G. Gettelfinger for the NCSX Engineering Team

1. NCSX Coil Test Facility Single Phase LN2Mechanical/Plumbing Final Design Review G. Gettelfinger for the NCSX Engineering Team November 10, 2004

2. PREAMBLE • The coil test facility (CTF) has had previous design sessions and reviews focusing on: • Overall ES&H themes • AC/DC high-amperage power • Low-level controls • Data Acquisition • Electrical construction and sequencing interlocks are complete • Today’s review focuses on plumbing NCSX Coil Test Facility Mechanical/Plumbing FDR

3. CHARGE FOR PLUMBING FDR • Assure that: • [1] the requirements are documented; • [2] the design satisfies the requirements; • [3] the design has appropriate safety features incorporated; and • [4] the design documentation is adequate and appropriate to complete the installation. NCSX Coil Test Facility Mechanical/Plumbing FDR

4. Coil Test Facility Thermo-Hydraulic Requirements • GRD Rev.2 suggests that 3.4e6J must be removed from a particular modular coil in 15 minutes. The CTF must support this operating scenario. • P. Goranson offers that the LN2 temperature will likely not exceed 95.4 K. He further expects 1.7 atmos. (25psid) pressure drop max. across the coil at about 6.2 gpm of liquid flow • The CTF must provide single phase flow to a particular coil. • All ES&H themes must be fully supported NCSX Coil Test Facility Mechanical/Plumbing FDR

5. A variable frequency-driven, existing-design production pump will be delivered on about Dec. 15. This can deliver up to about 10 gpm at 6500 rpm. The required scenario is supported at about 6100 rpm moving 7 gpm in the face of 35 psid (plenty of capability) CENTRIFUGAL PUMP NCSX Coil Test Facility Mechanical/Plumbing FDR

6. P&ID FOR COIL TEST FACILITY NCSX Coil Test Facility Mechanical/Plumbing FDR

7. P&ID FOR COIL TEST FACILITY • The design allows for: • Warm/cold cryostat purge • Warm/cold line/load purge • Suction pressure maintenance (63.8 psig for 95K) • Batch-in of replacement liquid (for minor leaks) • “Fill the bucket” flow measurement NCSX Coil Test Facility Mechanical/Plumbing FDR

8. PRESSURE LEVELS / CALCULATIONS • 64 psig Suction for 95K ops • 91 psig Likely pump press. for coil drop plus pipe drop • 150 psig Relief valve level • 200 psig Recommended to coil engineers on as test pressure for cooling circuits – 33% above auto action limit • 401 psig B31.3 limit for tank design • 947 psig Non-ASME limit for G-10/11 1” pipe • 1,120 psig B31.3 limit for ¾”-M tube (Hx) • 1,390 psig B31.3 limit for 1”-L tube (majority) NCSX Coil Test Facility Mechanical/Plumbing FDR

9. TANK(S) DESIGN • Schedule 10S 12-inch 304SS pipe with 10S caps form the hull of the tank. • Full penetration bevel-groove welds with backing • Welded half couplings and half nipples comprise the outlets. • ¼’ leg fillet welds NCSX Coil Test Facility Mechanical/Plumbing FDR

10. FIRST LOAD – PLANAR RACETRACK COIL • Planar racetrack coil will first be used • Next in queue: Twisted racetrack coil NCSX Coil Test Facility Mechanical/Plumbing FDR

11. HEAT EXCHANGER DESCRIPTION • Boiling heat transfer below critical heat flux • Calculation – A non-iterative method suggests that ONE six-foot bare ¾” copper tube immersed in LN2 may be adequate -6.3e6 J in 15 minutes (3.4e6 J required) • Design - overkill – strong is never wrong • 18-feet of finned tube per path($40/8 ft!) NCSX Coil Test Facility Mechanical/Plumbing FDR

12. Hx GRAPHICS (1of5) Hx contains 3 independent paths NCSX Coil Test Facility Mechanical/Plumbing FDR

13. Hx GRAPHICS (2of5) Each of 3 paths has 18-feet of 2 1/8 aluminum fins NCSX Coil Test Facility Mechanical/Plumbing FDR

14. Hx GRAPHICS (3of5) Bundles are provided with gravity supports NCSX Coil Test Facility Mechanical/Plumbing FDR

15. Hx GRAPHICS (4of5) Support scheme has baffles to shroud upper assemblies from gas bubbles generated underneath NCSX Coil Test Facility Mechanical/Plumbing FDR

16. Hx GRAPHICS (5of5) 3-path assembly resides in an aluminum tub to contain secondary, boiling fluid NCSX Coil Test Facility Mechanical/Plumbing FDR

17. SKID ARRANGEMENT • Shows bottom insulation, tanks, Hx, valve board, elec cab, pump, skid weldment • Insulation is Dow Trymer 2000 (K=.19 BTU/in*hr/ft2) NCSX Coil Test Facility Mechanical/Plumbing FDR

18. INDUSTRIAL HYGIENE TOPICS • Silver/Copper/Phosphorous brazing alloy will be used (many times). • No cadmium • Expanding polyurethane foam insulation will be used in CLOSE COORDINATION with IH personnel. NCSX Coil Test Facility Mechanical/Plumbing FDR

19. MECHANICAL SAFETY TOPICS • Liquid Oxygen/Liquid Air Hazard • LOx and LAir both condense above 77K • Annulus between field lines and insulation shall be filled with expanding polyurethane foam • Boil-off of N2 in conjunction with trap keeps cryostat free of atmospheric air • Pressure Safety • All components have adequate strength at the 150 psig relief pressure • Every isolable zone provided with ASME relief valve NCSX Coil Test Facility Mechanical/Plumbing FDR

20. COST AND SCHEDULE • $10K pump is accounted for (due Dec 15) • $12K additional M&S expected • NCSX schedule shows ops in late Jan ’05 • Eng Dept to consider resource availability for Fab & Ops • Ring-out late Feb ’05 seems plausible NCSX Coil Test Facility Mechanical/Plumbing FDR

21. CTF MECH/PLUMBING, SUMMARY • Requirements are stated • Design supports flow, heat removal objectives & fully rings out single-phase cooling concept • Safety themes dilligently considered and acted upon • P&ID, device/line lists, and models are ready for shop. NCSX Coil Test Facility Mechanical/Plumbing FDR