1. NCSX G. Gettelfinger for the NCSX Engineering Team November 10, 2004 NCSX Coil Test Facility Single Phase LN 2 Mechanical/Plumbing Final Design Review

2. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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

3. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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.

4. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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

5. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 5 CENTRIFUGAL PUMP 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)

6. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 6 P&ID FOR COIL TEST FACILITY

7. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 7 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 P&ID FOR COIL TEST FACILITY

8. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 8 PRESSURE LEVELS / CALCULATIONS 64 psigSuction for 95K ops 91 psigLikely pump press. for coil drop plus pipe drop 150 psigRelief valve level 200 psig Recommended to coil engineers on as test pressure for cooling circuits – 33% above auto action limit 401 psigB31.3 limit for tank design 947 psigNon-ASME limit for G-10/11 1” pipe 1,120 psigB31.3 limit for ¾”-M tube (Hx) 1,390 psigB31.3 limit for 1”-L tube (majority)

9. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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

10. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 10 FIRST LOAD – PLANAR RACETRACK COIL Planar racetrack coil will first be used Next in queue: Twisted racetrack coil

11. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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!)

12. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 12 Hx GRAPHICS (1of5) Hx contains 3 independent paths

13. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 13 Each of 3 paths has 18-feet of 2 1/8 aluminum fins Hx GRAPHICS (2of5)

14. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 14 Hx GRAPHICS (3of5) Bundles are provided with gravity supports

15. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 15 Hx GRAPHICS (4of5) Support scheme has baffles to shroud upper assemblies from gas bubbles generated underneath

16. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 16 Hx GRAPHICS (5of5) 3-path assembly resides in an aluminum tub to contain secondary, boiling fluid

17. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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/ft 2 )

18. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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.

19. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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

20. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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

21. NCSX November 10, 2004NCSX Coil Test Facility Mechanical/Plumbing FDR G. Gettelfinger 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.