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

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

3. 3 G.Croari – March 2008 1.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. 4 G.Croari – March 2008 1.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. 5 G.Croari – March 2008 1.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. 6 G.Croari – March 2008 1.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. 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. 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. 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. 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. 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. 12 G.Croari – March 2008 Test Facility Description Cryostat, Valve boxes, Satellite Test Facility Description Cryostat, Valve boxes, Satellite Valves Valve box detail

13. 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. 14 G.Croari – March 2008 Test Facility Description Power Supply Test Facility Description Power Supply Simplified schematicInput: 380 Vac 3-phase IoutTransformerThristorsLoad

15. 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. 16 G.Croari – March 2008 Test Facility Description Pumping System Test Facility Description Pumping System

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

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

19. 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. 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. 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 15 + 31 gr/sec LHe @ 300 K Refrigerating power = 200W @ 4,2 K LHe production = 70 Lt / hour 5000 Litres LHe tank

22. 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. 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. 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. 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. 26 G.Croari – March 2008 Coil test procedure Documentation Scope and Requirements

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

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

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

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

31. 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. 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. 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. 34 G.Croari – March 2008 Coil test procedure Coils Into Cryostat Coil at open cryostat: QD wire check, DC test

35. 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. 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. 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. 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. 39 G.Croari – March 2008 Coil test procedure Outgoing check Before shipment: QD wire check Outgoing check

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

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

42. 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. 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. 44 G.Croari – March 2008 Critical points on the coil: Ground Insulation Main Difficoulties DC Tests

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

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

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

48. 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. 49 G.Croari – March 2008 Critical points on the test facility: Cryostat connections (QD bucket) Hydraulic connections Holding system Main Difficulties DC Tests

50. 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. 51 G.Croari – March 2008 Main Difficulties Detail of some coils AAB10: Helium leak during current test 12345

52. 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. 53 G.Croari – March 2008 4. Conclusion a)My Contribution

54. 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. 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. 56 G.Croari – March 2008 Conclusion My contribution What I would like to improve: La Langue Française Control Systems Data Acquisition Systems

57. 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