Presented by B. Nelson for the QPS team QPS Conceptual Design Review June 23-24, 2003 ORNL

QPS Project Implementation Presented by B. Nelson for the QPS team QPS Conceptual Design Review June 23-24, 2003 ORNL

Presentation Outline Fabrication Plans How we plan to build QPS R&D, primarily Modular Coils Benefits of NCSX work QPS Schedule Overall schedule QPS schedule by major component QPS Cost Methodology Estimates Contingency June 23-24, 2003 QPS CDR - Project Implementation 2

Fabrication Plans and Options Most components built off-site and pre-assembled to the extent possible System In-Vessel Components - Divertor plates, limiters Vacuum Vessel Conventional Coils - TF, PF, Centerstack assy Modular Coils Structures -connecting structures, base columns Coil Services - electrical leads, cooling Assembly, incl. mod coil field period sub-assy Fabrication By: Fabricated off-site or in house Commercial Tank manufacturer - PF coils exist, refurbish on site - Centerstack, TF similar to NSTX, (but integration by vendor) - Winding forms by NCSX vendor - Winding, VPI, canning by Univ. TN Commercial manf, same as VV if possible Commercial leads, piping on site Assembly on-site by ORNL craft June 23-24, 2003 QPS CDR - Project Implementation 3

Modular Coil Fabrication Modular Coils are very similar to NCSX, but not the same: Cast-and-machined winding form Flexible cable conductor Canned for vacuum compatibility Vacuum pressure impregnated with epoxy Winding forms will be manufactured by same vendor as NCSX winding forms, if possible, and procured by PPPL Winding, canning, and VPI to be done by University of Tennessee June 23-24, 2003 QPS CDR - Project Implementation 4

We plan to build the coils at UT Less costly: Lower net labor costs (direct+indirect) (~ 50%) Space is available at no charge More flexible arrangement with respect to contract/design changes since UT is a partner in the QPS project Relatively close proximity to ORNL design team Strengthens UT / ORNL interaction Provides thesis topics, fusion interest for graduate students June 23-24, 2003 QPS CDR - Project Implementation 5

Organization for modular coil tasks at UT Separate organization set up within the Mechanical Engineering Department under Department Chair (Tom Shannon) Full time engineering manager will report to Tom Shannon Technicians hired as temporary employees by UT Graduate students will assist where appropriate QPS design team at ORNL will be responsible for design, and assist with technical oversight. Space will be prepared in the recently completed Science and Engineering Research Facility (SERF) 3 adjacent rooms envisioned, 24 x 32 ft each Elevators, loading dock, hallways, etc. are adequate for receiving and moving modular coils All processes to be developed through R&D June 23-24, 2003 QPS CDR - Project Implementation 6

One winding line planned, but space should accommodate two winding lines Process flows from winding to canning to VPI Dimensional and electrical inspection occurs continuously 24 ft 32 ft No autoclave is needed since coils will already be vacuumcanned Winding line #1 Winding line #2 canning TBD VPI June 23-24, 2003 QPS CDR - Project Implementation 7

Rolling cart fixture avoids handling issues Winding form shipped from vendor on cart, stays on cart for all winding, canning, VPI processing and shipping to ORNL 4 ft 10 ft Top View 8 ft Side View End View 10 ft June 23-24, 2003 QPS CDR - Project Implementation 8

R&D will be needed for modular coils R&D will be integrated with NCSX project Modular coil winding forms will be very similar, but no poloidal break Modular coil conductor and windings will be very similar Vacuum impregnation will be similar, but will not require cocoon Continue involvement of University of Tennessee as well as potential vendors for coil winding forms Draft specification and models for winding forms will be developed to obtain input from industry June 23-24, 2003 QPS CDR - Project Implementation 9

Winding Form R&D Issues Casting tolerance, repeatability Machining: reach and access, tolerances, machining time, cost Vacuum compatibility of casting Rough casting M3 winding form Machine winding form & flanges Plan All issues addressed in detail as part of NCSX project, except vacuum compatibility, by manufacturing studies and two full scale prototype winding forms QPS - specific manufacturing study will be conducted during advanced conceptual design Completed M1 coil June 23-24, 2003 QPS CDR - Project Implementation 10

Winding Form R&D: casting in vacuum o.k. Progress Cast tees procured by PPPL for NCSX Cast vacuum vessel procured by NCSX Results Three 120 degree field periods investment cast and welded together Vessel doesn t leak, minimum wall thickness = 0.125 inches Ref: PPPL and NCSX project 3 field periods welded together June 23-24, 2003 QPS CDR - Project Implementation 11

Winding R&D Issues Conductor insulation Keystoning of conductor around sharp bends (keystoning is distortion of cross-section) Handling fixtures Clamping tooling In-process measurements Keystoning of conductor around sharp bends Plan All winding issues addressed in detail as part of NCSX project QPS- specific fixtures and tooling will be developed in parallel / slightly after NCSX tooling is developed Practice winding planned for QPS to provide experience to UT winding crew and test QPS-specific tooling and fixtures Ref: PPPL and NCSX project June 23-24, 2003 QPS CDR - Project Implementation 12

Winding R&D Progress Keystoning tests are quantifying dimensional change vs bend radius Clamping tools being developed Metrology systems being evaluated Simulated coil form constructed Twisted Tee castings procured Results Half lapped insulation preferred Multi-cable conductor is harder to handle and insulate than single cable Keystoning jumps up at R/d < 4 QPS minimum R/d > 5 conductor width Ref: PPPL and NCSX project Conductor width vs inner bend radius Keystoning of conductor 7 w ide side around sharp bends 0.8 0.75 6 0.7 5 4 0.65 3 0.6 2 0.55 1 0.5 0 0 1 2 3 4 5 inner bend radius (in) R/d narrow side ref. dim. R/d R h w d June 23-24, 2003 QPS CDR - Project Implementation 13

Coil cooling R&D Issues Thermal contact of cooling lines and copper around winding Effective thermal conductivity of cable/epoxy/insulation composite, especially 4-conductor pack Copper conduction layer Plan Issues similar to NCSX, but details are different First test article should provide initial experimental data on winding properties and cool-down, will help to benchmark analyses Test must be repeated with actual copper conduction layer and conductor June 23-24, 2003 QPS CDR - Project Implementation 14

Coil cooling R&D In progress Copper cladding being applied to twisted tee, racetrack shapes New racetrack coil being constructed, will test cooling Thermal conductivity of composite material is being tested Ref: PPPL and NCSX project June 23-24, 2003 QPS CDR - Project Implementation 15

Vacuum canning R&D Issues - Forming of cans Winding Pack - Welding of cans without distortion of shape or damage to windings - Leak checking of cans after VPI Plan Joint R&D with U.T. - Weld process & testing - Welding prep design - Software for flat developments - Forming of can sides Vacuum Can (Cut Away) Flexible Conductor Copper Cladding Ground Wrap Conductor Insulation Vacuum Can Vacuum Weld June 23-24, 2003 QPS CDR - Project Implementation 16

Vacuum canning R&D: distortion small In progress Welding distortion tests Weld process Vacuum compatibility tests of casting: i.e., permeation and outgassing Results to date Weld temperature at windings benign Distortion Calculation: very localized, ~.002 in Measured: very small, <.002 in. Welds made w/o filler or special weld preps, trepans Ref: Univ. of Tennessee June 23-24, 2003 QPS CDR - Project Implementation 17

Vacuum canning windings ok after weld Winding temperature during welding Thin-to-thin can welds Thin-to-thick can to casting welds Calculation matches testing Conductor and insulation not damaged Ref: Univ. of Tennessee Ref: Univ. of Tennessee June 23-24, 2003 QPS CDR - Project Implementation 18

Vacuum Pressure Impregnation (VPI) Issues Selection of epoxy Setup and introduction of epoxy Wicking of epoxy into interstices of cable conductor Mechanical and thermal properties of cable/epoxy/insulation composite VPI fixture for property tests at PPPL Plan All VPI issues addressed in detail as part of NCSX project Ref: PPPL and NCSX project QPS may use cyanate ester formulation instead of CTD-101 epoxy for higher temperature properties (will require new mech. and thermal tests) VPI equipment is available from BWXT in Lynchburg VA after Aug, 2003 Practice coil with racetrack shape wound at UT, VPI at PPPL June 23-24, 2003 QPS CDR - Project Implementation 19

Vacuum Pressure Impregnation (VPI) In-progress Tests still underway at CTD for single and multiconductor samples Results Mechanical testing at UT indicates composite stiffness is 70% - 80% of solid copper All VPI tests at PPPL show excellent wicking into cable Tests at UT seem to indicate significant shrinkage of epoxy during cure, needs more investigation NCSX tee bundle NCSX tee bundle cross section after VPI Ref: PPPL and NCSX project June 23-24, 2003 QPS CDR - Project Implementation 20

Vacuum Pressure Impregnation (VPI) Ref: PPPL and NCSX project (0.005 inches diameter) June 23-24, 2003 QPS CDR - Project Implementation 21

First R&D test coil Provides test article for VPI, mechanical, electrical, and thermal testing Test article ready for test Coil wound with 18 turns of prototypical cable conductor using prototypical insulation scheme Copper chill plates installed on either side of winding VPI by PPPL Electrical, cooling tests at ORNL very soon June 23-24, 2003 QPS CDR - Project Implementation 22

Assembly R&D (of modular coil set) Completed coils shipped to ORNL from UT Coils will be pre-assembled in field periods at ORNL June 23-24, 2003 QPS CDR - Project Implementation 23

Assembly R&D Issues Measuring of conductor position after VPI to determine winding pack current center Positioning of coils to best fit location in assembly Vacuum compatible electrical insulation for shims between coils Plan All issues addressed by NCSX (except electrical insulation) Joint R&D with University of Tennessee: Measurement systems Software for best fit algorithms Materials search for ceramic insulation (ITER has process) June 23-24, 2003 QPS CDR - Project Implementation 24

QPS Summary Schedule Task Name QPS conceptual design Physics Validation Review Conceptual Design Conceptual Design Review 2001 2002 2003 2004 2005 2006 2007 2008 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 4/24 summary 6/23 Advanced Conceptual Design Modular Coil form R&D QPS project Engineering Design External Vessel Design Modular Coil Design Modular Coil winding R&D Fabrication External Vacuum Vessel Modular Coil Fabrication Final Assembly / Test Core Assembly, on-site Machine assembly completed Startup and Integrated Systems Testing First Plasma 7/26 summary 9/20 June 23-24, 2003 QPS CDR - Project Implementation 25

Plan prior to Project Start Successful CDR Proceed with advanced conceptual design Continue modular coil R&D Task Name Start Finish QPS conceptual design 4/24/01 9/7/04 2001 2002 2003 2004 J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J Physics Validation Review 4/24/01 4/24/01 4/24 Conceptual Design 5/30/01 6/23/03 Select final QPS coil configuration 7/30/02 7/30/02 7/30 External design assessment 12/12/02 12/12/02 12/12 Conceptual Design Review 6/23/03 6/23/03 6/23 CD-1 approval 9/30/03 9/30/03 9/30 Advanced Conceptual Design 6/24/03 9/7/04 Modular coil winding form prototype design 6/24/03 1/5/04 Complete spec and design for winding form 1/5/04 1/5/04 prototype Design tooling for modular coil R&D winding 10/1/03 9/7/04 1/5 Modular Coil form R&D 1/6/04 8/2/04 Bid and award mod coil winding form casting 1/6/04 3/1/04 Coil type 1 casting 3/2/04 8/2/04 June 23-24, 2003 QPS CDR - Project Implementation 26

Advanced conceptual design for FY04 Modular coil set : Optimize shell cutouts for maximum access stresses are low Develop cooling, canning details concept in place Develop winding tooling design for winding at U.T. Procure prototype casting thru PPPL, NCSX winding form vendors Balance of design: Refine vacuum vessel port configuration increase access Develop vacuum pumping, bakeout, and wall conditioning scheme - concept in place Perform integrated stress/deflection analysis - in process June 23-24, 2003 QPS CDR - Project Implementation 27

QPS Project Schedule Task/milestone Start Finish Task Name Start Finish QPS project 10/1/04 9/20/07 2005 2006 2007 M A M A M A O N D J F M J J A S O N D J F M J J A S O N D J F M J J A S O N D J Project Start 1-Oct-04 Engineering Design 10/1/04 11/9/06 Modular Coil Design 10/1/04 3/31/05 Prelimnary design 10/1/04 12/16/04 Preliminary Design review 12/16/04 12/16/04 12/16 Final Design 12/17/04 3/31/05 Final Design Review 3/31/05 3/31/05 3/31 Mod coil R&D 6-Jan-04 15-Sep-05 Fabrication 4/1/05 7/5/07 Modular Coil Fabrication 4/1/05 2/22/07 bid contract for mod coil castings 4/1/05 5/12/05 Winding form casting and machining 5/27/05 8/3/06 Coil type 1 5/27/05 9/29/05 Mod coil fab. 1-Apr-05 22-Feb-07 Coil 1-1 5/27/05 8/18/05 Receive and prepare casting 8/19/05 9/7/06 Coil type 1 8/19/05 11/3/05 Coil 1-1 8/19/05 10/6/05 Conductor winding 10/7/05 1/11/07 Vacuum Vessel 9-Dec-05 26-Oct-06 Coil type 1 10/7/05 1/12/06 Coil 1-1 10/7/05 12/1/05 Coil 1-2 12/2/05 1/12/06 Coil type 2 1/13/06 7/13/06 Coil type 3 7/14/06 1/11/07 Can welding and leak checking 12/2/05 2/8/07 Centerstack 31-Mar-06 1-Mar-07 Coil type 3 9/8/06 2/8/07 Vacuum Pressure Impregnation, final 1/20/06 2/22/07 inspection and testing Coil type 3 10/27/06 2/22/07 Final Assembly / Test 3/20/06 9/20/07 Core Assembly, on-site 4/21/06 6/21/07 Core Assy 21-Apr-07 21-Jun-07 assemble second field period 1/12/07 3/22/07 Install Coil field period assemblies 3/23/07 4/5/07 install vessel spool piece 4/6/07 4/12/07 install upper VV lid with PF coils 4/13/07 4/19/07 install vacuum seals around modular coil 4/20/07 4/26/07 leads install blank port covers 4/27/07 5/10/07 Checkout 27-Jul-07 20-Sep-07 leak check vessel 5/11/07 5/24/07 Install TF coil outer legs 5/25/07 6/7/07 install modular coil leads, connect to building 6/8/07 6/21/07 buswork Diagnostics 6/22/07 7/26/07 Install day 1 diagnostics on machine 6/22/07 7/19/07 Run cables to control room and connect 6/29/07 7/26/07 First Plasma 20-Sep-07 (as scheduled) By Jan-08 (as costed) Machine assembly completed 7/26/07 7/26/07 Startup and Integrated Systems Testing 7/27/07 9/20/07 First Plasma 9/20/07 9/20/07 7/26 9/20 June 23-24, 2003 QPS CDR - Project Implementation 28

Schedule for modular coils R&D Task/milestone Start Finish Bid/Award casting Casting, coil 1 1-Jun-04 2-Mar-04 1-Mar-04 2-Aug-04 Task Name Start Finish Advanced Conceptual Design 6/24/03 9/7/04 Modular coil winding form prototype design 6/24/03 1/5/04 Complete spec and design for winding form 1/5/04 1/5/04 prototype Design tooling for modular coil R&D winding 10/1/03 9/7/04 Modular Coil form R&D 1/6/04 8/2/04 2004 2005 J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J 1/5 Bid and award mod coil winding form casting 1/6/04 3/1/04 Bid/Award machining 1-Oct-04 25-Nov-04 Coil type 1 casting 3/2/04 8/2/04 R&D 10/1/04 9/15/05 Modular Coil form R&D 10/1/04 2/3/05 Machining, coil 1 26-Nov-04 3-Feb-05 Bid and award mod coil winding form 10/1/04 11/25/04 machining Coil type 1 machining 11/26/04 2/3/05 Modular Coil winding R&D 10/1/04 9/15/05 Winding form prep 4-Apr-05 17-Mar-05 Coil winding tooling 10/1/04 1/6/05 bid and award winding tooling 10/1/04 10/28/04 fabricate winding tooling 10/29/04 1/6/05 coil type 1 2/4/05 9/15/05 Winding 18-Mar-05 2-Jun-05 inspection and preparation for winding, 2/4/05 3/17/05 add studs and copper winding 3/18/05 5/26/05 inspection of winding and electrical tests 5/27/05 6/2/05 Canning 3-Jun-05 28-Jul-05 fabricate vacuum cans 6/3/05 6/30/05 welding can and leak checking 7/1/05 7/28/05 vacuum impregnation 7/29/05 9/1/05 VPI 29-Jul-05 1-Sep-05 testing 9/2/05 9/15/05 Testing 2-Sep-05 15-Sep-05 June 23-24, 2003 QPS CDR - Project Implementation 29

Schedule for production modular coils Task/milestone Start Finish Task Name Start Finish Modular Coil Fabrication 4/1/05 2/22/07 bid contract for mod coil castings 4/1/05 5/12/05 2005 2006 200 J F M A M J J A S O N D J F M A M J J A S O N D J F M Bid/Award castings 1-Apr-05 12-May-05 award contract for Mod coil castings 5/12/05 5/12/05 Winding form casting and machining 5/27/05 8/3/06 5/12 Coil type 1 5/27/05 9/29/05 Coil 1-1 5/27/05 8/18/05 Castings, Type 1 27-May-05 29-Sep-05 Coil 1-2 7/8/05 9/29/05 Coil type 2 6/17/05 2/9/06 Coil type 3 12/9/05 8/3/06 Receive and prepare casting 8/19/05 9/7/06 Castings, Type 2 17-Jun-05 9-Feb-06 Coil type 1 8/19/05 11/3/05 Coil 1-1 8/19/05 10/6/05 Coil 1-2 9/30/05 11/3/05 Coil type 2 10/7/05 3/16/06 Castings, Type 3 9-Dec-05 3-Aug-06 Coil type 3 3/31/06 9/7/06 Conductor winding 10/7/05 1/11/07 Coil type 1 10/7/05 1/12/06 Coil 1-1 10/7/05 12/1/05 Coil 1 Prep, 19-Aug-05 2-Mar-06 Coil 1-2 12/2/05 1/12/06 Coil type 2 1/13/06 7/13/06 wind, can, VPI Coil type 3 7/14/06 1/11/07 Can welding and leak checking 12/2/05 2/8/07 Coil 2 Prep, 7-Oct-05 24-Aug-06 Coil type 1 12/2/05 2/16/06 Coil 1-1 12/2/05 1/19/06 wind, can, VPI Coil 1-2 1/20/06 2/16/06 Coil type 2 3/10/06 8/10/06 Coil type 3 9/8/06 2/8/07 Coil 3 Prep, 31-Mar-06 27-Feb-07 Vacuum Pressure Impregnation, final 1/20/06 2/22/07 inspection and testing Coil type 1 1/20/06 3/2/06 wind, can, VPI Coil 1-1 1/20/06 2/9/06 Coil 1-2 2/17/06 3/2/06 Coil type 2 4/28/06 8/24/06 Coil type 3 10/27/06 2/22/07 June 23-24, 2003 QPS CDR - Project Implementation 30

Schedule for fabrication of other components Task/milestone Vacuum Vessel Start 9-Dec-05 Finish 26-Oct-06 Task Name Start Finish External Vacuum Vessel 12/9/05 10/26/06 bid contract for new external tank 12/9/05 1/5/06 2006 2007 J F M A M J J A S O N D J F M A M J J A award contract for new tank 1/5/06 1/5/06 1/5 PF Coils 31-Mar-06 1-Mar-07 Shop Drawing and Tooling 1/6/06 4/27/06 Fabricate new tank 4/28/06 10/26/06 PF Coils 3/31/06 3/1/07 bid and award solenoid 3/31/06 5/25/06 Centerstack 31-Mar-06 1-Mar-07 fabricate new solenoid 5/26/06 3/1/07 Refurbish ATF and PBX coils 3/31/06 6/22/06 Centerstack assembly 3/31/06 3/1/07 TF Coil legs 17-Feb-06 18-Jan-05 bid and award centerstack assembly 3/31/06 6/8/06 fabricate centerstack assembly 6/9/06 3/1/07 TF Coil outer legs and transitions 2/17/06 1/18/07 bid and award TF outer legs and transitions 2/17/06 5/11/06 TF PF supports 1-Sep-05 2-Aug-07 fabricate TF ouer legs and transitions 5/12/06 1/18/07 TF/PF Coil Support Structure 9/2/05 8/3/06 bid and award support structure 9/2/05 11/24/05 fabricate support structure 11/25/05 8/3/06 Machine Base 26-Aug-05 20-Apr-06 Machine base 8/26/05 4/20/06 bid and award machine base assembly 8/26/05 10/20/05 fabricate machine base 10/21/05 4/20/06 Coil Leads 10-Nov-06 24-May-07 Coil leads 11/10/06 5/24/07 bid and award coil leads 11/10/06 1/4/07 fabricate coil leads 1/5/07 5/24/07 Coil cooling distribution system 11/10/06 7/5/07 Coil cooling distr. 10-Nov-06 5-Jul-07 bid and award coolant distribution system 11/10/06 1/4/07 fabricate coolant distribution system 1/5/07 7/5/07 June 23-24, 2003 QPS CDR - Project Implementation 31

Schedule for machine core assembly Task/milestone Start Finish Assemble Mod period 1 Assemble Mod period 2 Base assembly 13-Oct-06 12-Jan-07 2-Oct-06 4-Jan-07 22-Mar-07 4-May-06 Task Name Start Finish Core Assembly, on-site 10/2/06 6/21/07 assemble first field period 10/13/06 1/4/07 assemble second field period 1/12/07 3/22/07 Install base assembly 10/2/06 10/6/06 Pre-position lower vv lid with PF Coils 10/27/06 11/9/06 2007 S O N D J F M A M J J A S O Install Coil field period assemblies 3/23/07 4/5/07 Final mod assy 23-Mar-07 5-Apr-06 install vessel spool piece 4/6/07 4/12/07 install upper VV lid with PF coils 4/13/07 4/19/07 Install centerstack assembly 4/20/07 4/26/07 Vacuum Vessel 25-Jan-06 25-May-06 install vacuum seals around modular coil leads 4/27/07 5/3/07 install blank port covers 5/4/07 5/17/07 leak check vessel 5/18/07 5/31/07 Centerstack 20-Apr-07 26-Apr-07 Install TF coil outer legs 6/1/07 6/14/07 install cooling lines from coils to facility system 6/15/07 6/21/07 TF Coil legs 1-Jun-07 14-Jun-07 install modular coil leads, connect to building buswork install PF/TF leads, connect to building buswork 6/15/07 6/21/07 6/15/07 6/21/07 Coil Leads, cooling 8-Jun-07 21-Jun-07 June 23-24, 2003 QPS CDR - Project Implementation 33

Schedule for Ancillary systems, Checkout Task/milestone Start Finish DAC 20-Mar-06 9-Jun-06 Diagnostics 26-Jun-06 21-Jul-06 Task Name Start Finish Data acquisition and control system 3/20/06 6/9/06 Install DAC sytem in control room 3/20/06 6/9/06 2006 2007 F M A M J J A S O N D J F M A M J J A S O N D install DAS backbone around machine 3/20/06 5/12/06 Startup and Integrated systems testing 31-Jul-06 29-Sep-06 Diagnostics 6/22/07 7/26/07 Install day 1 diagnostics on machine 6/22/07 7/19/07 Run cables to control room and connect 6/29/07 7/26/07 Machine assembly completed 7/26/07 7/26/07 Startup and Integrated Systems Testing 7/27/07 9/20/07 7/26 First Plasma 20-Sep-07 First Plasma 9/20/07 9/20/07 9/20 (schedule date) First Plasma 1-Jan-08 (for cost est) June 23-24, 2003 QPS CDR - Project Implementation 34