NCSX Racetrack Test Coil Test Program

1. NCSX Racetrack Test CoilTest Program July 31, 2003 Race Track Test Coil

2. Test Plans and Objectives • The objective of this activity is to manufacture a coil which closely represents the cross section, insulation, conductor and cooling methodology that will be used on the NCSX Modular coils. • Once fabricated, the coil will be tested to 24 KA under cryo conditions (Nitrogen cooled) as will be seen by the modular coils. • The test will provide preliminary data as to how the coils will react during Nitrogen cooled conditions. Race Track Test Coil

3. Design Features • 28 turns total/ 14 each side of tee • Nitrogen cooled • Wound onto a stainless Tee- cross section casting • Copper cladding for cooling • Insulation scheme typical of modular coil • Diagnostic instrumentation embedded in coil winding • Coil clamps typical of modular coils • Vacuum epoxy impregnated coil Race Track Test Coil

4. B A A B Internal Instrumentation • Thermocouples: • Type”E” (0.010 in. diameter) • Located in six locations inside of the coil. • Between columns A & B at layers 1, 4 and 7 • Optical (Fiso) Stain Gauges: • Positioned at the inside corners of the tee-section • Will be borrowed from ORNL for tests Optical Stain Gauges Race Track Test Coil

5. Instrumentation • Thermocouples Strain Gauges Race Track Test Coil

6. Winding- Layer 4 Race Track Test Coil

7. Racetrack Test Coil Race Track Test Coil

8. Coil Leads Copper tubes will be soldered over ends of 12 inch long coil leads to be used for bus connections Race Track Test Coil

9. Cooling connections Race Track Test Coil

10. Test Program- Preliminary • The Racetrack coil will be tested at the full modular coil operating current of 24 Ka • It will have a pulse length of 1 second • The coil will be tested while at a cool down temperature of 77 degrees Kelvin • Liquid nitrogen will flowed through the cooling tubes with the exhaust venting into the cryostat. • The test plan to determine the number of shots and at what level those test shots will be needs to be established, and will be reviewed at a later date. (ORNL Responsibility) • During the pulses, thermocouples will record the internal temperatures and strain gauges will monitor any movement, stresses that may arise in the tee-structure. Race Track Test Coil

11. Test Program- Preliminary • The present plan is to setup in the D-site basement a test stand that will be used to test the race track coil. • Geoff Gettelfinger is responsible for building a cryostat for the stand as well as providing nitrogen cooling to the coil and chamber. He has already completed a number of insulation tests to develop the cryostat insulation • Raki Ramakrishnan will be responsible for setting up the power system so that the test coil can be tested at the required 24 Ka current 1 second pulse level. • The test stand and the test program will need to be reviewed prior to beginning test. Race Track Test Coil

12. Safety and Environmental • A Job Hazard Analysis (JHA) report will be generated for the testing operations. • A pre-job briefing will be held prior to starting the winding and/or VPI operations • Integrated Safety Management (ISM) is and will be used or all aspects of the R&D activities. • Line management responsible for safety • Clear roles and responsibilities • Competence commensurate with responsibilities • Balanced Priorities • ID of safety standards and requirements • Hazard control tailored to work being performed • Operations authorizations Race Track Test Coil

13. Technical Documentation • Test Plan • New NEPA • New PPPL Work Planning Form(WP) Race Track Test Coil

14. Players • Test Director : Geoff Gettelfinger • Deputy Test Director: Gene Baker • Cryogenic needs: Geoff Gettelfinger • Power Feed to coils: Raki Ramakrishnan • Coil Protection: Bob Marsala • COE Interests: Bill Blanchard • Coil Computer Control: Ron Hatcher Race Track Test Coil