NCSX VACUUM VESSEL PL Goranson Thermal Insulation Final Design Review July 31, 2006 WBS12 NCSX

Talk Overview SCOPE CHARGE DOCUMENTATION STATUS INSULATION MODIFICATIONS ISSUES CONCLUSION

NCSX Scope The FDR covers all remaining design details for the vacuum vessel through field period assembly. This includes the modifications to the insulation system since the last FDR and the needed sequence of assembly drawings through the field period assembly.

NCSX Charge 1. Does the final insulation and boot seal design meet all performance requirements and satisfy questions raised at the last review? 2. Have potential failure modes been adequately addressed in the design? 3. Are the assembly sequence drawings adequate and all parts called out on the drawings? 4. Is the design documentation adequate?

NCSX Status-Drawings & Other Design Req. Assembly Drawings SE VV Field Period Assembly SE Vacuum Vessel Heating/Cooling Heating Cooling ASM Assembly SE VVSA Phase 1 Assembly SE VVSA Phase 2 AssemblyNew stud locations added SE VVSA Phase 3 Assembly SE Winding Form Insulation Assembly SE VV Winding Form Blanket Assembly Chits Outstanding chits from Insulation FDR resolved (Port plug drawings revised to compensate for MC shims) Specifications and Data Sheets NCSX-CSPEC Station 1 Field Period Assy NCSX-PRL Vacuum Vessel System Boot Seal and Port Over wrap Fabric Components FMECA Report Requirements determined from FMECA

NCSX Port Plug Concept Port 17 demonstrates the basic idea. Two G10 plates sandwich the boot and seal the hole in the MC. 1/4” Gore-tex® gasket around G10 is nominally compressed 25%. (gap is 3/16”). Sheet metal tab are be welded to the MC to hold each seal in place.

2 3 1 NCSX Plug Types There are three plug configurations Type 1 Plug not at insulation break. - simple bored hole - three required per field period Type 2 Plug ends at shell insulation break. - three required per field period Type 3 Plug cuts across shell insulation break. - six required per field period

NCSX Local Shimming of Shell Affects Type 3 Insulation in shell may require shimming to offset tolerances. Type 1 not affected. Type 2 is not a problem if the shim continues across hole. Sheet metal seals will adjust since they are in halves. Type 3 is a potential problem. - could vary gap + ½ inch -plug may not fit Fix required for Type 3. - oversize G10 plugs may be marked and ground down to fit -undersize plugs may be fitted with over-size “tadpole” seal - fix shown in next slide

PORT WALL HEATERS G11 PLATE BOOT SEAL RETAINING CLIP WIRE TIE TADPOLE(FILLER) SEAL MC SHELL INSULATION NCSX Type 3 Port Fix Over-size “tadpole” seal Fix required only in direction of shim joint. May be install over old seal or: Old seal cut out locally and replaced. Uses existing screw holes in plug halves. Can be made up as required. Seal sizes can be stocked in 1/8” increments.

NCSX Tadpole Seal

NCSX VV Fill Insulation Cabot Nanogel is material of choice Heat-treated product will be made available by Cabot Corp for operation above 250 C. - calcined version of standard - hot air through product burns off volatiles - test runs already completed - sample to be procured near term - insulating and mechanical characteristics believed to be unchanged

NCSX MC Face Insulation Made up with many identical pieces. - typical size detailed but length may be modified to fit - lap around three sides Daisy chained together. lap and stapled together through upstanding hems on Nomex - periodically fastened by studs and washers - laced

NCSX Blanket Concept

NCSX SE Installation Drawing

NCSX Blanket Detail Drawing

NCSX Removed Studs on A Coil Existing studs will not always be available Studs removed on A Coil New weld pins/studs required STUDS REMOVED AFTER VPI

NCSX Studs on A Coil Replaced by New Retainers Studs or weld pins may be added to replace those removed - 1/16” or 3/16” dia by 3/4 long adequate ATTACHMENT POSSIBLE FOR NEARLY ALL OF COIL LENGTH STUDS REMOVED OVER ~50% LENGTH VPI GROOVE

NCSX Failure Mode Report Report summarizes recommendations and requirements stemming from FMECA - identifies components required to detect faults and alert operator - identifies critical events and operator appropriate responses - identifies corrective action/repair

NCSX VV FP ASSY- SE

NCSX Issues No issues remain except confirmation of Nanogel acceptability and its procurement. Needs blessing from Cabot.

NCSX Conclusion Boot seals modifications have been made to assure fit with MC shims. Design/Material for MC coil insulation has been chosen and may be procured. - design uses yard goods and bulk product and does not require detailed drawings. - the installation method is shown in example drawings. Candidate for backfill insulation tentatively identified. Preparation of drawings is complete but several need check and/or promoting.