NCSX VACUUM VESSELPL Goranson

Comprehensive Final Design Review May 05, 2005

Vacuum Vessel SupportsHeating/Cooling System

NCSX

NCSXTalk Overview

STATUS

VACUUM VESSEL SUPPORT DESIGN

VACUUM VESSEL HEATING/COOLING SYSTEM DESIGN

ISSUES

CONCLUSION

NCSXStatus

Drawings• Vacuum Vessel Coolant Tube System

Drawings checked, not signed

• Vacuum Vessel Coolant Header AssemblyDrawings checked, not signed

• Vacuum Vessel Supports Vertical support rod drawings checked, and signed, not releasedLateral support drawings checked and signed, not released

• Vacuum Vessel NB Port Metal Seals and Seal TemplateDrawings complete, template procured, rings in fabrication

• Vacuum Vessel Heating/Cooling System & Diagnostics Top Assembly50% complete; not required for procurement

ICD• ICD-12-142-0001 Vacuum Vessel and Modular Coil Assembly Clearances

not signed• ICD-12-14-3-0001 Insulation

Complete• ICD-123-171-0001 VV/Cryostat Coolant Tube Interface

Complete• ICD-12-125-0001 VV Local I&C

Complete• ICD-123-310-0001 VV Magnetic Diagnostics

Complete• ICD-12-400-0001 VV Grounding

not signed• ICD-12-64-0001VV Cooling/Heating Requirements

Complete• ICD-12-4-5-0002 VV Port Resistance Heaters

Complete• ICD-121-300-0001 VV Diagnostic Port Allocation and Orientation

Complete

NCSXStatus Continued

DAC• NCSX-12-001-00 VV Local Thermal Analysis

Complete• NCSX-12-002-00 Vacuum Vessel Heating/Cooling Distribution System Thermo-hydraulic Analysis

not signed• NCSX-12-003-00 Vacuum Vessel Heat Balance Analysis

Complete• NCSX-12-004-00 Vacuum Vessel Support Rod Analysis

Complete• NCSX-12-005-00 Diagnostic Port Flange Weld Stress Resulting From Loss of Power Fault Condition

Complete• NCSX-12-006-00 Port 4 Weld Stress During Bake-out

Complete• NCSX-12-007-00 Design Basis Analysis VV Structural Analysis/Seismic Analysis

not signed

Coolant Tube Build To SpecificationDraft complete, not signed

VV SRDComplete

FMECADraft commented, not signed

CHITSOutstanding chits from PBR resolved

VV Supports

NCSX

VV Support Design Overview NCSX

• Six overhead support rods

carry weight of VV• Lateral supports, 120o 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 24,000 lbs Including flange extensions, covers, and NB Transition Ducts

• 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

VV Support Capability NCSX

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.

Upper Support Rod NCSX

• 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-11CR washer/spacer

• Titanium alloy rod for high strength, low thermal conductivity, low permeability

• ¾” diameter

Upper Support Rod Drawing NCSX

Lower Support Rod NCSX

• Six units react magnetic loads from VV

• VV end identical to upper support

• MC end is self-aligning & spring loaded- suspended between Bellville Washer stackswith 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-11CR washer/spacer

• Titanium rod for high strength, low thermal conductivity, low permeability

Lower Support Rod Drawing NCSX

Lateral Support NCSX

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

MIE Lateral Support Design NCSX

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

Support Rod Temperature Distribution NCSX

• Thickening shell end insulation reduces gradient, raises end, average temperature

• Baseline is 0.125”

• Loss is only 5.2 watts

SUPPORT ROD TEMPERATURE DISTRIBUTION AS A FUNCTION OF END INSULATION THICKNESS

Bakeout at 350 C

-100

-50

0

50

100

150

200

250

300

350

400

0 5 10 15 20 25

ROD ELEMENT (1.52 cm each)

RO

D T

EM

PE

RA

TU

RE

(C)

VV

Shell

0.5 inch insulation around rod G-10 on endLosses range from 3.2 w to 5.2 w.

0.125"

0.5"

0.25"

Heating/Cooling System Design

NCSX

Coolant System Design Status

• Tubing drawings checked– 5/16” O.D. 316L 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 bakeoutgaskets permit movement

• Discussions with tube bending vendors are in progress

• Draft build-to specification for Coolant Tubes complete, in comment cycle

NCSX

NCSX

Coolant Tube Installation

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

Mounting Clip Design

• 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.

1.250.645

5/16 DIA1/16

1/32

5/16 STUD.062

1.65

Gasket omitted for clarity

1.0

Ø.412

10.0°

R 0.44

.156

0.38

1/16" kerf

0.045

.06

SPS TLN 1035 C -5N spherical nut

0.50

optional

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

- decouple thermal load

NCSX

Tube Fabrication

• 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.

NCSX

NCSXTypical 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

Tube Configuration-planNCSX

Tube Configuration-elevationNCSX

Typical Tube DrawingNCSX

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

NCSXTubes Installed on VV

NCSXHeaders Installed

NCSX Tubes Installed on Port

NCSXInterface Flange Installed

Cryostat Interface-elevation NCSX

• Headers lie within Cryostat wall.

- Gives access for diagnostics above flange

- Requires only 4 bellows/port

• Insulation is backfill with Nanogel® beads.

CRYOSTAT

Boot

1" Insulation (Microtherm)

0.5" Insulation (Microtherm)

1 1/4" Pipe Ring Headers

Bellows Seal

Port Flange

5/16" Coolant Tubes (390 C)

"U" Bracket

Flange Heater Leads/ Thermo- couples/ Loops

Port Extension

Mount Post

4.38 Ref

Insulation fill (Nanogel beads)

(150 C)

(80 K)

6.0

1

Notes 1. Feedthrough shown is projected view. Actual location lies within 6" region.

Cryostat Interface Flange Provisions NCSX

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)

Coolant Circuit Schematic 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.

CRYOSTAT BOUNDARY 1

3 5

63

TOP

7

VERTICAL PORT

WBS12 Interface (TYP)

1 1/4" Ring Header

1 1/4" Ring Header

1 3

5

63

2 4

6

64

7 8

1 1/4" Ring

Flow

Break

Shutoff

BOTTOM

1 1/4" Ring Header

Flow

Break

Shutoff

2 4

6

Break Break

2 4

6 8

Rupture Disk

Rupture Disk

64

VACUUM VESSEL

Temperature Monitor

Pressure Monitor

Shutdown Controller

2" Supply Header

2" Supply Header

Cryostat Helium Detector

Check Valve

5/16" tubing (64 per field period)

Check Valve

2" Return Header

2" Return Header

CRYOSTAT BOUNDARY

CRYOSTAT BOUNDARY

CRYOSTAT BOUNDARY

Reference Calculation DocumentsNCSX-CALC-12-002 Vacuum Vessel Heating/Cooling Distribution System Thermo-hydraulic AnalysisNCSX-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 ParametersCoolant paths 192 parallelTube ID 0.63 cm (.25”)Average length 5.5 mCoolant Gaseous HeliumOperating Pressure 20 atmos. abs

NCSX

Heating/Cooling Calculations

Bakeout at 350 C• 17 kW required

Idle Operation at 20 C• 4.6 kW required

Thermo-hydraulics at bakeoutPressure drop 0.12 atmosEntrance Velocity 22 m/sTemperature drop 17 KFlow rate 731 k/hr (285 cfm)Capable of 24 kW with He skid upgrade

NCSX

Results-Heating

Heat Removal (14.4 MJ shot)• 16 kW

Thermo-hydraulicsPressure drop 0.22 atmos.Entrance Velocity 24.5 m/sAverage bulk temperature rise 4.9 KFlow rate 1660 kg/hr (305 cfm)Coolant entrance temperature 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

Results - Cooling

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

NCSX

Vacuum Vessel Cool down Analysis

NCSXVV Steady State Temperature As Function of Clamp Spacing

288

293

298

303

308

313

318

323

328

333

338

343

0 2 4 6 8 10 12

Vertical Spacing Between Cooling Tube Clamps (inches)

4 Inch Horizontal Spacing

8 Inch Horizontal Spacing

Ste

ad

y s

tate

te

mp

era

ture

(K

)

• 14.4 MJ

• 15 minute cool down

• Temperature shown is max temp between clamps.

NCSXVV Temperature Response

• 14.4 MJ

• 15 minute cool down

• Temperature shown is max temp between clamps.

• Clamps on 4 X 10 grid (about average)

Ref. NCSX-CALC-12-001-00- Local Thermal Analysis - Freudenberg

NCSX

Vacuum Vessel Stress

4 X 10 spacing – 38Ksi

Coolant Tube Build-to Specification NCSX

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:weldingcleaningweld inspectionmetrologyleak checkingpermeability

• Contour tolerances are captured by drawings

FMECA NCSX

Conn ector not hooked up

CRYOSTAT BOUNDARY

VERTICAL PORT

VACUUM VESSEL

Temperature Monitor

Signal Conditioner

Heater Current Controllers

Heater Power Supply

Port Thermocouple

Heater Tape

Typical Inner and Outer Port Extension

Programmable Process/Temperature

Controller

Feedthrough (WBS 7)

VV Body Thermocouple

Coolant Tube System

Power WBS 12 Interface

WBS 12 Interface

Diagnostic Flange (WBS 12)

Electrical Isolation

Connectors Thermocouples

CRYOSTAT BOUNDARY

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

• Emergency shutdown

Vacuum Vessel Temperature Control System

Issues NCSX

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.

Conclusion – VV Supports NCSX

• 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 the 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.

Conclusion – Heating/Cooling System NCSX

• 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.