1. NCSX NCSX Conceptual Design Review1 Manufacturing and R&D Phil Heitzenroeder for the NCSX Engineering Team

2. NCSX NCSX Conceptual Design Review2 Outline The NCSX Core –Conventional, readily manufactured components. –Challenging components Highlights of the Challenging Components Risk Mitigation R&D Plans Manufacturing Plans Conclusion

3. NCSX NCSX Conceptual Design Review3 The Large Majority of NCSX is of Conventional Design and Construction Cryostat – Foam/Epoxy Insulated Housing Base Structure – Stainless Steel Welded Structure A brief overview of NCSX’s major components, starting from the outside and working in ….

4. NCSX NCSX Conceptual Design Review4 External trim, PF, and TF Coils…Conventional Fiberglass Insulated, Hollow Conductor Copper Windings 18 “picture frame” cryoresistive external trim coils; 100 kAT each. 18 Cryoresistive TF coils 6 Pairs of Cryoresistive PF Coils

5. NCSX NCSX Conceptual Design Review5 TF and CS Structures: Straightforward SS Castings, Well Within the State of the Art Crown structure to support TF corners and PF 1&2 Coils TF support castings CS Detail

6. NCSX NCSX Conceptual Design Review6 We are Focusing On the Unusual and Challenging Parts : The Modular Coils and Vacuum Vessel Modular Coils Vacuum Vessel

7. NCSX NCSX Conceptual Design Review7 Modular Coil Challenges: Unusual highly shaped windings and support castings; tight alignment requirements; critical vacuum pressure impregnation of cable. SS Castings support windings and will be the primary factor in current center positional accuracy. (Critical Component) Vacuum pressure impregnation (Critical Operation ) Highly flexible cable; easy to wind, but needs to be carefully clamped during winding. 6 each of 3 different style coils; Total position tolerance of +/- 1.5 mm. Sharp bends will require keystoning compensation during cable positioning.

8. NCSX NCSX Conceptual Design Review8 Vacuum Vessel Challenges: Highly Shaped Vessel; Forming Inconel 625; 72 Shaped Ports; Tight Tolerances on inboard side. Inboard tolerance: +/- 3.8 mm Outboard tolerance: +/- 12.5 mm

9. NCSX NCSX Conceptual Design Review9 Risk Mitigation Plans Funded Manufacturing Studies for the VV and Modular Coils - Goals: to obtain industrial input during the Conceptual Design phase on:  the proposed specifications  designs  costs and schedules Focused VV and Modular Coil R&D - Goals:  To provide technical design data (examples: cable keystoning; weld distortion)  To develop processes (examples: heat treatment of castings to control distortion)  To produce prototypes (VV sector; Modular coil castings; complete modular coil).  To provide experience in manufacturing prototypical parts so firm fixed price proposals can be developed which do not have excessive contingency built in.. Completed In FY 03

10. NCSX NCSX Conceptual Design Review10 Funded Manufacturing Studies Were Performed for the Vacuum Vessel and Modular Coils Prototypical specifications were prepared for the vacuum vessel and modular coils to guide these studies. Modular Coil Study Participants: 1.Hitachi 2.Mitsubishi 3.Ansaldo (coils only) 4.Atlas Foundry and Machine Co. (castings only) 5.Osterby (castings only) Vacuum Vessel Study Participants : 1.A Kharkov consortium. 2.Major Tool and Machine, Inc. 3.Hitachi 4.Mitsubishi 5.Atlas Foundry and Machine Co. / PCC Structurals

11. NCSX NCSX Conceptual Design Review11 The Manufacturing Studies Were Extremely Beneficial and Helped Us Develop NCSX’s Plans Most importantly, these studies confirmed that the vacuum vessel and modular coils, though challenging, ARE WELL WITHIN THE STATE OF THE ART. The studies confirmed that there are a number of capable and interested potential suppliers for both the modular coils and vacuum vessel. Many technical recommendations were made which will be evaluated. Included were recommendations to consider alternative manufacturing techniques for the vacuum vessel (cold forming; investment casting) and coil castings (investment casting).

12. NCSX NCSX Conceptual Design Review12 Inputs from the Manufacturing Studies Were Used to Develop NCSX’s Plans The budgets and schedules shown reflect the inputs received. The critical issues technical identified in the studies are emphasized in the R&D plans. A very significant finding: schedules for manufacturing the modular coils were longer than anticipated. –In response to this, a PPPL manufacturing study based on procuring the castings and then finishing the modular coils on site was performed. This approach was found to have a number of advantages: The schedule can be improved by ~8 months. Splitting the casting manufacture from the winding fabrication opens up more competition in the casting area. Better risk mitigation: PPPL will be monitoring the production of the windings full time with this approach, will be able to react to production problems quicker and with greater confidence, and has more flexibility. PPPL’s first hand experience in all aspects of coil manufacturing are a good fit with the modular coil manufacturing requirements. Consequently, the modular coil castings will be procured from industry and PPPL will complete manufacture of the modular coils on site.

13. NCSX NCSX Conceptual Design Review13 R&D and Manufacturing Plans for the Vacuum Vessel Vacuum Vessel R&D –R&D period of performance: February – October, 2003. –Two competitively awarded contracts for 60 0 vessel segments (ie, ½ field period). Vacuum Vessel Manufacture –A single competitively awarded contract will be issued for the vessel and ports. Suppliers are to be qualified by producing a full scale partial prototype. Two procurement strategies are being evaluated: 1.Competition limited to the two R&D participants. 2.Fully open competition. –Key dates: Vessel manufacture: March ’04-October ’05. Ports delivered January ’06. –Deliveries are consistent with assembly schedule.

14. NCSX NCSX Conceptual Design Review14 Modular Coil Casting R&D and Manufacturing Plans Casting R&D –Period of performance: December ’02-June ’03. –Two contracts will be given for prototype modular coil castings. –One casting will be used by PPPL to manufacture a prototype coil. –The second, if acceptable as a “first article” casting, will be used to manufacture the first coil. Casting Manufacture –A single competitively awarded contract will be issued for the modular coil castings. Supplier to be qualified by producing a full scale prototype. Two procurement strategies are being evaluated: 1.Fully open competition. 2.Competition limited to the two R&D participants –Key Dates: Manufacturing contract to be awarded November, ’03. First casting delivered January’05. Subsequent castings delivered every 3 weeks. This schedule supports NCSX’s assembly schedule.

15. NCSX NCSX Conceptual Design Review15 Limited R&D Has Already Been Performed to Characterize the Cable Cable Fabrication: 300 m. of cable was produced with a packing fraction of 78%. Cable Bend Characteristics: Used to develop guidelines for minimum bend radii in coils. Keystoning when bent around a 8.12 cm. dia. mandrel: difference between height and width is 3.8 mm bent the “hard way”; 2.3 mm bent the “easy way”. Cable Resistance: Room temperature resistance was measured. MIT is performing cryogenic resistance tests. Epoxy Fill: Experiments at Auburn confirmed that epoxy does wick into the interstices between the wire strands. Impregnated cable strength and stiffness tests: “Punch shear” tests of a central conductor of a 9 conductor array with and without Kapton failed between 7.4 and 27 MPa (1-4 ksi) Compression tests: Ultimate compression strengths of 154-188 MPa (22-27 ksi) were obtained. Apparent modulus of elasticity 8-12 GPa (1200 to 1700 ksi) (~10% of the value of solid copper). A low modulus is beneficial, since it will result in most of the EM loads being transferred to the structure.

16. NCSX NCSX Conceptual Design Review16 Additional Modular Coil R&D Is Planned to Mitigate Risks Additional cable characterization tests will be performed. –To obtain data based on a reasonable sample size. –To develop turn to turn and turn to ground electrical breakdown data. Pre-Prototype R&D: –Conductors will be bent to actual bend radii so keystoning compensation can be built into casting and insulation details. –Vacuum Pressure Impregnation Process Development: This is considered a CRITICAL PROCESS, and will receive a great deal of attention. Will build upon PPPL’s extensive experience in vacuum pressure impregnation. Will also draw upon ITER’s CS model coil VPI experience. –Will probably use the epoxy used for the ITER CS coil, or, alternatively, the CTD resin originally proposed for it.

17. NCSX NCSX Conceptual Design Review17 Modular Coil Trial Windings and VPI Development PPPL will fabricate a series of 6-12 “mock up” windings. –Formed steel I-beams will be used to simulate the castings. –The conductor will be insulated and wound onto the forms. Processes and tooling for handling and holding the conductor will be co-developed during this step. –The windings will be vacuum-pressure impregnated, using a bag molding/autoclave process. –After curing, the windings will be evaluated: Electrical tests, turn to turn and turn to ground. Casting will be cut apart to permit the epoxy impregnation evaluation. Test specimens will be made to check compressive and shear strength.

18. NCSX NCSX Conceptual Design Review18 Modular Coil Vacuum Pressure Impregnation (VPI) R&D Plans Modular Coil X-Section A Modified Version of the TFTR PF VPI Process Will Be Used for the Modular Coils: Sprue boards will be installed the sides of the windings to provide uniform epoxy delivery. Tedlar mold release film will be applied over the windings. Chopped glass/epoxy will be sprayed over the winding to “bag” the winding. The winding will be epoxy vacuum-pressure impregnated in an autoclave to equalize forces on the “bag” and minimize the possibility of leaks. The winding will be cured in the electrically heated autoclave. TFTR PF Coil Mold Details Epoxy Delivery System Bag Sprue plates

19. NCSX NCSX Conceptual Design Review19 Modular Coil Fabrication Castings will be delivered to PPPL by suppliers at a frequency of one every 3 weeks. PPPL will install the windings onto the castings, vacuum pressure impregnate the windings, finish, test, and assemble the machine modules in the former TFTR Test Cell. (Refer to J. Chrzanowski’s presentation) –Winding begins in January, ’05. –Last winding is completed in March, ’06. D-Site Winding / Assembly Area

20. NCSX NCSX Conceptual Design Review20 Manufacturing of PF, TF, and External Trim Coils and Structures The PF, TF, and External Trim coils are simple conventional coils: –Hollow copper conductor (largest is 27 mm x 22 mm x 13.5 mm dia.) –Glass/epoxy insulation. –PF coils range from R=0.22 to 2.7m. –TF coils are 3.1 m x 2.4 m. –External trim coil “picture frames” have perimeters of 5.1 to 8.5 m. –A single RFP will be issued for a fixed price contract for all of the coils. (April, ’04) Proposers will be requested to itemize costs and schedules. We will award one or more contracts on the most favorable basis.. The primary PF and TF coil structures are all stainless steel castings. –A single RFP will be issued for a fixed price contract for all of castings. (April, ’04) Proposers will be requested to itemize costs and schedules. One or more contracts will be awarded contract(s) on the most favorable basis.

21. NCSX NCSX Conceptual Design Review21 Manufacturing of Cryostat and Support Structures Cryostat The cryostat is a simple fiberglass frame supporting urethane foam/fiberglass panels. A single fixed price competitive procurement is planned. Base Support and Miscellaneous Components A single fixed price competitive procurement is planned for the base support. Miscellaneous supports and components will be competitively awarded. Some may be produced in-house, based on “make-buy” analyses.

22. NCSX NCSX Conceptual Design Review22 Conclusion Most of NCSX’s core elements are of conventional design and construction. The most challenging components are the vacuum vessel and the modular coils. Recognizing this, we have taken steps to mitigate risks in these areas: –Through manufacturing studies which have been completed and which have provided a wealth of information that has been used in developing our plans. –By adopting a modified manufacturing plan for the modular coil manufacture that procures the castings from industry but finishes the windings at PPPL. This improves the schedule, provides better flexibility, oversight, and control. –Through a strong R&D plan with particular emphasis on the critical items: the vacuum vessel and modular coils. We are confident that NCSX can be built on time and on cost!