NCSX NCSX TF Coil Procurement 1 February 3, 2006 Michael Kalish NCSX TF Coil Procurement

NCSX NCSX TF Coil Procurement 2 February 3, 2006 Outline Modifications Since FDR Specifications / RFQ Chit Resolution

NCSX NCSX TF Coil Procurement 3 February 3, 2006 Changes Since FDR Changes to Wedge Structure –Wedge Structure ECN allows for machining at assembly –New Wedge Weldment Option / Specification added Assembly Drawing Adds detail for outside procurement –Wedge Structure Assembly Details added –Assembly tolerances and inspection criteria –Braze notes and details –Diagnostic Loop Detail Specifications and SOW address Testing and QC –Electrical –Hydrostatic –Flow

NCSX NCSX TF Coil Procurement 4 February 3, 2006 Coil wrapped with glass then VPI process applied while assembly is in fixture Outside of wedge support over wrapped with glass in five locations after VPI Wedge Assembly Technique Defined in FDR FDR defined Wedge Assembly Technique but specification and drawing did not provide assembly tolerances

NCSX NCSX TF Coil Procurement 5 February 3, 2006 Wedge Assembly Technique Detail Added Further detail added to assembly drawing and specification defines requirement PPPL to approve MIT/QC procedures

NCSX NCSX TF Coil Procurement 6 February 3, 2006 Wedge Structure ECN Wedge Structure drawing allows for casting or weldment New Weldment Specification generated Facilitates final machining at assembly level

NCSX NCSX TF Coil Procurement 7 February 3, 2006 Manufacturing Tolerances Defined Tolerances defined for completed assembly to match TF coil alignment requirements.

NCSX NCSX TF Coil Procurement 8 February 3, 2006 Braze Details Added Braze details defined in winding drawing Braze test requirements defined in Specification PPPL to approve MIT/QC procedures

NCSX NCSX TF Coil Procurement 9 February 3, 2006 Diagnostic Loop Wire Details Added SOW states that PPPL will supply wire and Box As defined in FDR wire is on coil ID under last layer of insulation

NCSX NCSX TF Coil Procurement 10 February 3, 2006 Testing Details Added To Specification Flow Test Criteria Hydrostatic Test Electrical Tests with criteria –Verification of Terminal-to-ground Voltage Standoff Each TF coil assembly shall be Megger tested at room temperature (20ºC) to 13.5 kV during acceptance testing to verify compliance with Section This test shall be performed: Prior to ground wrapping the coil at 1kV instead of 13.5kV After Coil VPI but before adhesion of the wedge castings Final test after adhesion of wedge castings For the first article two additional tests are required, one at LN2 temperatures and one more after warming to room temperature

NCSX NCSX TF Coil Procurement 11 February 3, 2006 RFQ, Evaluation Criteria Provide a description of the fixturing or final machining proposed to maintain critical final dimensions of the wedged surface for the Wedge + Coil Assembly. Explain how, based on past experience and/or on measures specifically developed for this effort, the Offeror proposes to maintain winding tolerances and limit the potential for “spring back” in the final coil assembly. Provide a description of how the coils will be packaged and shipped to ensure their safe arrival at PPPL. Provide description of Offeror’s capabilities to perform induction brazing. Provide a description of any proposed development work which may include but is not limited to VPI samples, bending tests, or brazing samples.

NCSX NCSX TF Coil Procurement 12 February 3, 2006 Provide a description of the measures that will be taken to maintain a clean environment in each stage of the fabrication process to ensure that no foreign materials that could contribute to subsequent coil failure are incorporated into the coils. Such measures may include, but are not limited to: provisions for component cleaning and preparation; use of a low grade clean room for coil assembly; use of collection mats at assembly area egress/exit points, etc. RFQ, Evaluation Criteria

NCSX NCSX TF Coil Procurement 13 February 3, 2006 RFQ, Evaluation Criteria Provide a description of the Offeror’s plan to meet PPPL’s electrical testing requirements, and demonstrate that the plan meets the requirements of the Production Specification. Provide a description of the Offeror’s capabilities and procedures for measurement and inspection, and specific steps the Offeror will take to meet winding tolerances. Provide examples of the Offeror’s documentation for inspection and verification of each manufacturing step, including a sample manufacturing/inspection/test (MIT) plan. Provide a description of planned oversight, including an explanation of the means by which independent QC oversight will be maintained and coordinated with the fabrication and assembly efforts.

NCSX NCSX TF Coil Procurement 14 February 3, 2006 FDR Chit Resolution

NCSX NCSX TF Coil Procurement 15 February 3, 2006 FDR Chit Resolution

NCSX NCSX TF Coil Procurement 16 February 3, 2006 Analysis Check “In general, the coil stresses reviewed in the analysis are moderately low and provide adequate margins over the design allowables for conductor, case, and insulation.” “The analysis check generally validates the conclusions of Myatt Consultings’ primary analysis with the following caveats: –the 0.5 Tesla loading should not be considered a normal operating condition without a validating analysis which defines the maximum allowable out of plane loads –The assumption of infinitely rigid coil supports.. provides only an upper estimate of the structural support reaction forces and a lower bound on the actual coil deflections. A model which includes a more detailed elastic support structure to confirm that the coil stresses, and deflections are within acceptable project limits should be implemented “

NCSX NCSX TF Coil Procurement 17 February 3, 2006 Interfaces ScopeLead ResponsibilityDeliverable Determine differential pressure across the coil, minimum inlet pressure, and flow requirements for Cryogenic System WBS 62Calculation provided to WBS 17 defining requirements Provide Voltage standoff requirements vs design standoff of winding pack insulation scheme WBS 4Table summarizing voltage standoff requirements documented at FDR Liquid Nitrogen Connections / Fittings for the Cryo System WBS 16Fittings are documented on drawings. Choice of fittings reviewed with WBS16 Mechanical interfaces with the TF Support structure must be defined including effects of Static and EM loading WBS 15Pro E Model used as input to FEA Analysis, Calculation Memos documented Determine effects of EM loading from other coil systems WBS 132 WBS 14 Calculation memo documents overall effect of EM loads including PF and Modular coils

NCSX NCSX TF Coil Procurement 18 February 3, 2006 Interfaces InterfaceWBSComment Verify that clearances for TF Coil in final position and during TF Coil Assembly. This includes clearance to MCWF, and MC Leads. WBS 12 WBS 18 TF Coil Rotated about global model to show no interferences. Tom Brown produced power point slide to be posted on web to document interference study Determine metrology requirements necessary to maintain required positional tolerances WBS 7Meetings held to review drawings and specifications to determine metrology requirements. Specific Inspection criteria added to the specification to develop the required dimensions to allow for measurement and positioning of coil Diagnostic requirements for sensor loops to be WBS 3Meetings held to review diagnostic loop requirements. Drawings and specifications now include wire installation details

NCSX NCSX TF Coil Procurement 19 February 3, 2006 END

NCSX NCSX TF Coil Procurement 20 February 3, 2006 Wedge Stresses Less Than 50% of Allowables General Primary Membrane (PM < 1.0Sm): –σ(PM) = ~24 MPa (Fig ) < 270 MPa (1.0Sm) Primary Membrane + Bending (PM+PB < 1.5Sm): –σ(PM+ PB) = 172 MPa (Fig ) < 400 MPa (1.5Sm) Local lip shear stress (hand calculation) –76 MPa < 160 MPa Low wedge stresses allow for weldment with minimal inspection criteria