Transcript Lehman_headers_presen_a_plg_B.Nelson.ppt

WBS 16 Coil Services System
Cost Estimate Design Basis
P Goranson 8/1/07
Coil Services System Description
The coil services consist of the cryogenic feeds and electrical leads
inside the cryostat, serving all of the coils, including conventional.
It includes the specification of requirements
for the coil protection system.
Lower-level elements include:
LN2 Distribution System (WBS 161);
Coil Electrical Leads (WBS 162); and
Coil Protection Requirements (WBS 163)
WBS 161 LN2 Distribution System
Description
This element covers the distribution of liquid nitrogen (LN2) coolant
within the cryostat. The system serves all the coils: the TF (WBS
131), PF (WBS 132), External Trim (WBS 133), and Modular (WBS
14) Coils.
Scope
Work includes engineering design, procurement, and fabrication of
manifolds, cooling hoses, jumper hosing, valving, and associated
supports. I&C is procured in 1408. WBS161 responsibility ends at the
LN2 supply/return header interfaces within the Cryostat. Work in this
WBS ends with delivery of components to machine assembly
operations.
WBS 162 Coil Electrical Leads
Description
This element covers the electrical leads within the cryostat, serving all the coils: the
TF (WBS 131), PF (WBS 132), External Trim (WBS 133), and Modular (WBS 14)
Coils.
Scope
Work includes engineering design, procurement, and fabrication of cables, mounting
brackets, thermal transition boxes, and associated supports. The WBS161 interface
ends at the cryostat thermal transition/terminal box. It does not include I&C, bus work,
or routing in the test area. Work in this WBS ends with delivery of components to
machine assembly operations.
WBS 163 Coil Protection System
Description
This element covers the specification of coil protection requirements for the coil
protection system.
Scope
Work covers Title I, II, and III Engineering support for development of the system,
including drawings, Electrical and I&C schematics, analyses, and procurement
specifications.
Design Overview
• View graphs deal primarily with MC design
• To date, most of design effort has
concentrated in this area
• Conventional coils will be handled in a
similar manner and use identical
components.( same cable, hoses, brackets,
terminations, manifold connectors, etc.)
NCSX Device Showing Coils
Modular Coil and Conventional Coil Cooling
Requirements
• Operate at 77 K with LN2.
• Operating pressure 5 atmospheres absolute.
• Routing and distribution of coolant between coil input and output
terminations and supply/return manifolds.
- WBS16 provides distribution manifolds, tubing, hose, etc.
- WBS17 provides supply/return to headers and hook up interfaces
in the Cryostat
• Electric breaks in MC coil coolant lines poloidally.
• Electrical current limitation between cooling components. (bypass resistors
isolate hoses to ground)
• Flow balance between systems is required.
Conventional Coil Cooling System Diagram
2” Return Header
1.5” Ring Header( manifold)
MC hook up 1-48
2
1
PF Coils (pairs)
1&2
TF Coils
1-6
4
3
5
6
7
45 46 47 48
Resistor
TC TC TC TC
2
1
3
4
6
5
TC
1
2
TC
G-10 Insulator
With flow control orifice
Flow control valve
Outer
Inner
Insulated
jumper
MC
TF
PF
Poloidal
break
Flexible
hose
G-10 Insulator
6
5
1
2
3
7
45
46
47 48
1
2
3
4
5
6
2
1
4
4
MC hook up 1-48
1.5” Ring Header
Typical Field Period Cooling Circuit
- One side of a Modular Coil shown
TF Coils
1-6
2” Supply Header
PF Coils (pairs)
1&2
Cryostat Boundary
MC manifolds
• Manifolds lie outside TF coils
- supply near bottom of VV
- return near top of VV
• Tradeoff study was performed to study
pros and cons of inside vs outside positions
- outside position permits easier
access for installation and maintenance
- prevents “building in” and trapping
the manifolds.
G11
coupling
resistor
Header
Manifold Jumpers
Transition to flex hosing at the winding form
Manifold hose insulators
Hoses are isolated from the
manifolds by G10 plugs
- prototype will be tested
at 77K
-orientation of individual
connections is TBD
G10 CR Male / Female coupling
Resistor
316 SS braided hose with 5/16 OD
straight tube coupling at both
ends
316 SS Yor-Lok 5/16 OD tube
one end and ¼” NPT on other
end
MC Coolant loops and termination
• Each winding pack has four inlet/outlet lines,
with two lines interrupted by poloidal break
• One leads area chill plate per side
• Concept includes a manifold
mounted to winding form
MC Tube termination
Truly Tubular
Brazetyte 5FF-5-4
bleed hole
fittings
bracket
MC Lead area chill plates
G11
coupling
loop to pick up
chill plate
Leads
Requirements:
• Connect between bus bars in test cell and coil terminals inside
cryostat.
• Operate nominally at 77-80 K but no active cooling is required,
Cryo environment is sufficient to return temperature to
operating level between shots.
• Grounding protection cover over leads.
• Provide Cryostat seal interface.
– Minimize icing
– Maintain positive pressure in Cryostat
• React magnetic loads.
• Cancel (minimize) field errors.
Lead Configuration
Cable is 250 MCM
1” long spider/loom
5/16” Stud
Standard
1.5” Pipe Clamp
(1/8” thk x 1” Wide)
Casting
Typical interface of a modular coil’s leads as they transition from
coil attachment, thru the cryostat, to room temp.
Cryostat Floor
Leads Junction Box
(Clear cover removed)
Typical modular coil leads attachment.
The configuration of this joint will be optimized
to reduce the resulting electrical loop
Flange joints to
make cable
insertion easier
Top View of an 8” diameter
pipe chase showing the
(6) modular coil leads
cables from a field period
Pipe Chase
Hard Bus to
power supplies
Type “A”
Modular Coil
Cryostat
Wall/”Bag”
TF Coil
Rigid
Cryostat
Floor
Junction Box
Insert showing Junction
Box location in test cell
Cryostat Floor
Cost Estimate Basis
•
LN2 hoses are catalog items.
– Lengths are based on ProE models.
•
Manifold designs and prices are based on a similar design used on the VV.
– Sizing is based on thermo hydraulics performed by Engineering.
•
Material cost is estimated on a $ per lb at current market.
•
Cable and spacers are catalog items.
– Lengths are based on sketches in work sheet.
•
Supports are based on a $/length of cable.
•
Engineering time is based on number and type of drawings for each element,
specifications, and the analyses anticipated.
Cost Estimate Risks
•
LN2 Distribution System (WBS 161)
Design is straight forward and procured items are by and large commercially stocked.
Manifolding is similar to gas system on VV, which is complete and costs are well
documented.
Maturity – high
Complexity – low
•
Coil Electrical Leads (WBS 162)
Design is straight forward and large ticket procured items (cable and mounts) are
commercially stocked. No complications such as active cooling are required.
Maturity – high
Complexity – low
•
Coil Protection Requirements (WBS 163)
Specifications may be replaced with data sheets, in that procured items are available
as stock items.
Maturity – high
Complexity – low