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Introduction to W7-X Coil Testing at CEA – Saclay, France

Introduction to W7-X Coil Testing at CEA – Saclay, France. G.Croari – March 2008. G.Croari – March 2008. Outline. Test facility description Coil test procedure Main difficulties Conclusion. G.Croari – March 2008. Outline. Test facility description Coil test procedure Main difficulties

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Introduction to W7-X Coil Testing at CEA – Saclay, France

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  1. Introduction to W7-XCoil Testing at CEA – Saclay, France G.Croari – March 2008

  2. G.Croari – March 2008 Outline • Test facility description • Coil test procedure • Main difficulties • Conclusion

  3. G.Croari – March 2008 Outline • Test facility description • Coil test procedure • Main difficulties • Conclusion • Cryostats, valve boxes, satellite • Power supply • Pumping system • Cryogenic part (Refrigerator/liquifier) • Data acquisition system

  4. G.Croari – March 2008 Outline • Test facility description • Coil test procedure • Main difficulties • Conclusion • Cryostats, valve boxes, satellite • Power supply • Pumping system • Cryogenic part (Refrigerator/liquifier) • Data acquisition system • Documentation • Incoming Inspection tests • Coils into cryostat • Outgoing check

  5. G.Croari – March 2008 Outline • Test facility description • Coil test procedure • Main difficulties • Conclusion • Cryostats, valve boxes, satellite • Power supply • Pumping system • Cryogenic part (Refrigerator/liquifier) • Data acquisition system • Documentation • Incoming Inspection tests • Coils into cryostat • Outgoing check • DC test • Leaks • Detail of some coils

  6. G.Croari – March 2008 Outline • Test facility description • Coil test procedure • Main difficulties • Conclusion • Cryostats, valve boxes, satellite • Power supply • Pumping system • Cryogenic part (Refrigerator/liquifier) • Data acquisition system • Documentation • Incoming Inspection tests • Coils into cryostat • Outgoing check • DC test • Leaks • Detail of some coils • My contribution

  7. G.Croari – March 2008 1. Test Facility Description • Cryostats, valve boxes, satellite • Power supply • Pumping system • Cryogenic part (Refrigerator/liquifier) • Data acquisition system

  8. G.Croari – March 2008 Test Facility DescriptionCryostat, Valve boxes, Satellite Cryostat 1 Valve box C 1 Satellite Valve box C 2 Cryostat 2 TestFrames

  9. G.Croari – March 2008 Test Facility DescriptionCryostat, Valve boxes, Satellite Satellite Valve box C 1 Valve box C 2 Power Supply terminals

  10. G.Croari – March 2008 Test Facility DescriptionCryostat, Valve boxes, Satellite Cryostat detail Connections for Coil A NitrogenShield Connections for Coil B

  11. G.Croari – March 2008 Test Facility DescriptionCryostat, Valve boxes, Satellite Valve box detail Current leads

  12. G.Croari – March 2008 Test Facility DescriptionCryostat, Valve boxes, Satellite Valve box detail Valves

  13. G.Croari – March 2008 Test Facility DescriptionCryostat, Valve boxes, Satellite Valve box detail Cablings Safety Valves Calibration Leak

  14. G.Croari – March 2008 Test Facility DescriptionPower Supply Input: 380 Vac 3-phase Simplified schematic Transformer Thristors Iout Load

  15. G.Croari – March 2008 Test Facility DescriptionPower Supply • Input: • Max absorption 980 A • Nominal Power 700 KVA • Water cooled • Output: • Max current 25KA • Max Voltage 10V • Regulation: • <+-10 E-4 on inductive Loads • <+-10 E-3 on resistive Loads

  16. G.Croari – March 2008 Test Facility DescriptionPumping System

  17. G.Croari – March 2008 Test Facility DescriptionPumping System Primary system

  18. G.Croari – March 2008 Test Facility DescriptionPumping System Secondary system

  19. G.Croari – March 2008 Test Facility DescriptionPumping System Primary system Secondary system Root pumps Vane pump Diffusion pump

  20. G.Croari – March 2008 Test Facility DescriptionCryogenic part: Refrigerator / Liquifier Cold Box Nitrogen Exchanger Heat Exchanger Turbine Cold Helium

  21. G.Croari – March 2008 Test Facility DescriptionCryogenic part Refrigerator / Liquifier • Specifications of cold part: • Total mass flow rate 15 + 31 gr/sec LHe @ 300 K • Refrigerating power = 200W @ 4,2 K • LHe production = 70 Lt / hour 5000 Litres LHe tank

  22. G.Croari – March 2008 Test Facility DescriptionData Acquisition System Coils & Test Facility Coils

  23. G.Croari – March 2008 Test Facility DescriptionData Acquisition System Measurement on coils: • Temperature sensors • Strain Gauges • Extensometer

  24. G.Croari – March 2008 Test Facility DescriptionData Acquisition System

  25. G.Croari – March 2008 2. Coil Test Procedure • Documentation • Incoming Inspection tests • Coils into cryostat • Outgoing check

  26. G.Croari – March 2008 Coil test procedureDocumentation • Scope and Requirements

  27. G.Croari – March 2008 Coil test procedureDocumentation • Scope and Requirements • Documentation

  28. G.Croari – March 2008 Coil test procedureDocumentation • Scope and Requirements • Documentation • Non Conformrmity Report

  29. G.Croari – March 2008 Coil test procedureIncoming Inspection Tests • Unloading from the lorry

  30. G.Croari – March 2008 Coil test procedureIncoming Inspection Tests • Unloading from the lorry • Installation under a test frame

  31. G.Croari – March 2008 Coil test procedureIncoming Inspection Tests • Unloading from the lorry • Installation under a test frame • Bending and Joint box installation

  32. G.Croari – March 2008 Coil test procedureIncoming Inspection Tests • Unloading from the lorry • Installation under a test frame • Bending and Joint box installation • Cablings and tests: Temperature sensors, Strain gauges, Extensometers

  33. G.Croari – March 2008 Coil test procedureIncoming Inspection Tests • Unloading from the lorry • Installation under a test frame • Bending and Joint box installation • Cablings and tests: Temperature sensors, Strain gauges, Extensometers • QD Wire check, DC insulation test

  34. G.Croari – March 2008 Coil test procedureCoils Into Cryostat • Coil at open cryostat: QD wire check, DC test

  35. G.Croari – March 2008 Coil test procedureCoils Into Cryostat • Coil at open cryostat: QD wire check, DC test • Under Vacuum: Leak test Calibration leak Coil leak

  36. G.Croari – March 2008 Coil test procedureCoils Into Cryostat • At open cryostat: QD wire check, DC test • Under Vacuum: Leak test • Coils at cryogenic temperature: Current test, AC test, DC test

  37. G.Croari – March 2008 Coil test procedureCoils Into Cryostat • At open cryostat: QD wire check, DC test • Under Vacuum: Leak test • Coils at cryogenic temperature: Current test, AC test, DC test AC test is to test the interlayer insulation

  38. G.Croari – March 2008 Coil test procedureCoils Into Cryostat • At open cryostat: QD wire check, DC test • Under Vacuum: Leak test • Coils at cryogenic temperature: Current test, AC test, DC test DC test is a general check of insulation

  39. G.Croari – March 2008 Coil test procedureOutgoing check • Before shipment: QD wire check • Outgoing check

  40. G.Croari – March 2008 3. Main Difficulties • DC test • Leaks • Detail of some coils

  41. G.Croari – March 2008 Main DifficultiesDC Tests Coil Arrival Coil Departure Room T Cryo T After warm up

  42. G.Croari – March 2008 Main DifficultiesDC Tests Coil Arrival Coil Departure Room T Cryo T After warm up If it failed at Cryo T It fails at room T too 100% OK about 70% Not OK about 30% OK

  43. G.Croari – March 2008 Main DifficultiesDC Tests DC test failures: possible explanations In the coil In the test facility • Ground Insulation • QD wires • Cryostat connections • Hydraulic connections • Holding system

  44. G.Croari – March 2008 Main DifficoultiesDC Tests • Critical points on the coil: • Ground Insulation

  45. G.Croari – March 2008 Main DifficultiesDC Tests • Critical points on the coil: • Ground Insulation

  46. G.Croari – March 2008 Main DifficultiesDC Tests • Critical points on the coil: • Ground Insulation • QD Wires

  47. G.Croari – March 2008 Main DifficultiesDC Tests • Critical points on the test facility: • Cryostat connections (QD bucket)

  48. G.Croari – March 2008 Main DifficultiesDC Tests • Critical points on the test facility: • Cryostat connections (QD bucket) • Hydraulic connections Internal view of a valve box

  49. G.Croari – March 2008 Main DifficultiesDC Tests • Critical points on the test facility: • Cryostat connections (QD bucket) • Hydraulic connections • Holding system

  50. G.Croari – March 2008 Main DifficoultiesLeaks Coils Test facility AAB10 welding during current test (03/08/2007) Valve box potential breaker (28/03/2007)

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