Status of Modular Coil Design D. Williamson, 4/9/03 Prototype Winding Form - Interim model based on m50_e03 - PF/TF supports, poloidal break added - To

Status of Modular Coil DesignD. Williamson, 4/9/03

Prototype Winding Form- Interim model based on m50_e03- PF/TF supports, poloidal break added- To be superseded by Production Type-C

Production Coils and Forms- WC, XV updated to m50_256.z01- Tweak of shell surface, coil twist in progress- Pattern of clamps being optimized for space- Additional features are being added - Type-C model will become prototype

View at V=0 (NB Port)

Inboard View at V=0 (NB Port)Current, kA 653Width, in 4.100Height, in 4.671

Tee Width, in 0.750HT Layer, in 0.040Groundwrap, in 0.030Turn Insulation, in 0.054Clamp Width, in 0.000

Cond Width, in 0.660Cond Height, in 0.395

Current Density, kA/cm2 13.8

A A B

C

Inboard View at V=1/2 (FP Joint)

C CBA B

Interface A-A

Interface A-B

Interface B-C

# ITEM REQUIREMENT RESP SUCCESS STATUS 4/9/2003

1 General requirementsSpecify general requirements for NCSX facility. Emphasis on performance characteristics of sub- systems during typical operating scenarios and off- normal conditions.

Reiersen Issue for commentIssued

8/12/02 Complete

2 Conduct peer review of GRD ReiersenResolve comments,

sign and place under change control

Peer review scheduled for

4/3/03Complete

3Modular coil design

requirements

Specify functional requirements, characteristics, and constraints for modular coil systems. Requirements flow from GRD.

Williamson Issue for commentTo be issued

4/16/03 50% needs formatting

4 Conduct peer review of MC Design Requirements Doc WilliamsonResolve comments,

sign and place under change control

5 Basic geometry

Develop ProE models that define basic coil configuration, including electrical, thermal, and structural features: - Winding center and x- vector - Winding pack dimensions

Williamson Post in IntralinkUpdating e03 to

z01, to be posted 4/9/03

70%

shell shape and winding twist are still the biggest issues

6Develop overview drawing of each coil assembly. Include weight calculation for ICD: Support Structures. Review drawings as part of Task #37.

Williamson Post in IntralinkTo be posted

4/11/03 30%falls out quickly once models are done

7 STL models Create STL models of vessel and coils. WilliamsonPost .zip file in

Intralink

Waiting on vessel, coil

models

8 Procure models through quickparts.com WilliamsonSend to QuickParts,

receive modelsNeed to send

by 5/1/03

9Interface scope

sheetsPrepare list of functional and physical interfaces between modular coils and other primary systems.

SimmonsIssue for comment, resolve comments,

post on web

Posted 12/19/02 Complete

10ICD: Support Structures

Develop a drawing that defines the physical interface between MC assembly and PF/TF structure. Write ICD.

WilliamsonPost in Intralink,

review with Feder, issue ICD

To be posted 4/23/03

11Calculate net EM loads from MC to support structure. Output of Task #30. Write ICD.

FanIssue EM loads memo,

issue ICDTo be issued

5/9/03

ICD: Vacuum VesselDevelop a drawing that describes the physical interface between MC assembly and vacuum vessel. Write ICD.


review with Goranson, issue ICD


12 ICD: Coil ServicesDevelop a drawing that defines the position of electrical leads on the MC assembly.


review with self, issue ICD


13Develop a drawing that defines location of LN2 connection between MC assembly and cryostat manifold.


review with self, issue ICD


14 ICD: CryostatCalculate mod coil parameters that affect cool- down, heat load to cryostat. Document on MC assembly drawings.

Williamson

Post in Intralink, review with

Gettlefinger, issue ICD

To be issued 4/25/03

15 ICD: AssemblyDefine asm related attachments, lifting points, clearance requirements for field period and final assembly. Document on MC assembly drawings.

Williamson

Post in Intralink, review with

Chrzanowski, issue ICD


16 ICD: RF SystemDevelop a drawing that defines access for RF system coax feeds.


review with Majeski, issue ICD


17 ICD: DiagnosticsDefine co- wound magnetic sensor loops for mod coils. Document on MC assembly drawings.

StrattonSketch and ICD from

Stratton, Post in Intralink

ICD issued 3/23/03,

drawings to be posted 4/23/03

70%

REQUIREMENTS

CONFIGURATION AND INTERFACES

PDR Tasks

PDR Tasks

18Develop detailed ProE models and drawings of production winding forms. Include comments on ICDs and feedback from Manuf Dev tasks.


5/9/03 20%will go quickly once type C is figured out

19Develop detailed ProE models and drawings of winding packs, including leads.



20Develop detailed ProE models and drawings of clamps and cooling system.



21Develop assembly models and drawings, including bolts, insulation, assembly features.



22 Develop draft specification for production winding forms. Williamson Issue specificationTo be issued


23Conduct peer review of draft spec and drawings before releasing to Manuf Dev teams.

WilliamsonResolve comments, promote models and

drawings

to be scheduled before 5/1/03

24 ElectricalCalculate current waveforms and electrical parameters. Document as technical data on web.

Reiersen Post on webTo be posted

4/4/03 30% needs conductor size

25Calculate eddy current time constants for MC structure. Document in memo.

Brooks

Issue eddy current memo, resolve

comments, post on web

To be issued 4/4/03 90% Need memo

26 ThermalCalculate heat transfer and temperature distribution in winding pack due to current pulse. Document in memo.

Fan

Issue thermal analysis memo, resolve


To be issued 4/4/03 90% Need memo

27Calculate thermal stress in winding pack and clamps due to current pulse.

Freudenberg

Issue thermal stress memo, resolve


To be issued 5/9/03 30%

reasonable progress with modeling technique, clamp spacing

28Calculate cool- down of MC assembly from room temperature to 80- K. Document in memo.

Fan

Issue cool- down memo, resolve


To be issued 5/9/03

UT is doing similar analysis and this may help us

29 EM / StructuralDevelop finite element models for integrated EM and structural analysis.

Fan 30% Progress being made

30Calculate electromagnetic loads and identify critical load cases. Document in memo.

FanIssue EM loads memo,

resolve comments, post on web

To be issued 5/9/03

re- do 7 cases for new currents

31Incorporate winding pack material properties based on R&D test results.

Fanproperty data will be late

32Perform stress analysis for critical EM load cases and compare to allowables. Document in memo.

Fan

Issue stress analysis memo, resolve



MODELS AND DRAWINGS

ANALYSIS

PDR Tasks

33 Conductor PropertiesProduce samples of vacuum- pressure impregnated conductor for use in mechanical and thermal tests.

Zatz Samples ready

34Perform mechanical and thermal tests to determine properties of single and bundled conductor. Document through vendor reports.

Zatz Report from CTD Due in Aprilsamples to CTD next week

35Establish design allowables and document through structural design criteria.

ZatzIssue for comment, resolve comments,

post on web

Posted 5/13/02, awaits revision

36 Winding Form R&D Develop detailed drawings of Type C winding form. Williamson Post in Intralink Post by 4/11/03 50%drawings go relatively fast after models are done

37 Conduct peer review of Type C models and drawings. Williamson

Resolve chits, sign spec and drawings,

authorize vendors to proceed

38Describe manufacturing methods for all three forms and recommended casting alloy.

Heitzenroeder Report from EIO/ J PP Due 4/28/03

39Describe mold fabrication and analysis. Describe plan for heat treatment, repair, and inspection.


40Describe preliminary MIT plan and budgetary cost estimate for production coils.


41 PPPL Winding R&DConduct VPI trials on straight tee section. Develop VPI procedure, recommendation on needed design features. Document VPI procedure, current center analysis.

ChrzanowskiIssue for comment, resolve comments,

post on webIssued 3/21/03 Complete

42Perform keystone trials on coil fixture using single and bundled conductor. Document recommendations.


post on web

To be completed in

Aprilstarts next week

43Wind and VPI a racetrack demonstration coil with spliced crossover joint and leads. Document fabrication, test plan.


post on web

Winding, VPI done late April

winding form delivered for PPPL coil, UT coil to be

44Prepare FMECA identifying potential failure modes and recovery provisions.

WilliamsonIssue FMECA, resolve comments, post on

web


45Document design approach, analysis results, and comparison with performance requirements. Write design basis document.

Williamson

Issue design basis document, resolve comments, post on

web


46Develop cost and schedule estimates for MC Winding and Assy (WBS 142)

Chrzanowski

47Provide integrated cost and schedule inputs to Strykowsky for WBS 14

Williamson

48 Prepare Preliminary Design Report Williamson

49 Prepare presentations for PDR Williamson

MANUFACTURING DEVELOPMENT

DESIGN EVALUATION

COST AND SCHEDULE

PDR PREPARATION

Documents

Status of Modular Coil Design D. Williamson, 4/9/03 Prototype Winding Form - Interim model based on m50_e03 - PF/TF supports, poloidal break added - To