Post on 19-Jan-2018
description
NCSX TF Coil Conductor FDR 5/17/05 1
NCSX
Michael Kalish
NCSX TF Conductor
NCSX TF Coil Conductor FDR 5/17/05 2
NCSX
Outline
• Requirements• Design• Calculations• Specification, SOW• Procurement
NCSX TF Coil Conductor FDR 5/17/05 3
NCSX
Requirements
• Is the material specified correctly?• Are the yield and ultimate specified for the
conductor appropriate?• Is the hole big enough?• Is the copper cross-section big enough?
NCSX TF Coil Conductor FDR 5/17/05 4
NCSX
TF Coil Winding Pack
• Winding Pack 3x4• Extruded Conductor
Wound “Hard Way”• Center Hole LN2 Cooled• Each Layer Requires 88’,
100’ to 110’ supplied• 4 Spools Required per Coil
NCSX TF Coil Conductor FDR 5/17/05 5
NCSX
Drawing / Tolerances
• Discussions with Vendor Indicate Tolerances Reasonable
• Edge Radius results from R&D
NCSX TF Coil Conductor FDR 5/17/05 6
NCSX
Winding Pack Insulation Scheme
3/8” Groundwrap on outboard leg
1/8” Groundwrap on inboard wedging leg
• Inner TF leg ground wrap thickness is 1/8”• Outer leg of TF coil allows for the use of tough 3/8” ground
wrap• Insulation thickness can accommodate potential .020 inch
tolerance build up easily
NCSX TF Coil Conductor FDR 5/17/05 7
NCSX
Conductor Material Properties
• Yield Strength– Yield Strength shall be 26,000 psi min. (180 MPa) to 30,000 psi
max. (0.5% extension under load) at room temperature– At LN2 Temperature 225 MPa Min.
• Tensile Strength– Ultimate Tensile Strength shall be 36,000 psi min. (248 MPa) with
a minimum extension under load of 25% at room temperature– At LN2 Temperature 340 MPa Min.
• Hardness– The conductor shall have a Rockwell Hardness F between 60 and
70 at room temperature. If there is a discrepancy between the Hardness requirement and the Yield Strength requirement the Yield Strength measurement shall be the governing requirement.
NCSX TF Coil Conductor FDR 5/17/05 8
NCSX
Maximum Conductor Stress
• Requirement + Assumptions showing Highest Conductor Stress
• Half Tesla TF Only Analysis
• Un-bonded assumption• Maximum Stress = 117
MPa
NCSX TF Coil Conductor FDR 5/17/05 9
NCSX
Yield and Tensile Requirement Adequate per Analysis
• Primary Membrane + Bending (PM+PB < 1.5Sm):
σ(PM+ PB) =117 MPa < 225 MPa (1.5Sm)
• General Primary Membrane (PM < 1.0Sm):
σ(PM) = FZ/ACu = 30 MPa <150 MPa (1.0Sm)
NCSX TF Coil Conductor FDR 5/17/05 10
NCSX
Fatigue Requirements Met
• Fatigue (Cumulative Usage Factor, CUF < 1.0)Entering the 2x stress design-basis fatigue curve with an alternating stress of 74 MPa yields an
allowable number of cycles ~100,000 cycles > 13,000 cycles required
σeq(alt) = σalt /{1 - σmean/σut} = 62/{1-55/340} = 74 MPa
NCSX TF Coil Conductor FDR 5/17/05 11
NCSX
Thermal / Hydraulic Analysis Verifies Cross Section and Hole Diameter
• With given cross section and hole size:• Peak temperature and recovery time
calculated for maximum required pulse (0.5 Tesla TF field) for 16.2 kA peak current with a 1.64 second equivalent square wave (ESW).
• Peak temperature rise of the coil is ~3.5 deg.K (~6 deg.R) per pulse
• LN2 system will be pressurized to a min. pressure of 60psi allowing a max temp of 95K for single phase LN2 flow
• Peak temperature insensitive to flow rate• Full recovery to 80 deg.K after ~720
seconds with a 60 psi differential pressure applied.
•Pre-Pulse Temp 80K•System pressure adequate to guarantee single phase flow•Pulse repetition rate shall not exceed 15 minutes
NCSX TF Coil Conductor FDR 5/17/05 12
NCSX
Procurement
• Cost and Delivery based on preliminary quotes• Cost per Spool
247 lbs per spool x $4.47/lb = $1104• Conductor order for 19 coils + one spool for R&D
Total = $1104 x 77 spools = $85K• Delivery = 60 days
(+shipping for OutoKumpu)