1. J. H. ChrzanowskiNSTX TF Flag Joint Design Review1 NSTX TF Flag Joint Design Review Fabrication and Assembly April 10, 2003 By: James H. Chrzanowski

2. J. H. ChrzanowskiNSTX TF Flag Joint Design Review2 Contents of Presentation Identify the components of the Hub Assembly Discuss improvements to TF bundle Discuss new TF flag assembly Discuss differences between the upper and lower hub assemblies Discuss fabrication issues Discuss the assembly details and sequence

3. J. H. ChrzanowskiNSTX TF Flag Joint Design Review3 TF Flag Assembly Identification Upper TF Hub Assy. Lower TF Hub Assy. Upper Inner TF Flags TF Flag Support Box Upper Outer TF Flags Lower Outer TF Flags Lower Inner TF Flags Upper Hub structure Lower Hub structure Torque restraint collar

4. J. H. ChrzanowskiNSTX TF Flag Joint Design Review4 New TF Bundle/ Hub Assembly The new TF bundle will be fabricated in-house This decision is based upon quality and schedule issues PPPL has also retained possession of the original molds used in the TF bundle fabrication There were several Quality concerns associated with the original TF bundle construction by the outside vendor. These quality concerns resulted in: –coolant leaks –Additional rework of electrical faces in-house In-house fabrication will result in closer supervision and better quality control

5. J. H. ChrzanowskiNSTX TF Flag Joint Design Review5 New TF Bundle Fabrication Once leaks were found on the TF bundle, new conductor was procured in FY-01 for possible future replacement of the TF bundle (CDA10700 OFHC silver bearing copper) An epoxy cure oven is presently being designed and fabricated for this purpose (ready by end of May)

6. J. H. ChrzanowskiNSTX TF Flag Joint Design Review6 TF Bundle Epoxy Cure Oven Oven will be used for curing the B-stage T/T and groundwall insulation on the TF bundle Will be used for soldering the coolant tubes into the conductors Sized to accommodate the OH solenoid molds for possible future upgrades Modular design oven for easy disassembly & storage

7. J. H. ChrzanowskiNSTX TF Flag Joint Design Review7 Quality Problems with Original TF Bundle Numerous coolant tube leaks developed once operations began

8. J. H. ChrzanowskiNSTX TF Flag Joint Design Review8 Improvements to TF Bundle Design Improvements: Coolant Tubes –Improve integrity of coolant tube design –Routing- Upper tubes to come straight out the top –Type of tubing- straight length seamless Cu Joint Improvements –Replace joint Inserts- Tap-lok Inserts –Improve shimming- Flag box –New fastener design

9. J. H. ChrzanowskiNSTX TF Flag Joint Design Review9 Upper Hub Assembly The new upper hub assembly has (2) different flag designs –Inner Flag- Bolted joint –Outer Flag- E-beam welded flag

10. J. H. ChrzanowskiNSTX TF Flag Joint Design Review10 E-Beam Welding of Upper Outer Flags Weld flags to upper outer conductors following initial machining, but prior to final machining and bundle assembly Bolt on electrical end flags following epoxy fill of flag boxes

11. J. H. ChrzanowskiNSTX TF Flag Joint Design Review11 Kapton insulation along entire length of flag Dry glass insulation along length of interface fills space between flag and box TF Flag Structural Boxes Epoxy fill holes Stainless steel boxes Gaskets for sealing box Blind tapped holes 0.010 in. allowance for fitup of flag to conductor

12. J. H. ChrzanowskiNSTX TF Flag Joint Design Review12 Typical TF Flag Joint- (Upper inner; lower inner & outer) Tap-lok inserts Stainless steel washer plate, belleville washers and nuts A-286 fasteners Shear Pin & Block (stainless steel) Flag box (stainless steel) * Fasteners will be discussed in detail by Mike Kalish Flag resistance lead

13. J. H. ChrzanowskiNSTX TF Flag Joint Design Review13 Upper TF Hub Assembly-1 Preposition lower hub plate [1] Insulate flags (Kapton & glass) [2] Position flag boxes over flags [3] Attach front contact face [4] –Note: front contact faces may be attached either prior to or after epoxy fill of boxes) 1342 Lower hub plate

14. J. H. ChrzanowskiNSTX TF Flag Joint Design Review14 Upper TF Hub Assembly-2 Complete assembly of Flag boxes [1] Install center hub structure into position [2] Fasten upper and lower plates to the flag boxes [3] 123 Center hub structure

15. J. H. ChrzanowskiNSTX TF Flag Joint Design Review15 Upper TF Hub Assembly-3 Install shear blocks and pins [1] Install leads for flag resistance measurements Install studs and pre-assembled boxed inner flags into position [2] Jack flags to contact shear blocks Install upper hub plate Secure the mid and upper plates to the flag boxes [3] 122 Upper hub plate

16. J. H. ChrzanowskiNSTX TF Flag Joint Design Review16 Upper TF Hub Assembly-4 Jack flags to contact shear blocks Vacuum fill the individual flag boxes with Hysol epoxy [1] Install the torque restraint support ring to the TF bundle via epoxy/ glass lay up [2] 12

17. J. H. ChrzanowskiNSTX TF Flag Joint Design Review17 Installation of Torque Restraint Support Ring Install torque restraint collarBuildup of dry glass and Hysol epoxy (wet lay-up) over ground wall

18. J. H. ChrzanowskiNSTX TF Flag Joint Design Review18 Pre-Assemble the Lower Hub Assembly Pre-assemble lower hub structure prior to TF installation Epoxy fill the flag boxes Do not install lower torque restraint collar Disassemble lower hub structure

19. J. H. ChrzanowskiNSTX TF Flag Joint Design Review19 Installation of TF Bundle

20. J. H. ChrzanowskiNSTX TF Flag Joint Design Review20 Final Assembly of Lower Hub Assembly Complete assembly of the lower hub structure including torque restraint collar Install pedestal and complete bus and umbrella component assembly