under Vacuum: Leak test Coils at cryogenic temperature: Current test, AC test, DC test DC test is a general check of insulation

39 G.Croari – March 2008 Coil test procedure Outgoing check Before shipment: QD wire check Outgoing check

40 G.Croari – March 2008 a)DC test b)Leaks c)Detail of some coils Main Difficulties 3. Main Difficulties

41 G.Croari – March 2008 Main Difficulties DC Tests Coil Arrival Coil Departure Room T After warm up Cryo T

42 G.Croari – March 2008 Main Difficulties DC Tests Coil Arrival Coil Departure Room T After warm up 100% OK about 30% OK If it failed at Cryo T It fails at room T too Cryo T about 70% Not OK

43 G.Croari – March 2008 Main Difficulties DC Tests DC test failures: possible explanations In the coil In the test facility Ground Insulation QD wires Cryostat connections Hydraulic connections Holding system

44 G.Croari – March 2008 Critical points on the coil: Ground Insulation Main Difficoulties DC Tests

45 G.Croari – March 2008 Critical points on the coil: Ground Insulation Main Difficulties DC Tests

46 G.Croari – March 2008 Critical points on the coil: Ground Insulation QD Wires Main Difficulties DC Tests

47 G.Croari – March 2008 Critical points on the test facility: Cryostat connections (QD bucket) Main Difficulties DC Tests

48 G.Croari – March 2008 Critical points on the test facility: Cryostat connections (QD bucket) Hydraulic connections Main Difficulties DC Tests Internal view of a valve box

49 G.Croari – March 2008 Critical points on the test facility: Cryostat connections (QD bucket) Hydraulic connections Holding system Main Difficulties DC Tests

50 G.Croari – March 2008 Main Difficoulties Leaks Coils Test facility AAB10 welding during current test (03/08/2007) Valve box potential breaker (28/03/2007)

51 G.Croari – March 2008 Main Difficulties Detail of some coils AAB10: Helium leak during current test 12345

52 G.Croari – March 2008 Main Difficulties Detail of some coils AAB54: Too high joint boxes resistance Electrical Contacts Warm up the coil and redo the test

53 G.Croari – March Conclusion a)My Contribution

54 G.Croari – March 2008 Conclusion Coil testing is about 60 % accomplished The testing rate increased significantly from 2 coils / year in 2003 up to 18 coils / year in 2007 A failure can be considered as a chance to learn more

55 G.Croari – March 2008 Conclusion My contribution Daily communication between CEA and IPP Documentation in case of unexpected behaviour during test Understanding of the test facility

56 G.Croari – March 2008 Conclusion My contribution What I would like to improve: La Langue Française Control Systems Data Acquisition Systems

57 G.Croari – March 2008 Thanks to... CEA: L.Genini B.Renard L.Vieillard All the French technicians IPP: K.Hertel H.Viebke J.Baldzuhn H.Ehmler