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Modular Coil Cooling Issues With Baseline & Status of Cooling R&D

Explore the issues with baseline cooling schemes and the status of cooling R&D in modular coil winding. Learn about cost risks and objectives of the cooling program. Discuss various challenges and solutions for effective cooling in the workshop.

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Modular Coil Cooling Issues With Baseline & Status of Cooling R&D

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  1. Modular Coil Cooling Issues With Baseline & Status of Cooling R&D James H. Chrzanowski Modular Coil Winding & Cooling Workshop June 10, 2004 PPPL Modular Coil Winding & Cooling Workshop

  2. Cost or schedule Risk • #1- Cooling Scheme • The complex geometry of the proposed chill plate cooling scheme could possibly add additional time to the installation process • Fitup of the plates and attachment of the cooling tubes are all issues that need to be addressed. • Possible cost risk (+ $500.0 k ) Cooling plates and tubing Modular Coil Winding & Cooling Workshop

  3. General Statement • All of the options that have been and will be discussed are achievable. They are options that will solve the cooling requirements for the modular coils. “All it takes is money and schedule” • The details and requirements for the latest cooling system will increase the installation time during winding. Modular Coil Winding & Cooling Workshop

  4. Cooling Program Objective • Objective Performance: • Provide the necessary cooling required to operate the modular coils • Cooling system must incorporate dielectric breaks as required • Objective Installation: • Hold costs and schedule • Minimize the amount of on-line time required to install cooling system. Compare the modular coil fabrication activities to an automobile assembly line. • Stage as many sub-assembly activities off-line. Modular Coil Winding & Cooling Workshop

  5. Issues With Baseline • Issues • Dielectric break requirements • Installation of outer chill plates • Attachment of cooling lines? • Working area- remember that installation of components is not performed on bench • Minimize the number of small parts (rivets) potential for lost parts in coil • More parts = longer installation times • Copper braid option: Introduces risk of the copper strands penetrating insulation prior to VPI Modular Coil Winding & Cooling Workshop

  6. Baseline Cooling Concept cladding Cooling tube • Requirements / constraints: • 15 minute cool-down • copper is electrically isolated from tee • No electrical continuity (loops) in copper parts in any direction • No copper parts larger than 2 inches • No electrical continuity through cooling tubing • Fits in .08 inches laterally (not tube) • Design • Copper cladding, formed from flat developments, next to tee • Copper chill plates on outside of winding pack connected to cladding • Chill plates have electrical break • Tubing brazed to copper strips • Strips attached to chill plates chill plates Electrical break Modular Coil Winding & Cooling Workshop

  7. Inner Cladding Plates • Present design with vertical slits work well • Easy installation • Partially annealed, water-jet cut, pre-formed plates • Complete cladding fitup in place Provide mating joint for plates Modular Coil Winding & Cooling Workshop

  8. Cladding to Chill Plates -149 degrees C 124 degrees K • Several options for connecting cladding to chill plates • Brazing- damage insulation • Tig welding- damage insulation • Riveting- tested • Staking- tested • Dielectric Break • Provide break using B-stage cryogenic insulation • Appears to work • -179 deg C to –149 degrees C (10 minutes) (no cryostat was used) • More tests needed -179 degrees C 94.6 degrees K Modular Coil Winding & Cooling Workshop

  9. Riveting Ends • Will be difficult to install in place • Too many loose parts • Time consuming Modular Coil Winding & Cooling Workshop

  10. Staking the Edge Connections • Looks good. No real difficulties • Fast efficient method • No loose parts Modular Coil Winding & Cooling Workshop

  11. Outer Chill Plates and Tubing • Installation of outer cooling tubes needs additional work • Pre-forming of cooing tube looks like good option. • Brazing or soldering tube in-place would damage insulation. • Pre-brazing to plates –alignment of components very difficult. • Attaching tubes with fasteners- real possibilities. Modular Coil Winding & Cooling Workshop

  12. Mounting Cooling Tubes to Chill Plates Modular Coil Winding & Cooling Workshop

  13. R&D Activities • R&D activities performed • Cladding to chill plate termination • Dielectric break cladding to chill plate • Cladding installation trials • R&D activities to be performed • Outer chill plate installation • Cooling tube to chill plates Modular Coil Winding & Cooling Workshop

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