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NSTX TF Flag Joint Design Review Fabrication and Assembly April 10, 2003 By: James NSTX TF Flag Joint Design Review Fabrication and Assembly April 10, 2003 By: James H. Chrzanowski J. H. Chrzanowski NSTX TF Flag Joint Design Review 1

Contents of Presentation • • Identify the components of the Hub Assembly Discuss improvements Contents of Presentation • • Identify the components of the Hub Assembly Discuss improvements to TF bundle Discuss new TF flag assembly Discuss differences between the upper and lower hub assemblies • Discuss fabrication issues • Discuss the assembly details and sequence J. H. Chrzanowski NSTX TF Flag Joint Design Review 2

TF Flag Assembly Identification Upper Inner TF Flags Upper Hub structure Upper Outer TF TF Flag Assembly Identification Upper Inner TF Flags Upper Hub structure Upper Outer TF Flags Lower Hub structure TF Flag Support Box Torque restraint collar Lower Inner TF Flags Upper TF Hub Assy. J. H. Chrzanowski Lower TF Hub Assy. NSTX TF Flag Joint Design Review 3

New TF Bundle/ Hub Assembly • The new TF bundle will be fabricated in-house New TF Bundle/ Hub Assembly • The new TF bundle will be fabricated in-house • This decision is based upon quality and schedule issues • PPPL has also retained possession of the original molds used in the TF bundle fabrication • There were several Quality concerns associated with the original TF bundle construction by the outside vendor. • These quality concerns resulted in: – coolant leaks – Additional rework of electrical faces in-house • In-house fabrication will result in closer supervision and better quality control J. H. Chrzanowski NSTX TF Flag Joint Design Review 4

New TF Bundle Fabrication • Once leaks were found on the TF bundle, new New TF Bundle Fabrication • Once leaks were found on the TF bundle, new conductor was procured in FY-01 for possible future replacement of the TF bundle (CDA 10700 OFHC silver bearing copper) • An epoxy cure oven is presently being designed and fabricated for this purpose (ready by end of May) J. H. Chrzanowski NSTX TF Flag Joint Design Review 5

TF Bundle Epoxy Cure Oven • Oven will be used for curing the B-stage TF Bundle Epoxy Cure Oven • Oven will be used for curing the B-stage T/T and groundwall insulation on the TF bundle • Will be used for soldering the coolant tubes into the conductors • Sized to accommodate the OH solenoid molds for possible future upgrades • Modular design oven for easy disassembly & storage J. H. Chrzanowski NSTX TF Flag Joint Design Review 6

Quality Problems with Original TF Bundle Numerous coolant tube leaks developed once operations began Quality Problems with Original TF Bundle Numerous coolant tube leaks developed once operations began J. H. Chrzanowski NSTX TF Flag Joint Design Review 7

Improvements to TF Bundle • Design Improvements: • Coolant Tubes – Improve integrity of Improvements to TF Bundle • Design Improvements: • Coolant Tubes – Improve integrity of coolant tube design – Routing- Upper tubes to come straight out the top – Type of tubing- straight length seamless Cu • Joint Improvements – Replace joint Inserts- Tap-lok Inserts – Improve shimming- Flag box – New fastener design J. H. Chrzanowski NSTX TF Flag Joint Design Review 8

Upper Hub Assembly • The new upper hub assembly has (2) different flag designs Upper Hub Assembly • The new upper hub assembly has (2) different flag designs – Inner Flag- Bolted joint – Outer Flag- E-beam welded flag J. H. Chrzanowski NSTX TF Flag Joint Design Review 9

E-Beam Welding of Upper Outer Flags Weld flags to upper outer conductors following initial E-Beam Welding of Upper Outer Flags Weld flags to upper outer conductors following initial machining, but prior to final machining and bundle assembly • Bolt on electrical end flags following epoxy fill of flag boxes J. H. Chrzanowski NSTX TF Flag Joint Design Review 10

TF Flag Structural Boxes Kapton insulation along entire length of flag Blind tapped holes TF Flag Structural Boxes Kapton insulation along entire length of flag Blind tapped holes Gaskets for sealing box Epoxy fill holes Dry glass insulation along length of interface fills space between flag and box Stainless steel boxes J. H. Chrzanowski 0. 010 in. allowance for fitup of flag to conductor NSTX TF Flag Joint Design Review 11

Typical TF Flag Joint-(Upper inner; lower inner & outer) Stainless steel washer plate, belleville Typical TF Flag Joint-(Upper inner; lower inner & outer) Stainless steel washer plate, belleville washers and nuts Tap-lok inserts A-286 fasteners Flag resistance lead Shear Pin & Block (stainless steel) Flag box (stainless steel) * Fasteners will be discussed in detail by Mike Kalish J. H. Chrzanowski NSTX TF Flag Joint Design Review 12

Upper TF Hub Assembly-1 Preposition lower hub plate [1] Insulate flags (Kapton & glass) Upper TF Hub Assembly-1 Preposition lower hub plate [1] Insulate flags (Kapton & glass) [2] • Position flag boxes over flags [3] • Lower hub plate • • 2 Attach front contact face [4] 3 – Note: front contact faces may be attached either prior to or after epoxy fill of boxes) 1 4 J. H. Chrzanowski NSTX TF Flag Joint Design Review 13

Upper TF Hub Assembly-2 • Complete assembly of Flag boxes [1] • Install center Upper TF Hub Assembly-2 • Complete assembly of Flag boxes [1] • Install center hub structure into position [2] • Center hub structure Fasten upper and lower plates to the flag boxes [3] 2 3 J. H. Chrzanowski 1 NSTX TF Flag Joint Design Review 14

Upper TF Hub Assembly-3 Install shear blocks and pins [1] Install leads for flag Upper TF Hub Assembly-3 Install shear blocks and pins [1] Install leads for flag resistance measurements • Install studs and pre-assembled boxed inner flags into position [2] • Jack flags to contact shear blocks • Install upper hub plate • 2 • • Upper hub plate Secure the mid and upper plates to the flag boxes [3] 1 2 J. H. Chrzanowski NSTX TF Flag Joint Design Review 15

Upper TF Hub Assembly-4 1 • Jack flags to contact shear blocks • Vacuum Upper TF Hub Assembly-4 1 • Jack flags to contact shear blocks • Vacuum fill the individual flag boxes with Hysol epoxy [1] • Install the torque restraint support ring to the TF bundle via epoxy/ glass lay up [2] 2 J. H. Chrzanowski NSTX TF Flag Joint Design Review 16

Installation of Torque Restraint Support Ring Buildup of dry glass and Hysol epoxy (wet Installation of Torque Restraint Support Ring Buildup of dry glass and Hysol epoxy (wet lay-up) over ground wall J. H. Chrzanowski • Install torque restraint collar NSTX TF Flag Joint Design Review 17

Pre-Assemble the Lower Hub Assembly • Pre-assemble lower hub structure prior to TF installation Pre-Assemble the Lower Hub Assembly • Pre-assemble lower hub structure prior to TF installation • Epoxy fill the flag boxes • Do not install lower torque restraint collar • Disassemble lower hub structure J. H. Chrzanowski NSTX TF Flag Joint Design Review 18

Installation of TF Bundle J. H. Chrzanowski NSTX TF Flag Joint Design Review 19 Installation of TF Bundle J. H. Chrzanowski NSTX TF Flag Joint Design Review 19

Final Assembly of Lower Hub Assembly • Complete assembly of the lower hub structure Final Assembly of Lower Hub Assembly • Complete assembly of the lower hub structure including torque restraint collar • Install pedestal and complete bus and umbrella component assembly J. H. Chrzanowski NSTX TF Flag Joint Design Review 20