1. TF Joint Testing Data Acquisition Special Test Equipment Hans Schneider with Robert Marsala (609) 243-2017 hschneid@pppl.gov Engineering Operations April 2003

2. Hans Schneider Engineering Operations 2 Resistance Measurement Plan Prototype & Insitu Joints Mechanical Prototype Testing Electrical Prototype Testing Maintenance Insitu Testing Commissioning Insitu Testing

3. Hans Schneider Engineering Operations 3 Resistance Measurement Plan Mechanical TF Joint Test System MTS Hydraulic Test Stand

4. Hans Schneider Engineering Operations 4 Resistance Measurement Plan Mechanical TF Joint Test System Mechanical Prototype Testing –Cyclical Mechanical Loads Applied to Prototype Joint –Measure Joint Voltage Drop with 100 Amperes Applied –Voltage Measured at Two Joint Locations –Automated Test Stand Control & Data Acquisition

5. Hans Schneider Engineering Operations 5 Resistance Measurement Plan Mechanical TF Joint Test System Mechanical Prototype Testing –Cyclical Mechanical Loads Applied to Prototype Joint –Measure Joint Voltage Drop with 100 Amperes Applied –Voltage Measured at Two Joint Locations –Automated Test Stand Control & Data Acquisition Joint Voltage Drop Accuracy Factors –Limited by Cycle Time –Initial Investigation Indicates 0.5% Should be Possible –Cycle Dwells Could Increase Accuracy to 0.2% or Better

6. Hans Schneider Engineering Operations 6 Kepco ATE 6-100M 100A @ 6V +-+- Empro HA-150-50 150A @ 50mV Shunt Flag Joint 0.5u Ohms Nominal Agilent 34420A Nano-Volt Meter NI 100kS/s 16-Bit Multifunction DAQ Card GPIB Interface Card HP 3456 Multi-Meter IBM PC & LabVIEW Software GPIB Interface GPIB Interface 50uV 33mV 100A Current Control Hydraulic Test Stand CASS Bld. Current Control Load & Displacement Data Load Control x2 Resistance Measurement Plan Mechanical TF Joint Test System

7. Hans Schneider Engineering Operations 7 Resistance Measurement Plan Electrical TF Joint Test System Transition Area, TFTR Test Cell basement

8. Hans Schneider Engineering Operations 8 Resistance Measurement Plan Electrical TF Joint Test System Electrical Prototype Testing –Cyclical Electrical Loads Applied to Prototype Joint –Measure Joint Voltage Drop with > 70,000 Amperes Applied –Voltage Measured at Up to Eight Joint Locations –Remote Control of Automated Data Acquisition System

9. Hans Schneider Engineering Operations 9 Resistance Measurement Plan Electrical TF Joint Test System Electrical Prototype Testing –Cyclical Electrical Loads Applied to Prototype Joint –Measure Joint Voltage Drop with 72,100 Amperes Applied –Voltage Measured at Up to Eight Joint Locations –Remote Control of Automated Data Acquisition System Joint Voltage Drop Accuracy Factors –TF Power Supply Current Measurement Accuracy –Magnetic Field Influences on Measurement Leads & System

10. Hans Schneider Engineering Operations 10 Fiber Optic Interface (In House) +-+- Hallmar Current Sensor X 2 Flag Joint 0.5u Ohms Nominal SCXI-1001 Chassis And Cards mV, Temp, Strain Cables, etc. (Buy) NI 100kS/s Multifunction DAQ Card (Bought) IBM PC & LabVIEW Software (In House) 35mV 70,000A SOP/EOP x2 Remote Control PC (in house) TF PWR SUPPLIES Ethernet to Fiber (in house) Load Cell (Baker) x8 Hallmar Signal Conditioner x4 Thermocouples x8 (Buy) Strain Gages x8 buy Hall Sensors x8 buy Fiber (in house) PCI NIC (buy) Resistance Measurement Plan Electrical TF Joint Test System

11. Hans Schneider Engineering Operations 11 Resistance Measurement Plan Insitu Test Systems NSTX TEST CELL

12. Hans Schneider Engineering Operations 12 Resistance Measurement Plan Insitu Maintenance Test System Maintenance Insitu Testing –Permanent Test Cell Installation –Measure Joint Voltage Drop with +/-200 Amperes Applied –Each of 48 Joints Measured at One Joint Location –Automated Test Cell Data Acquisition System

13. Hans Schneider Engineering Operations 13 Resistance Measurement Plan Insitu Maintenance Test System Maintenance Insitu Testing –Permanent Test Cell Installation –Measure Joint Voltage Drop with +/-200 Amperes Applied –Each of 48 Joints Measured at One Joint Location –Automated Test Cell Data Acquisition System Joint Voltage Drop Accuracy Factors –“Ambient” Electrical Noise & Long Joint Cable Leads –Combat with DC Current Reversal & Long Integration Times –Unknown Accuracy at This Time

14. Hans Schneider Engineering Operations 14 Resistance Measurement Plan Insitu Maintenance Test System 36 Lower Joints 12 Upper Joints #24AWG Twisted Pair Teflon (1000V) Silicon Rubber Tube (25kV) Winchester Connectors SCXI Chassis with Multiplexer Cards 48 Joints Agilent 34420A Nano-Volt Meter Agilent 6671A 220A @ 8V FCPC Open Line & Ground Switches TF Coil 4.5mH 6.3m Ohms 90J @ 200A 1N4047 275A 200V NO/NC Relay 300A Transorbs 450J 50kA 340V 200A 1 Ohm 275W Shunt 50mV 300A PC LabVIEW

15. Hans Schneider Engineering Operations 15 Resistance Measurement Plan Insitu Commissioning Test System Commissioning Insitu Testing –Utilizes Maintenance System Wiring –Measure Joint Voltage Drop with Up to 72,000 Amperes –Instrument One, Possibly Two TF Flag Joints –Data Collected via 908 or 3232 Transient Digitizer

16. Hans Schneider Engineering Operations 16 Resistance Measurement Plan Insitu Commissioning Test System Commissioning Insitu Testing –Utilizes Maintenance System Wiring –Measure Joint Voltage Drop with Up to 72,000 Amperes –Instrument One, Possibly Two TF Flag Joints –Data Collected via 908 or 3232 Transient Digitizer Joint Voltage Drop Accuracy Factors –TF Power Supply Current Measurement Accuracy –Magnetic Field Influences on Measurement Leads & System

17. Hans Schneider Engineering Operations 17 Resistance Measurement Plan Insitu Commissioning Test System 36 Lower Joints 12 Upper Joints #24AWG Twisted Pair Teflon (1000V) Silicon Rubber Tube (25kV) 1 of 48 Joints FCPC Closed Line & Ground Switches 72,000A, 1000V TF Coil 4.5mH 6.3m Ohms 90J @ 200A MDS PLUS Transient Digitizer Marsala Isolation Amplifier (5kV) Isolation Amplifier Instrumentation Amplifier Winchester Connectors

18. Hans Schneider Engineering Operations 18 Software LabVIEW Graphical Programming Language –Seamless integration with associated hardware –Reduced development, deployment and maintenance efforts “Front Panel” “Code”

19. Hans Schneider Engineering Operations 19 Two tap options –Red Option: attach under shear shoe –Blue Option: attach at flag end Red Option is preferred –Advantages: reduced linked flux excludes flag resistance wiring at common potential, not crossing over hub assembly Tap wire twisted along water tube and covered with heat shrink insulation Voltage Tap Location

20. Hans Schneider Engineering Operations 20 Measured Resistance vs. Tap Location vs. Contact Resistance Range of Interest  /in 2 From ANSYS Finite Element Model... R=(V tap -V tube )/I  V from bottom to top of flag is not significant Micro-Ohms Measured Distance from Bottom of Flag (inch)

21. Hans Schneider Engineering Operations 21 Resistance Measurement Plan Prototype & Insitu Joints Mechanical Prototype Testing Electrical Prototype Testing Maintenance Insitu Testing Commissioning Insitu Testing