June 12, 2003FDR Race Track Test Coil1 Final Design Review Racetrack Test Coil James H. Chrzanowski (PPPL) and Oak Ridge National Laboratory June 12, 2003

FDR Race Track Test Coil2 Charge for Racetrack Coil FDR CHARGE 1.Are the test plans and objectives for the racetrack coil defined? 2.Does the design of the racetrack coil incorporate all of the features required to perform the planned tests and achieve the test objectives? 3.Do the design features in the racetrack coil faithfully represent the features in the modular coil (especially for those features pertinent to the test objectives)? 4.Have safety and environmental consideration been adequately addressed? 5.Is the technical documentation of the racetrack coil adequate for its fabrication, installation, and testing?

June 12, 2003FDR Race Track Test Coil3 Test Plans and Objectives The objective of this activity is to manufacture a coil which closely represents the cross section, insulation, conductor and cooling methodology that will be used on the NCSX Modular coils. Once fabricated, the coil will be tested to 24 KA under cryo conditions (Nitrogen cooled) as will be seen by the modular coils. The test will provide preliminary data as to how the coils will react during Nitrogen cooled conditions.

June 12, 2003FDR Race Track Test Coil4 Test Plans and Objectives A review of the test stand- electrical power and cryostat requirements will be covered in a follow- up review. At that time a detail test plan will also be discussed.

June 12, 2003FDR Race Track Test Coil5 Design Features 28 turns total/ 14 each side of tee Nitrogen cooled Wound onto a stainless Tee- cross section casting Copper cladding for cooling Insulation scheme typical of modular coil Diagnostic instrumentation embedded in coil winding Coil clamps typical of modular coils Vacuum epoxy impregnated coil

June 12, 2003FDR Race Track Test Coil6 Race Track Coil Winding Form Stainless steel casting procured from J.P. Pattern Casting has pockets and threaded holes for the coil clamps Provisions for eight coil clamps Originally planned for leads exiting through and epoxy filling from base.

June 12, 2003FDR Race Track Test Coil7 Racetrack Coil Casting

June 12, 2003FDR Race Track Test Coil8 Conductor Conductor: –A turn conductor consists of (4) x in. compacted copper ropes combined together with turn insulation –Conductor purchased from New England Electric Wire Corp. –32 gauge strands- 7x 7/25/32 bare OFHC copper compacted to

June 12, 2003FDR Race Track Test Coil9 Insulation Turn Insulation –(1) Butt lapped layer of in. dry glass –(3) Butt lapped layers of co- wound Kapton and dry glass (0.010 in.) Ground Wrap Insulation –(3) Butt lapped layers of in. thick dry glass Turn Insulation will be applied by hand just prior to be wound onto the form. Butt layer of Dry glass in. thick = in. build (3) Butt lapped layers of co-wound in. Kapton and in. thick dry glass For combined thickness in. = in. build in in.

June 12, 2003FDR Race Track Test Coil10 Inner Wall Copper Cladding inch thick copper sheet Connects to clamp studs on side of casting. Bottom surface does not need to be continuous Custom fitup of cladding at assembly

June 12, 2003FDR Race Track Test Coil11 Inner Wall Copper Cladding

June 12, 2003FDR Race Track Test Coil12 Internal Instrumentation Thermocouples: Type”E” (0.010 in. diameter) Located in six locations inside of the coil. Between columns A & B at layers 1, 4 and 7 Optical (Fiso) Stain Gauges: Positioned at the inside corners of the tee-section Will be borrowed from ORNL for tests ABBA Optical Stain Gauges

June 12, 2003FDR Race Track Test Coil13 Winding Procedure 1)The coil will be wound in the RESA building. (extra care must be taken because of cleanliness issues) 2)The stainless steel winding form will be cleaned and mold released. 3)Install optical strain gauges 4)Winding clamps will be installed to hold turns in place during winding 5)Install the copper cladding 6)Install ground wrap

June 12, 2003FDR Race Track Test Coil14 Winding Plan Starting point Conductor winding spool - Layer 1 Conductor winding spool - Layer 2

June 12, 2003FDR Race Track Test Coil15 Winding-Layer 1 Conductor will be hand insulated Install thermocouples

June 12, 2003FDR Race Track Test Coil16 Winding – Layer 2

June 12, 2003FDR Race Track Test Coil17 Winding – Layer 3 Install thermocouples

June 12, 2003FDR Race Track Test Coil18 Winding- Layer 4

June 12, 2003FDR Race Track Test Coil19 Coil Leads Copper tubes will be soldered over ends of coil leads to be used for bus connections

June 12, 2003FDR Race Track Test Coil20 Final Coil Preparations Following winding –Complete Ground wrap installation –Install outer cladding and clamps

June 12, 2003FDR Race Track Test Coil21 Beta Clamp Coil clamp designed by ORNL Analysis completed by ORNL and presented at May 29 th. NCSX meeting 3-Part clamp Allows for expansion of winding both vertically and horizontally through Belleville washers and the shape of the connection between the upper and lower portions of clamp. One size fits all Clamp assembly shown exploded

June 12, 2003FDR Race Track Test Coil22 Beta Coil Clamps Belleville Washers Cooling Tubes 1/4” bolts 3/8” Bolts Unexploded * Slanted Edge on top portion of clamp allows for expansion in both winding directions. Exploded

June 12, 2003FDR Race Track Test Coil23 Clamps installed on cladding assembly

June 12, 2003FDR Race Track Test Coil24 Tubing connections made to the clamp assemblies

June 12, 2003FDR Race Track Test Coil25 Vacuum Impregnation of Test Coil Vacuum impregnate using CTD-101K epoxy system Bag mold with groove seal Testing out new sprues New Bag mold sealing method The installation of Bag Mold and VPI operations will occur in the D-site Basement

June 12, 2003FDR Race Track Test Coil26 Test Coil VPI Process Leads will sealed with vulcanizing tape to allow VPI of coil Thermocouples and strain gauge leads need to be sealed as well Bag mold using vulcanized rubber, silicone RTV and Epoxy/glass shell

June 12, 2003FDR Race Track Test Coil27 Test Program- Preliminary The Racetrack coil will be tested at the full modular coil operating current of 24 Ka It will have a pulse length of 1 second The coil will be tested while at a cool down temperature of 77 degrees Kelvin –Liquid nitrogen will flowed through the cooling tubes with the exhaust venting into the cryostat. The test plan to determine the number of shots and at what level those test shots will be needs to be established, and will be reviewed at a later date. During the pulses, thermocouples will record the internal temperatures and strain gauges will monitor any movement, stresses that may arise in the tee-structure.

June 12, 2003FDR Race Track Test Coil28 Test Program- Preliminary The present plan is to setup in the D-site basement a test stand that will be used to test the race track coil. It can also be used to later test additional small test coils as required. Geoff Gettelfinger is responsible for building a cryostat for the stand as well as providing nitrogen cooling to the coil and chamber. He has already completed a number of insulation tests to develop the cryostat insulation Raki Ramakrishnan will be responsible for setting up the power system so that the test coil can be tested at the required 24 Ka current 1 second pulse level. The test stand and the test program will be reviewed at a later design review.

June 12, 2003FDR Race Track Test Coil29 CRYOGENIC TESTING PREPARATION Geoff has already begun a testing program for the cryostat. A 12 x 12 x 12” aluminum test module has been fabricated to qualify pedestrian insulation types for the above requirement 4” of layered spun glass duct board performed adequately without dew formation difficulties Primary lesson learned: A thin gas layer is desirable between the liquid tray and the underlying insulation Next step: Collaborate with Electrical Engineer on the power feedthroughs

June 12, 2003FDR Race Track Test Coil30 INSULATION TEST MODULE 12” x 12” x 12” Test Module 2” Duct Board Sample

June 12, 2003FDR Race Track Test Coil31 INSULATION TEST MODULE, 2” TRIAL Gaseous Vent Dew/Frost Forming LN2 Feed Line

June 12, 2003FDR Race Track Test Coil32 Safety and Environmental A Job Hazard Analysis (JHA) report will be generated for the winding and VPI operations. A pre-job briefing will be held prior to starting the winding and/or VPI operations Integrated Safety Management (ISM) is and will be used or all aspects of the R&D activities. –Line management responsible for safety –Clear roles and responsibilities –Competence commensurate with responsibilities –Balanced Priorities –ID of safety standards and requirements –Hazard control tailored to work being performed –Operations authorizations

June 12, 2003FDR Race Track Test Coil33 Technical Documentation Statement of work NCSX-SOW covers the winding of test coils for the R&D program Approved NEPA is available No PPPL Work Planning Form WP-1016 covers the Modular Coil Winding Development Activities

June 12, 2003FDR Race Track Test Coil34 Technical Documentation An R&D statement of work is being written which will outline the details for winding and VPI activities associated with the Racetrack Test coil Action: Chrzanowski

June 12, 2003FDR Race Track Test Coil35 Present Status Casting is mounted and ready for winding Copper conductor has been spooled and ready Insulation has been pre-spooled (Kapton/glass) Cladding- has been fabricated requires custom fitup Need strain gauges prior to starting winding operations