1. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 1 Modular Coil Cooling Issues With Baseline & Status of Cooling R&D James H. Chrzanowski Modular Coil Winding & Cooling Workshop June 10, 2004 PPPL

2. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 2 Cost or schedule Risk  #1- Cooling Scheme The complex geometry of the proposed chill plate cooling scheme could possibly add additional time to the installation process Fitup of the plates and attachment of the cooling tubes are all issues that need to be addressed. Possible cost risk (+ $500.0 k ) Cooling plates and tubing

3. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 3 General Statement  All of the options that have been and will be discussed are achievable. They are options that will solve the cooling requirements for the modular coils. “All it takes is money and schedule”  The details and requirements for the latest cooling system will increase the installation time during winding.

4. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 4 Cooling Program Objective  Objective Performance: Provide the necessary cooling required to operate the modular coils Cooling system must incorporate dielectric breaks as required  Objective Installation: Hold costs and schedule Minimize the amount of on-line time required to install cooling system. Compare the modular coil fabrication activities to an automobile assembly line. Stage as many sub-assembly activities off-line.

5. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 5 Issues With Baseline  Issues Dielectric break requirements Installation of outer chill plates Attachment of cooling lines? Working area- remember that installation of components is not performed on bench Minimize the number of small parts (rivets) potential for lost parts in coil More parts = longer installation times Copper braid option: Introduces risk of the copper strands penetrating insulation prior to VPI

6. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 6  Requirements / constraints: 15 minute cool-down copper is electrically isolated from tee No electrical continuity (loops) in copper parts in any direction No copper parts larger than 2 inches No electrical continuity through cooling tubing Fits in.08 inches laterally (not tube)  Design Copper cladding, formed from flat developments, next to tee Copper chill plates on outside of winding pack connected to cladding Chill plates have electrical break Tubing brazed to copper strips Strips attached to chill plates cladding Cooling tube chill plates Electrical break Baseline Cooling Concept

7. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 7 Inner Cladding Plates  Present design with vertical slits work well  Easy installation  Partially annealed, water-jet cut, pre-formed plates  Complete cladding fitup in place Provide mating joint for plates

8. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 8  Several options for connecting cladding to chill plates Brazing- damage insulation Tig welding- damage insulation Riveting- tested Staking- tested  Dielectric Break Provide break using B-stage cryogenic insulation Appears to work -179 deg C to –149 degrees C (10 minutes) (no cryostat was used) More tests needed Cladding to Chill Plates -179 degrees C 94.6 degrees K -149 degrees C 124 degrees K

9. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 9 Riveting Ends  Will be difficult to install in place  Too many loose parts  Time consuming

10. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 10 Staking the Edge Connections  Looks good. No real difficulties  Fast efficient method  No loose parts

11. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 11 Outer Chill Plates and Tubing  Installation of outer cooling tubes needs additional work  Pre-forming of cooing tube looks like good option.  Brazing or soldering tube in-place would damage insulation.  Pre-brazing to plates –alignment of components very difficult.  Attaching tubes with fasteners- real possibilities.

12. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 12 Mounting Cooling Tubes to Chill Plates

13. June 10, 2004Modular Coil Winding & Cooling WorkshopJ.H. Chrzanowski 13 R&D Activities  R&D activities performed Cladding to chill plate termination Dielectric break cladding to chill plate Cladding installation trials  R&D activities to be performed Outer chill plate installation Cooling tube to chill plates