1 / 48

FDR - NCSX Central Solenoid Support Structure Fred Dahlgren Joe Rushinski 6 Sept 2006

FDR - NCSX Central Solenoid Support Structure Fred Dahlgren Joe Rushinski 6 Sept 2006. FDR - Central Solenoid Support Structure - 9/6/06. Charge: Does the coil structure provide adequate support for the PF1a coils with sufficient margins of safety?

zohar
Download Presentation

FDR - NCSX Central Solenoid Support Structure Fred Dahlgren Joe Rushinski 6 Sept 2006

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. FDR - NCSX Central Solenoid Support Structure Fred Dahlgren Joe Rushinski 6 Sept 2006

  2. FDR - Central Solenoid Support Structure - 9/6/06 Charge: Does the coil structure provide adequate support for the PF1a coils with sufficient margins of safety? Have the interfaces with other sub-systems been defined and are they compatible? Are the drawings and supporting documents complete and ready for sign-off? Has the analysis been documented and checked? Are the cost, procurement and assembly schedule consistent with the program schedule and budget?

  3. FDR - Central Solenoid Support Structure - 9/6/06 Design Description: •The structure consists of solution annealed 304L stainless weldments fabricated mainly from 1/4”, 3/8”, 1/2” and 3/4” thick plate (µ < 1.02). •The individual structural segments are 120 degrees with G-11CR insulating plates, bushings, and washers between the adjacent segments. •A mid-plane sub-assembly will space the top & bottom PF1A coils (re-claimed from NSTX), at ± 40 cm from the mid-plane. •The top and bottom sub-assemblies will have six 3/4” tie rods with nuts and belleville washers and will provide a 12,000 lb. axial pre-load clamping force on the two PF1A coils. The bellevilles’ will accommodate up to 0.015” of differential thermal contraction/expansion (~ 0.007” amount required). •Twelve radial support arms (6-top & 6-bottom) will attach the solenoid structure to the main coil structure. •All bolting materials (nuts, bolts, washers, etc.) will be 316 stainless.

  4. FDR - Central Solenoid Support Structure - 9/6/06 Coil Dimensions: 12.8” I.D. 16.26” O.D. 21.08” axial length 48 turns Cu area: 0.52 sq.in. Hole dia.: 0.354” Leads: 12.6” & 16.9” Fabr. Details see: NSTX-SPEC-13-041 Coil Description: 48 turn double layer spiral wound, 0.787” square CDA107 drawn Cu conductor with 0.354 dia. coolant hole. Insulation: 0.026” thk. CTD112P w/0.0065” Kapton-1/2-lapped (0.052” turn to turn) & 0.054” thk. ground wrap. PF1a Coil Modification: Water fittings & tubes must be re-worked & re-insulated

  5. FDR - Central Solenoid Support Structure - 9/6/06 PF1a Coil/Structure Assembly - Pre-assembled

  6. FDR - Central Solenoid Support Structure - 9/6/06 111.5”

  7. FDR - Central Solenoid Support Structure - 9/6/06 Assembly will have ~55” clearance for lift

  8. Materials: 304L solution annealed plates ER316LN weld filler 316L nuts, bolts, washers, & rods G10/11CR insulating plates @ 120 deg. G10/11CR washers & bushings Copper tubing Brass Swagelok (B-600 series) tube fittings Interfaces: Cryogen cooling lines connect to top & bottom LN2 feed/return lines. Pressure & flow requirements defined, connecting lines (with insulating breaks) to cryogen supply & return plenums are needed. Four thermocouples are required to monitor coil inlet/outlet. Bus pads at the top & bottom locations are defined. Bus connection to power supply are needed. Bus interface defined, scenario A.1.3.4 defines the current & voltage requirements. Top & bottom mounting pads bolt to same threaded holes to be used for permanent solenoid supports. Loading @ support interface defined.

  9. FDR - Central Solenoid Support Structure - 9/6/06 * * From Allegheny Ludlum Technical Data Blue Sheet

  10. 304L Properties* 2/3rd Yield allowable @80K = 46.6ksi * From Allegheny Ludlum Technical Data Blue Sheet

  11. 0.787 Ø 0.354 FDR - Central Solenoid Support Structure - 9/6/06 Cooling analysis: Plot of the PF1a exit temperature vs. time DP = 10 psi Qdot = 1.14 GPM AMPS = 19.3 kA ESW = 0.16 sec. Rep.Rate = 900 sec. Cooling Analysis Shows < 1 deg.K rise per pulse & no ratcheting

  12. FDR - Central Solenoid Support Structure - 9/6/06 FEA Model of PF1A & Supporting Structure: • A 1/6th-Upper half Nastran linear FEA model was used. • PF1A coil modeled as discrete turns with insulating layers (CHEXA & CPENTA). • Structural components modeled with plate elements (CQUAD4 & CTRIA3). • Tie rods modeled with solid elements (CHEXA & CPENTA). • Bolts modeled with CBAR elements attaching plates & adjacent weldments. • EM loads on PF1A determined from dforce7b (Biot-Savart - U.C. code). • Symmetry boundary conditions were applied (toroidal, vertical and rotational). • Coil top & bottom surfaces not permitted to slide radially (rel. to supports). • Model Summary: Number of GRID Points = 21979 Number of CBAR Element = 57 Number of CHEXA Elements = 13232 Number of CPENTA Elements = 1696 Number of CQUAD4 Elements = 2287 Number of CTRIA3 Elements = 170 • Loading Conditions considered: Gravity, EM, Thermal, Seismic

  13. FDR - Central Solenoid Support Structure - 9/6/06 3/4” Tie Rod / belleville washer, and bolted connection modeled

  14. FDR - Central Solenoid Support Structure - 9/6/06 PF1A Coil Model: CPENTA & CHEXA isotropic Cu & Epoxy Glass

  15. FDR - Central Solenoid Support Structure - 9/6/06 Loads considered: Gravity Loads with 1g & 2g vertical downward, B.C.: Symmetry & fixed at the upper bracket bolts (attached to the inner segmented ring castings which are assumed rigid). Horizontal seismic loading using static 0.15g acceleration per the NCSX/IBC2000 criteria (h~15ft, Fp=0.108 x 1.369 = 0.147 ~ 0.15g). B.C.: Symmetry & fixed @ upper bracket bolts. Thermally induced stress from cool down and temperature differentials using mean CTEs from R.T. to 77 oK. B.C.: Symmetry & fixed @ upper bracket bolts. (CTE-Cu from NIST data, CTE-304L from ITER data) Electro-magnetic loading for coil day-1 scenario A.1.3.2: Ipf1a = 19,299 A & 23,500 A (simulates M.C. loading) Ipf4 = 3,141 A Ipf6 = 241 A Ipl = -26,068 A & 0.0 A(Ipl = 0.0 was highest loading) B.C.: Symmetry & fixed @ upper bracket bolts.

  16. FDR - Central Solenoid Support Structure - 9/6/06 Vertical Displacements for a 1-g gravity: Max = 0.0025”

  17. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress: 3.44ksi Peak Tresca stress - 1-g loading: 3.44 ksi @ mtg. bolt holes

  18. FDR - Central Solenoid Support Structure - 9/6/06 Vertical Displacements for (fault) 2g loading condition: -.005” max.

  19. FDR - Central Solenoid Support Structure - 9/6/06 Tresca Z2 stress for a 2g loading condition (ie. if bottom supports loose or removed) Max Stress: 7ksi @ the mounting bolt holes

  20. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress 2.0ksi Lateral 0.15g seismic displ. 0.002” at the middle of the tierod Peak Tresca stress 2 ksi @ the bolt hole Seismic (static) load 0.15g horizontal acceleration with top mtg. bracket fixed

  21. FDR - Central Solenoid Support Structure - 9/6/06 Thermal Loading: Coil @ 80K & Structure @ R.T.(extreme case) Max Vertical displacement: -0.085” @ the top of the coil

  22. FDR - Central Solenoid Support Structure - 9/6/06 Need to avoid extreme thermal differentials during cooldown Peak Tresca Stress 78.6 ksi >> yield stress & allowable

  23. FDR - Central Solenoid Support Structure - 9/6/06 ∂y ~0.005” ∂y (tot.): -0.0115” A more realistic thermal loading assumes a temperature difference of 30 K and yields a relative vertical displacement of -0.012”. The differential rod & bellville to top plate shows about 0.005” - just over 50% of it’s linear range.

  24. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca: 15.6 ksi Peak Tresca stress for a 30 K temperature differential: 15.6 ksi

  25. FDR - Central Solenoid Support Structure - 9/6/06 Tresca Peak Stress is 4.6 ksi in coil insulation for 30 oK temperature differential

  26. FDR - Central Solenoid Support Structure - 9/6/06 Baseline EM Loads assumed the 0.5T 1st Plasma Scenario Coil EM Loading No Plasma: Fr = 4,369 lbs/in [5,660 lbs/in*] Fz = -3,722 lbs (total) [-6,355 lbs*] DFORCE7b result: Hoop Stress(avg.)=1.27ksi [1.84ksi*] Net Stress = 1.54ksi With Ipl = -26,068 amps Fr = 4,318 lbs/in Fz = -3,647 lbs (total) DFORCE7b result: Hoop Stress (avg.)=1.25ksi Net Stress = 1.53ksi *For Ipf1a = 23,500 Amps

  27. FDR - Central Solenoid Support Structure - 9/6/06 EM Loading was calculated as J x B body forces at each coil turn. Genforce subroutine added to DFORCE7b to generate Nastran Force input. Equivalent discrete forces for the worst cases were applied at each of 6 interior element grid points. Centroidal currents (@ each turn) were assumed. The loading from the M.C. field was simulated by running a 23.5 kA PF1a current case, which duplicates the peak vertical loading from the M.C. radial fields.

  28. FDR - Central Solenoid Support Structure - 9/6/06 Typical EM grid point load resultants @ 6 interior points in conductor

  29. FDR - Central Solenoid Support Structure - 9/6/06 Peak Displ. 0.0005” Coil Displacements (SRSS) From 19.3kA EM Loads - No Axial Pre-load No Plasma -Maximum displacement was 0.0005” at the coil mid-plane

  30. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca: 1.83ksi Peak Tresca stress in the coil from 19.3kA EM loading only: 1.83 ksi

  31. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress in supports 19.3kA EM + Thermal (cool-down): 14.0 ksi (with CONROD elements at bolt hole perimeter)

  32. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress in supports 19.3kA EM + Thermal (cool-down): 2.51 ksi (with MPCs replacing CONROD elements at bolt hole perimeter)

  33. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress in Cu 2.78 ksi Peak Tresca Stress in Coil for 23.5 kA EM-only loading, 2.78 ksi (Loading includes the effects of the M.C. peak fields)

  34. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress in Support for 23.5 kA EM loading, 3.68 ksi

  35. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress: 3.17 ksi Peak Cu Tresca Stress: ~2.9 ksi Peak Tresca Stress in coil insul. for 23.5 kA EM-Cold loading, 3.17 ksi, 2.9 ksi in Cu

  36. FDR - Central Solenoid Support Structure - 9/6/06 Peak Displ. 0.167” (SRSS) Displacements for combined gravity, thermal, EM loading

  37. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress = 3.16 ksi - insulation Average coil Tresca stress ~2-3ksi Tresca stress in coil from combined gravity, thermal, and EM loading

  38. FDR - Central Solenoid Support Structure - 9/6/06 Peak Tresca Stress 2.68 ksi Peak Stress in supports from combined gravity, thermal, and EM load

  39. FDR - Central Solenoid Support Structure - 9/6/06 Stress Analysis Summary *Allowable 304L @ 80 oK = 46.6 ksi (321 MPa) (2/3rd yield criteria) Allowable CDA107(10%CW) Cu @ 80 oK = 16 ksi (110.6 MPa) (2/3rd yield criteria) ** Allowable CTD112P-w/Kapton @ 80 oK = 8.86 ksi (61.3 Mpa 2/3rd ultimate criteria) -per ITER test data § Actual margins on max shear are double these values (C2 = 0.6, Sc= 0.0 - Eqn. From NCSX design criteria, 5.6 ksi no compr.) **Sy = 124 - 0.241xT +14.1xCW - 0.166xCW2 = 230.5MPa, 2 x sigma = 64 MPa, 230 - 64 = 166, 2/3 x 166 = 110.6 MPa (16 ksi) (From NIST Monograph 177 -Simon, Drexler, Reed)

  40. FDR - Central Solenoid Support Structure - 9/6/06 Coil Testing Requirements: Electrical After re-configuring and re-insulation of coolant tubes, coils will require a hi-pot to ground at 2 kV (2 x Vop. +1000) and a megger at room temperature and 80 deg.K. Insulating breaks between field periods will be meggered @ 2kV Mechanical During cool-down for 80 deg.K electrical test, a flow measurement for a delta-P of 10psi will be required. Thermocouples on inlet and outlet tubes will be needed to provide a record of T vs. time for the cool-down.

  41. FDR - Central Solenoid Support Structure - 9/6/06 Cost & schedule: •Build in-house preliminary est: ~75k$ •Will issue an RFQ for 304L & 316L by late Sept.’06 •Anticipate a 4-6mo. Delivery •A 316L material may delay things a month or two and may cost 30% more.

  42. FDR - Central Solenoid Support Structure - 9/6/06 Conclusions: Charge: Does the coil structure provide adequate support for the PF1a coils with sufficient margins of safety? A: Stress margins on allowables for both coil and support exceed project & code requirements. Have the interfaces with other sub-systems been defined and are they compatible? A: Interfaces to machine structure, cryo-system, and electrical power defined & compatible. Are the drawings and supporting documents complete and ready for sign-off? A: Drawings & BOM are complete and ready for checking/sign-off. Has the analysis been documented and checked? A: The stress & thermal analysis have been documented & are being checked. Are the cost, procurement and assembly schedule consistent with the program schedule and budget? A: Cost & schedule are consistent with project schedule and, pending responses from RFQ, should fall within the current project budget.

  43. FDR - Central Solenoid Support Structure - 9/6/06 per A.Brooks 9/1/06

  44. FDR - Central Solenoid Support Structure - 9/6/06 per A.Brooks 9/1/06

  45. FDR - Central Solenoid Support Structure - 9/6/06 Fatigue analysis: 304L Peak Tresca Stress: 15.6 ksi (EM + 1g + 30 oK delta) Operating stress below the s/2 @ 130,000 cycles 15 20x life The 2/20 project criteria for fatigue is satisfied although the anticipated usage of the PF1a coils and supports is significantly less than the 130,000 cycles.

  46. FDR - Central Solenoid Support Structure - 9/6/06 Shear Strength CTD112P (w/Kapton) 13.3 ksi @77 deg.K

  47. FDR - Central Solenoid Support Structure - 9/6/06 ITER shear-compression tests Max Shear: 6.78 ksi for 15 degree angle(12ksi compr.) @ 77 deg. K 6.7 ksi 40 MPa, 5.8 ksi-static & fatigue

  48. FDR - Central Solenoid Support Structure - 9/6/06 Inner radial stop will maintain central alignment of PF1a coils

More Related