PF Coil Fabrication Overview
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- Randolf Doyle
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1 PF Coil Fabrication Overview PF Coils Information Meeting Barcelona - 15 th October 2012 This presentation is intended for reference purposes only and is not a legally binding document
2 PF Building Layout Possible Building Layout for fabrication of PF2 to PF6 (overlap of several stages at the same time) Workflow goes from left to right, where coils exits Building will have area for extension on the north side Clean Areas (ISO Class 9) areas B and D PF Coils Information Meeting, Barcelona - 15 th October
3 PF Coil Fabrication CICC preparation DP Impregnation Winding & Insulation Clamping & Covering VPI(vacuum Pressure Impregnation) DP Stacking & Ground Wrapping PF Coils Information Meeting, Barcelona - 15 th October
4 PF Conductor CICC PF 6 PF 2,3,4 PF 5 PF Coils Information Meeting, Barcelona - 15th October
5 1.2 = 0.4 (bounding layer)+0.8 (pancake shim) Conductor Insulation 5 layers of interleaved polyimide and fiberglass with 50% overlapping + 1 layer of 50% overlapped fiberglass. Pancake insulation Conductor insulation SS Jacket Superconducting strands Cable wrapping Turn shim Turn shim Shims to compensate for mechanical tolerances Central spriral Subcable wrapping PF Coils Information Meeting, Barcelona - 15th October
6 DPs: 2-in-hand winding 2 conductors (Yellow and Red) wound in parallel in a DP DP-joint connects one end of each conductor to the another DPs PJ joint connects the 2 conductors in the middle of the DP PF Coils Information Meeting, Barcelona - 15th October
7 Winding of DPs Conductor pre-treatment #1 Conductor pre-treatment #2 PF Coils Information Meeting, Barcelona - 15th October
8 Winding of DPs PF Coils Information Meeting, Barcelona - 15th October
9 Winding of DPs PF Coils Information Meeting, Barcelona - 15th October
10 PF Winding Pack Typical PF Coil Winding Pack: PF Coils Information Meeting, Barcelona - 15th October
11 He Inlets He inlets are in the inner turn of each DP, in the middle of the vertical joggle They are embedded in a longitudinal 450 mm long machined groove Cover with tube welded on the groove Groove Conductor Cover with tube PF Coils Information Meeting, Barcelona - 15th October
12 Winding of DPs He Inlets PF Coils Information Meeting, Barcelona - 15th October
13 PF Coil Fabrication CICC preparation DP Impregnation Winding & Insulation Clamping & Covering VPI(vacuum Pressure Impregnation) DP Stacking & Ground Wrapping PF Coils Information Meeting, Barcelona - 15 th October
14 DP impregnation DP impregnation preparation (in Clean Area) Protect the conductor ends from impregnation Assembly of the impregnation vessel DP impregnation: Control of the leak tightness of the vessel Impregnation Cleaning the excess of resin Geometrical control HV test between conductors PF Coils Information Meeting, Barcelona - 15th October
15 VPI Configuration Resin Stirring Motor Hardener + Accelerator Trap Trap Heater Flow Meter F Static Mixer F Thermal Insulation Heater Flow Control Pump F Argon Trap Accumulation Chamber Vacuum Pump Vacuum Pump Heater Coil Mould Vacuum Pump PF Coils Information Meeting, Barcelona - 15th October
16 DP impregnation PF Coils Information Meeting, Barcelona - 15th October
17 WP Impregnation PF Coils Information Meeting, Barcelona - 15th October
18 He Inlets (Qualification) He inlets are in the inner turn of each DP, in the middle of the vertical joggle They are embedded in a longitudinal 450 mm long machined groove Cover with tube welded on the groove Groove Conductor Cover with tube PF Coils Information Meeting, Barcelona - 15th October
19 He Inlet Qualification Dummy conductor to be used 4 samples for each conductor type 4-metre conductor formed to coil ID radius Secure the formed piece in a fixture which mimics the installation on WT Machine the slot in the conduit Check there is no visible damage to the superconducting strands Remove the outer wrap and the subscale wraps visible through the slot Plant the thermocouples in at least six places under the weld Fit the cover plate Weld the cover plate All samples shall be leak tested All samples carry out several (at least 5) cool down cycles to 77⁰K One sample will be sectioned to verify the full penetration defect free welds One sample is used for cutting samples for fatigue tests at 77⁰K One sample will be full-size tested against fatigue at 77⁰K PF Coils Information Meeting, Barcelona - 15th October
20 Insulation Qualification Tensile & Shear tests of 77⁰K 70.0 R ± ± = l P 23.0 = t = 4.0 ± Tensile strength sample For information only: relation l/t has to be adjusted for achieving interlaminar shear failure: l/t = 4 5 Shear strength sample Bonding to the St Steel on samples testing shear/compression strength at 77⁰K High Voltage test between 77⁰K High Voltage test to 77⁰K PF Coils Information Meeting, Barcelona - 15th October
21 Tail Qualification To qualify the manufacturing process of a bonded tail in a PF coil; To verify the mechanical performance of a bonded tail; To verify the electrical performance of the tail insulation. Weld Qualification and cool-down tests to 77⁰K Bonding qualification fatigue 77⁰K Electrical Insulation PF Coils Information Meeting, Barcelona - 15th October
22 Joint Qualification Dummy joint sample - fatigue 77⁰K Three samples to establish the manufacturing process Weld Procedure Qualification Soldering Procedure Qualification Steel box Steel-copper explosion-bonded joint Solder interface Compacted superconducting cable Copper sole PF Coils Information Meeting, Barcelona - 15th October
23 Dummy Double Pancake Manufacture Qualify the tooling and critical fabrication processes: winding process, transitions forming, insulation application, inlets installation, joint terminations preparation, installation of the spacers to maintain tight tolerances, assembly of the internal joints VPI process For PF6 the dummy double pancake is type A For PF5 (incl. PF2) and PF4 (incl. PF3) it is 5 turns Coil PF6 PF5 PF4 DP pattern A F K Number of turns Full DP 5 turns 5 turns PF Coils Information Meeting, Barcelona - 15th October
24 Coil assembly and Ground insulation Coil assembly is done in a Clean Area Operations: DP stacking Ground Insulation wrapping, The ground insulation covers the winding pack Excludes the joints that have their own ground insulation Joint connection, assembly of the joint supports Joint Ground insulation PF Coils Information Meeting, Barcelona - 15th October
25 Final Coil Assembly Coil assembly not needed to be done in Clean Area. Operations: Coil impregnation together with the joints Cleaning the excess of resin and geometrical control Pipe, terminal and instrumentation installation Wrapping of the coil with a conductive tape (ground surface) Clamp installation Protection cover installation HV and leak tests Delivery to cold test facility Attendance at the Cold Tests (carried out under another contract) Delivery to transport PF Coils Information Meeting, Barcelona - 15th October
26 Final Coil assembly PF Coils Information Meeting, Barcelona - 15th October
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