NCSX NCSX Planar Coil "ASIPP" Presentation 1 December 8-10, 2005 Michael Kalish NCSX TF and PF Coils

NCSX NCSX Planar Coil "ASIPP" Presentation 2 December 8-10, 2005 Outline Design –TF Coil Assembly –PF Coils Analysis and Test Fabrication Topics for Discussion

NCSX NCSX Planar Coil "ASIPP" Presentation 3 December 8-10, 2005 NCSX Coil Planar Coils TF Coils Upper PF Coils Lower PF Coils

NCSX NCSX Planar Coil "ASIPP" Presentation 4 December 8-10, 2005 TF Coil Subassembly D Shaped Wedging Coil SS castings on leading edge 3x4 Cross-section Solid Copper Conductor LN2 Cooled Coil Winding + Wedge Castings = TF Coil Subassembly

NCSX NCSX Planar Coil "ASIPP" Presentation 5 December 8-10, 2005 TF Coil ½ Field Period TF Coils Assembled into Field Periods Field Periods Assembled over MCWF

NCSX NCSX Planar Coil "ASIPP" Presentation 6 December 8-10, 2005 TF Coil Assembly on MCWF TF Coils are rotated onto the Modular Coil Winding Form as an assembly

NCSX NCSX Planar Coil "ASIPP" Presentation 7 December 8-10, 2005 Support Structure Reacts Critical Loads Reaction Loads –In Plane EM reacted by wedging –Out of Plane EM and Gravity by structure –Radial pre-load required to ensure wedging Wedging Out of Plane Vertical / Gravity Top and Bottom Radial Pre-load Top and Bottom

NCSX NCSX Planar Coil "ASIPP" Presentation 8 December 8-10, 2005 Jack Screw Device Pulls Coil Forward Bellville washers ensure constant 4000 lbf load

NCSX NCSX Planar Coil "ASIPP" Presentation 9 December 8-10, 2005 Structures / Exploded View Structure designed as castings Must be low magnetic permeability PPPL would like to consider fabrication of these structures by ASIPP

NCSX NCSX Planar Coil "ASIPP" Presentation 10 December 8-10, 2005 Structure adjusts to account for tolerance build up Out of plane adjustments with outer leg restraints Upper and Lower supports provide vertical adjustment In plane installed perturbations less than +/- 3mm inboard and +/- 6mm outboard Out of plane installed perturbations less than +/- 3mm

NCSX NCSX Planar Coil "ASIPP" Presentation 11 December 8-10, 2005 Winding Pack Insulation Design 3/8” Groundwrap on outboard leg 1/8” Groundwrap on inboard wedging leg Kapton Tape applied directly to conductor to enhance turn to turn dielectric standoff and allow for decoupling of insulation from conductor during cool down. Inner TF leg ground wrap thickness is 1/8” Outer leg of TF coil allows for the use of tough 3/8” ground wrap

NCSX NCSX Planar Coil "ASIPP" Presentation 12 December 8-10, 2005 Turn To Turn Voltage Standoff Requirement Electrical Requirements –TF Coils in Series –Voltage standoff to resist maximum operating voltage of 4KV Turn to Turn dielectric standoff exceeds requirement by substantial margin. Electrical Testing of Prototype TF winding pack bar before and after mechanical cycling shows insulation scheme has large margins. Tested to 5kV with 0 micro amps Then to 20 kV with.3 micro amps leakage

NCSX NCSX Planar Coil "ASIPP" Presentation 13 December 8-10, 2005 Winding Pack Insulation Design Half Lap Layer of Kapton to provide primary dielectric strength Three half lap layers of glass are applied on top of the Kapton tape to make up the turn to turn insulation

NCSX NCSX Planar Coil "ASIPP" Presentation 14 December 8-10, 2005 Ground Plane Voltage Standoff Requirement Electrical Requirements –TF Coils in Series –Voltage standoff to resist maximum operating voltage of 4KV –Design Voltage Standoff to ground is 20KV Testing of Prototype TF winding pack bar before and after mechanical cycling shows insulation scheme has adequate margins. Tested to 15kV with 0 micro amps leakage Brought to 60kV at 44 micro amps (corona with surface contamination)

NCSX NCSX Planar Coil "ASIPP" Presentation 15 December 8-10, 2005 TF Coil Lead Spur Design Use of a solid lead spur reduces maximum stress to 70 MPa This compares to a maximum allowable stress of 270 MPa (1.5Sm) Location of braze is away from high stress areas and allows for annealing of copper

NCSX NCSX Planar Coil "ASIPP" Presentation 16 December 8-10, 2005 TF Coil Lead Spur Design G11 Fillers trap leads and fill voids All Transitions occur near lead area G11 Fillers transfer EM loads from opposing leads

NCSX NCSX Planar Coil "ASIPP" Presentation 17 December 8-10, 2005 PF Coils Design PF1 PF4 PF5 PF6

NCSX NCSX Planar Coil "ASIPP" Presentation 18 December 8-10, 2005 PF Coil Cross Section PF Coils of conventional design Rectangular cross section Round Geometry

NCSX NCSX Planar Coil "ASIPP" Presentation 19 December 8-10, 2005 PF Coil Drawings PF Coil drawings are not final but adequate for estimating cost and schedule.

NCSX NCSX Planar Coil "ASIPP" Presentation 20 December 8-10, 2005 PF Coils, Conductor A single copper conductor size is used for all four different types of PF coils to simplify their manufacture and reduce costs.

NCSX NCSX Planar Coil "ASIPP" Presentation 21 December 8-10, 2005 Center Stack Assembly, PF1 – PF3 The windings of all three coil pairs are identical; only the lead details differ. The solenoid assembly is clamped together by end castings (with 3 electrical breaks) and tie rods.

NCSX NCSX Planar Coil "ASIPP" Presentation 22 December 8-10, 2005 Outline Design Analysis and Test Fabrication Topics for Discussion

NCSX NCSX Planar Coil "ASIPP" Presentation 23 December 8-10, 2005 TF Design Analysis Global Model Deformations Smeared Properties Island Study Deformations Worst Case Loading Stress Analysis.5 Tesla TF Only Model Modified Radial Preload

NCSX NCSX Planar Coil "ASIPP" Presentation 24 December 8-10, 2005 Front Preload - Stresses Due to Preload +.5Tesla Operation Unbonded wedge casting bending Stress at 117 MPa with front preload Analysis with Bonded wedge casting shows lower stresses Stress Check: 117 MPa < 270 MPa (1.5S m )

NCSX NCSX Planar Coil "ASIPP" Presentation 25 December 8-10, 2005 Testing TF Winding Pack, Thermal & Fatigue Prototype bar undergoes both thermal and stress cycling 1. Proves durability of winding pack design –mechanical properties maintained after cycling –electrical properties maintained, successful hipot tests 2. Proves validity of TF FEA as measured by: –bench mark of mechanical properties to TF Bar model before and after cycling of prototype

NCSX NCSX Planar Coil "ASIPP" Presentation 26 December 8-10, 2005 Sealed Insulation box with TF coil Inside TF Coil in the fixture with insulation box Testing TF Winding Pack, Thermal / Fatigue/ Electrical Bar Fitted with Probes for Electrical Testing after Cycling

NCSX NCSX Planar Coil "ASIPP" Presentation 27 December 8-10, 2005 Testing TF Winding Pack, Thermal / Fatigue Max Load ≈ 8000 lbs. Total cycles ≈ 140,000 Beam Test Validates Analysis Measured stiffness of beam bracketed by unbonded and bonded insulation analysis Beam Test Meets Mechanical Criteria Stiffness of beam relatively unchanged after 140,000 cycles Kevin Freudenberg.

NCSX NCSX Planar Coil "ASIPP" Presentation 28 December 8-10, 2005 Outline Design Analysis and Test Fabrication Topics for Discussion

NCSX NCSX Planar Coil "ASIPP" Presentation 29 December 8-10, 2005 Clean Room Built to Control Contamination

NCSX NCSX Planar Coil "ASIPP" Presentation 30 December 8-10, 2005 TF Coil Winding Pattern TF Coils wound in 3 x 4 Layers Filler blocks applied in sequence All Transitions in or near lead area

NCSX NCSX Planar Coil "ASIPP" Presentation 31 December 8-10, 2005 TF Brazed Joint Technique Example of a Typical Brazed Joint Sleeve is used with “Sil-Fos” Wafer and 1.5mm diameter ring. to ensure full coverage and no voids

NCSX NCSX Planar Coil "ASIPP" Presentation 32 December 8-10, 2005 Autoclave for VPI TF Coil placed in mold Vacuum Impregnated in an Autoclave

NCSX NCSX Planar Coil "ASIPP" Presentation 33 December 8-10, 2005 Sensor Loop Placement Sensor Loops applied to ID of coil Applied under last layer of ground wrap insulation Twisted and brought out near leads Mounting provisions provided for splice box or strain relief

NCSX NCSX Planar Coil "ASIPP" Presentation 34 December 8-10, 2005 Wedge Castings Wedge Casting drawings and specification are complete We will accept part as weldment if dimensional and magnetic permeability requirements are met

NCSX NCSX Planar Coil "ASIPP" Presentation 35 December 8-10, 2005 Wedge Casting Assembled to Coil Wedge Casting Assembled to front face of Coil Clearance in back provided for fit to be filled when VPI applied

NCSX NCSX Planar Coil "ASIPP" Presentation 36 December 8-10, 2005 Wedge Casting Assembly Fixture

NCSX NCSX Planar Coil "ASIPP" Presentation 37 December 8-10, 2005 Coil wrapped with glass then VPI process applied while assembly is in fixture Outside of Castings over wrapped with glass in five locations after VPI Wedge Casting Assembled to Coil

NCSX NCSX Planar Coil "ASIPP" Presentation 38 December 8-10, 2005 Fabrication / Measurement To maintain required tolerances measurements must be monitored and recorded during coil winding –Mandrel will be measured and placed precisely –Coil Geometry measured when removed from mandrel for ground wrapping –Ground insulation thickness measured –Post VPI coil Geometry measured –Positioning of Coil for wedge casting installation Tracking of measurements will ensure consistency from coil to coil All measurements will be documented in fabrication procedure

NCSX NCSX Planar Coil "ASIPP" Presentation 39 December 8-10, 2005 Fabrication / Test The plan for the electrical testing of the TF coils is to test: –Resistance –Inductance –Megger –Hipot –Impulse (used to identify breakdown in the turn to turn resistance) Each of these tests at room temperature before and after cryogenic cycling for the first coil At room temperature for subsequent coils

NCSX NCSX Planar Coil "ASIPP" Presentation 40 December 8-10, 2005 Specification Example: C-Spec Electrical Isolation to Ground Component Definition & Verification Ground Insulation The ground insulation is composed of.015 inch thick by two inch wide S2 glass. The S2 glass is applied in half lap layers to bring the total build of the turn to turn insulation to.125 inches at the front leg of the coil and.375 inches around the top, bottom, and back leg of the coil (ref. dwg. SE ). The glass and tape thicknesses, width and number of layers may be adjusted to reach the required overall thickness and to facilitate manufacturing requirements with the approval of the WBS manager. Any changes in the groundwrap insulation build up must meet the TF electrical standoff requirements. The number of ground wrap layers is to be optimized so that the compression of the coil in the VPI mold minimizes resin rich areas. Voids in the corners of the VPI mold are to be eliminated with the use of radiused fillers. Measurements and parameters such as the number of layers are to be recorded in the winding procedure for each coil Ref Section Verification Electrical Isolation to Ground Verification Electrical Isolation to Ground The completed coil will be tested at 13.5kV.to ground and to the wedge castings Ref. Section

NCSX NCSX Planar Coil "ASIPP" Presentation 41 December 8-10, 2005 Manufacturing Procedures Example Manufacturing Procedure to provide quality control to guarantee requirements in design specification are met Example of Manufacturing Procedure from Modular Coil Winding Measurements and signatures required at all critical steps for each coil

NCSX NCSX Planar Coil "ASIPP" Presentation 42 December 8-10, 2005 Outline Design Analysis and Test Fabrication Topics for Discussion

NCSX NCSX Planar Coil "ASIPP" Presentation 43 December 8-10, 2005 Quality - Topics for Discussion How does ASIPP address cleanliness? Can ASIPP provide a (low grade) clean room environment for coil winding? What is the training and qualification for welding and brazing? What are ASIPP’s capabilities and procedures for electrical testing? What are ASIPP’s capabilities and procedures for measurement and inspection and what steps will ASIPP take to meet winding tolerances What kind of documentation does ASIPP plan for fabrication with respect to inspection and verification at each manufacturing step?

NCSX NCSX Planar Coil "ASIPP" Presentation 44 December 8-10, 2005 Management - Topics for Discussion We are interested in ASIPP’s approach to project management, specifically with respect to controlling quality and schedule. Would a single project manager and contact person be assigned to this project? How would priorities relative to other work at ASIPP be decided?

NCSX NCSX Planar Coil "ASIPP" Presentation 45 December 8-10, 2005 Required Delivery For the TF Coils –There are a total of 18 TF Coil Assemblies. –The first three are required at PPPL by February of –The remaining 15 coil assemblies are required by September of 2007 For the PF 4, PF 5, and PF 6 Coils –Delivery required in Dec. of 2007 Center Stack Coils PF1 –Schedule is flexible, later delivery Structures –Delivery required in Sept. of 2007