NCSX VACUUM VESSEL PL Goranson Vacuum Vessel Supports

NCSX VACUUM VESSEL PL Goranson Vacuum Vessel Supports Heating/Cooling System Comprehensive Final Design Review May 05, 2005

NCSX Talk Overview STATUS VACUUM VESSEL SUPPORT DESIGN VACUUM VESSEL HEATING/COOLING SYSTEM DESIGN ISSUES CONCLUSION

Status NCSX Drawings • Vacuum Vessel Coolant Tube System Drawings checked, not signed • Vacuum Vessel Coolant Header Assembly Drawings checked, not signed • Vacuum Vessel Supports Vertical support rod drawings checked, and signed, not released Lateral support drawings checked and signed, not released • Vacuum Vessel NB Port Metal Seals and Seal Template Drawings complete, template procured, rings in fabrication • Vacuum Vessel Heating/Cooling System & Diagnostics Top Assembly 50% complete; not required for procurement ICD • • • ICD-12 -142 -0001 not signed ICD-12 -14 -3 -0001 Complete ICD-123 -171 -0001 Complete ICD-12 -125 -0001 Complete ICD-123 -310 -0001 Complete ICD-12 -400 -0001 not signed ICD-12 -64 -0001 Complete ICD-12 -4 -5 -0002 Complete ICD-121 -300 -0001 Complete Vacuum Vessel and Modular Coil Assembly Clearances Insulation VV/Cryostat Coolant Tube Interface VV Local I&C VV Magnetic Diagnostics VV Grounding VV Cooling/Heating Requirements VV Port Resistance Heaters VV Diagnostic Port Allocation and Orientation

Status Continued NCSX DAC • • NCSX-12 -001 -00 Complete NCSX-12 -00 not signed NCSX-12 -003 -00 Complete NCSX-12 -004 -00 Complete NCSX-12 -005 -00 Complete NCSX-12 -006 -00 Complete NCSX-12 -007 -00 not signed VV Local Thermal Analysis Vacuum Vessel Heating/Cooling Distribution System Thermo-hydraulic Analysis Vacuum Vessel Heat Balance Analysis Vacuum Vessel Support Rod Analysis Diagnostic Port Flange Weld Stress Resulting From Loss of Power Fault Condition Port 4 Weld Stress During Bake-out Design Basis Analysis VV Structural Analysis/Seismic Analysis Coolant Tube Build To Specification Draft complete, not signed VV SRD Complete FMECA Draft commented, not signed CHITS Outstanding chits from PBR resolved

NCSX VV Supports

NCSX VV Support Design Overview • Six overhead support rods carry weight of VV • Lateral supports, 120 o apart, react lateral and out-of plane loads -Three take CW load (toroidal) -Three take CCW load (toroidal) -Two take radial load - Four take overturning moment • Six lower rods react vertical magnetic loads

VV Support Loads NCSX • VV Weight Including flange extensions, covers, and NB Transition Ducts 24, 000 lbs • Diagnostic weight (per ICD) 10, 750 lbs • Lateral out-of plane (radial) ? • Lateral vacuum radial 3, 200 lbs • Rotational (toroidal) magnetic 0 (halo? ) • Vertical magnetic loads ± 16, 800 lbs • Future PFC internals 13, 250 lbs

NCSX VV Support Capability Critical component is commercial rod end. • Nominal dead load, including diagnostics and PFC internals is 8, 000 lbs each. Assumes no lower support rods. • Rod end ultimate load is 29, 300 lbs – Safety factor is 3. 7 static, 3. 41 during vertical disruption. – Failure mode is permanent deformation, not catastrophic separation. • Lower supports could potentially remove 2, 840 lbs from each upper support.

NCSX Upper Support Rod • Self-aligning design permits thermal growth – MC shell/VV relative movement 5/8”(radial) – shell end is spherical nut/washer – vv end is commercial spherical rod end/threaded lug • Adjusted for nominal VV height at 40 C • Shell end insulated (thermally and electrically) with G-11 CR washer/spacer • Titanium alloy rod for high strength, low thermal conductivity, low permeability • ¾” diameter

NCSX Upper Support Rod Drawing

NCSX Lower Support Rod • Six units react magnetic loads from VV • VV end identical to upper support • MC end is self-aligning & spring loaded - suspended between Bellville Washer stacks with 0. 43” stroke - self-contained subassembly - both upward and downward preload adjustable - permits 0. 205 relative thermal growth during bakeout • MC end insulated with G-11 CR washer/spacer • Titanium rod for high strength, low thermal conductivity, low permeability

NCSX Lower Support Rod Drawing

NCSX Lateral Support Design Requirements • Permit radial and vertical growth • React lateral, radial imbalance forces • Adjust lateral & rotational alignment of vessel • Electrical isolation for VV Baseline Design Change • FDR design reacted loads from pads on NB transition duct into shell mounted pads • MIE does not have NB Ducts FDR DESIGN

NCSX MIE Lateral Support Design Features • Modification kit reacts load into NB blankoff flange • Utilizes baseline MC pads with no changes • Retrofit onto NB blankoff port –installed in field MIE DESIGN

NCSX Support Rod Temperature Distribution • Thickening shell end insulation reduces gradient, raises end, average temperature • Baseline is 0. 125” VV • Loss is only 5. 2 watts 0. 5" 0. 25" 0. 125" Shell 0. 5 inch insulation around rod G-10 on end Losses range from 3. 2 w to 5. 2 w.

NCSX Heating/Cooling System Design

NCSX • Coolant System Design Status Tubing drawings checked – 5/16” O. D. 316 L annealed stainless tubing – Held with weld studs, clamps, and Grafoil® gaskets • Helium Supply/Return Header and Support drawings checked • Tubing thermal analysis complete - Thermal performance acceptable - Thermal coef. mismatch not a concern total differential growth only 0. 2” in 17 feet. temperature ramped during bakeout gaskets permit movement • Discussions with tube bending vendors are in progress • Draft build-to specification for Coolant Tubes complete, in comment cycle

NCSX Coolant Tube Installation

NCSX Tubing Design Concept Reflects vendor comments • Tube tolerance requires robust design mounting clip. • Installation of studs must be done at assy of tubes on to VV. • Vendor will work from xyz coordinate table, not models.

NCSX • Compensates for misalignment in tube pair. + 1/16 lateral (each) + 1/8 vertical (each) • Utilizes self aligning nut. • Maintains 1/8” clearance for magnetic loops. Mounting Clip Design

NCSX Vertical Port (12) Tube Supports • One support near VV - the flange end is supported by header • Uses commercial (Jiffy) clips on elevated mount plate - permits ½” insulation under the tubes. - maximizes routing space for cables/wires • No gasket

NCSX • Vendor can not fab in one piece. – Tubes hit bender or floor before completion. • 3 -4 piece design will be used. – Body tube – Upper Port Tube – Lower Port Tube – Possibly a mid-plane splice • Weld together at assembly • Only 2 configurations of Port Tubes are required. Tube Fabrication

NCSX Typical CNC Bending Machine • Bends clockwise and counterclockwise rotation. • Simultaneous head rotation around part, with collet rotation. • Stacked bend rollers with die shifter can bend tubes up to four different radii • Optional push bending technique enables bending coils

NCSX Tube Configuration-plan

NCSX Tube Configuration-elevation

NCSX Typical Tube Drawing

NCSX Supply Header Configuration Following VG show assembly and configuration of Tubing, Headers, and Cryostat interface. • Order is flexible, headers can go on first or last. • Competing interfaces not shown - Magnetic Loops - Thermocouples - Heaters - Insulation

NCSX Tubes Installed on VV

NCSX Headers Installed

NCSX Tubes Installed on Port

NCSX Interface Flange Installed

NCSX Cryostat Interface-elevation 6. 0 Port Flange (150 C) Bellows Seal Flange Heater Leads/ Thermocouples/ 1 Loops Boot 4. 38 Ref CRYOSTA T Mount Post (80 K) Insulation fill (Nanogel beads) 1 1/4" Pipe Ring Headers "U" Bracket Port Extension 0. 5" Insulation (Microtherm) 5/16" Coolant Tubes (390 C) 1" Insulation (Microtherm) Notes 1. Feedthrough shown is projected view. Actual location lies within 6" region. • Headers lie within Cryostat wall. - Gives access for diagnostics above flange - Requires only 4 bellows/port • Insulation is backfill with Nanogel® beads.

NCSX Cryostat Interface Flange Provisions 8 generic 2. 75” CF flanges are provided at each interface • Cost effective means to get gas seal between Cryostat/VV • O-rings are adequate • 3 flanges for thermocouple hookups (18 top/19 bottom pairs required) -10 pair positions on each flange -20 thermocouple positions total -Backups not connected) • 4 flanges for magnetic loop hookups -19 pins each - 38 wire pairs (loops) total • 1 flange for heater hookups - 4 pairs (includes backups)

NCSX Diagram is for full Field Period • WBS 12 interface extends through electric break. • Tubing alternates to two header systems, giving a degree of redundancy. - 2 ring headers on each side of port 12. Coolant Circuit Schematic

NCSX Heating/Cooling Calculations Reference Calculation Documents NCSX-CALC-12 -002 Vacuum Vessel Heating/Cooling Distribution System Thermo-hydraulic Analysis NCSX-CALC-12 -003 Vacuum Vessel Heat Balance Analysis Design Assumptions-Insulation - 75% efficiency - Microtherm or equivalent insulation - VV 2. 54 cm - Port, 3. 81 cm inside MC, 5 cm outside MC - Areas between MC assemblies filled - Port ends 2. 54 cm System Design Parameters Coolant paths 192 parallel Tube ID 0. 63 cm (. 25”) Average length 5. 5 m Coolant Gaseous Helium Operating Pressure 20 atmos. abs

NCSX Bakeout at 350 C • 17 k. W required Idle Operation at 20 C • 4. 6 k. W required Thermo-hydraulics at bakeout Pressure drop 0. 12 atmos Entrance Velocity 22 m/s Temperature drop 17 K Flow rate 731 k/hr (285 cfm) Capable of 24 k. W with He skid upgrade Results-Heating

NCSX Results - Cooling Heat Removal (14. 4 MJ shot) • 16 k. W Thermo-hydraulics Pressure drop Entrance Velocity Average bulk temperature rise Flow rate Coolant entrance temperature 0. 22 atmos. 24. 5 m/s 4. 9 K 1660 kg/hr (305 cfm) 20 C VV does not return to room temperature at this flow rate • Bulk temperature rise is somewhat less than calculated - 1 -D model does not take into account the partial VV coverage by the tubes • Ratcheting discussed in later view graph, covered by DAC.

NCSX Vacuum Vessel Cool down Analysis NCSX-CALC-12 -001 -00 - Local Thermal Analysis - Freudenberg Analyzes cool down time, thermal ratcheting, clamp spacing, and thermal stresses in VV. Thermal Criteria – As set forth in SRD • Cool down in 15 minutes for: • 14. 4 MJ pulse • Even heat distribution • VV returns to re-pulse temperature of 40 -80 C Results • Cooling clamps on staggered 4” X 10” spacing pattern meets criteria. – Space is maximum, nominal spacing is much closer – Compacts at upper and lower regions • VV stresses are acceptable

VV Steady State Temperature As Function of Clamp Spacing NCSX • 14. 4 MJ 343 • 15 minute cool down 8 Inch Horizontal Spacing 338 333 328 Steady state temperature (K) • Temperature shown is max temp between clamps. 4 Inch Horizontal Spacing 323 318 313 308 303 298 293 288 0 2 4 6 8 10 Vertical Spacing Between Cooling Tube Clamps (inches) 12

NCSX • 14. 4 MJ • 15 minute cool down • Temperature shown is max temp between clamps. • Clamps on 4 X 10 grid (about average) VV Temperature Response

NCSX Ref. NCSX-CALC-12 -001 -00 - Local Thermal Analysis - Freudenberg 4 X 10 spacing – 38 Ksi Vacuum Vessel Stress

NCSX Coolant Tube Build-to Specification Covers the following: • Applicable drawing and models. Drawings tabulate bending coordinates. • Number of assemblies being fabricated (32 types, 6 of each) • Standards, including stainless tubing, welding. • QA Requirements for: welding cleaning weld inspection metrology leak checking permeability • Contour tolerances are captured by drawings

FMECA NCSX Coolant Tube System Includes Heating/Cooling System Off-Normal Operation • Loss of coolant • Loss of heaters • Abnormal port flange and/or VV temperature System integration of temperature monitoring and control • Resistance Heaters • Helium Coolant System VERTICAL PORT Typical Inner and Outer Port Extension Diagnostic Flange (WBS 12) Heater Power Supply WBS 12 Interface Heater Current Controllers Feedthrough (WBS 7) CRYOSTAT BOUNDARY Heater Tape Process/Temperature Programmable Controller VV Body Thermocouple VACUUM VESSEL Port Thermocouple Temperature Monitor Power CRYOSTAT BOUNDARY WBS 12 Interface Signal Conditioner Electrical Isolation • Emergency shutdown Connectors Thermocouples Vacuum Vessel Temperature Control System Conn ector not hooked up

NCSX Issues Supports • Lateral supports not yet analyzed Heating/Cooling • R&D prototype of Coolant Tube may be required. Bidders are nervous about the complexity of the geometry.

NCSX • • • Conclusion – VV Supports Support system strength is adequate for present and future operation. Analysis included the weight of port extensions, NB transition ducts, diagnostics, and upgrade PFCs. Support thermal isolation reduces thermal load to the MC to an inconsequential level. The system permits thermal growth during temperature cycling. The system is adjustable and can align the VV in 6 axes. The system provides electrical isolation. Wherever possible, the system uses off-the-shelf commercial components.

NCSX • • Conclusion – Heating/Cooling System The system can provide adequate heat for idle and bakeout operation. The system can provide sufficient cooling to cool down the VV in the prescribed 15 minutes and stay within maximum steady state temperature requirement set forth in the SRD. The system is adequately insulated to reduce MC and Cryostat thermal loads to a manageable level. The stresses induced into the VV by thermal gradients are within safe levels. Provisions have been made to monitor temperatures, analyze them, and provide compensation in the event they are outside the design thresholds Interfaces through the Cryostat are provided which accommodates all of the cooling lines as well as local diagnostics, heater lines, and magnetic loops. Consequences of off-normal operation have been studied and documented in a FMECA. Commercial vendors were consulted to comment on the designs.