**N****CSX**

**Product Specification**

**Prototype Modular Coil Winding Form**

**NCSX-CSPEC-141-02-00**

**April 6, 2004**

Prepared By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

P. Heitzenroeder, Technical Representative for Modular Coil (WBS 14)
Procurements

Concurred By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

D. Williamson, WBS Manager for Modular Coils (WBS 14)

Concurred By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

B. Nelson, Project Engineer for Stellarator Core Systems (WBS 1)

Concurred By:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

F. Malinowski, PPPL Procurement QA Representative

Approved by:
\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

W. Reiersen, NCSX Engineering Manager

#  {#section .toc-title}

# REVISIONS {#revisions .toc-title}

  ------------------ ---------------------------------------------- ----------
  [Revision          [Affected Pgs.]{.underline}                    Date
  No.]{.underline}                                                  

  Rev. 0 (Initial    All                                            04/05/04
  Release)                                                          

                                                                    

                                                                    

                                                                    

                                                                    

                                                                    

                                                                    

                                                                    

                                                                    

                                                                    

                                                                    
  ------------------ ---------------------------------------------- ----------

#  TABLE OF CONTENTS {#table-of-contents .toc-title}

# [1 INTRODUCTION AND SCOPE 1](#introduction-and-scope) {#introduction-and-scope-1 .TOC-1}

## [1.1 Introduction 1](#introduction) {#introduction-1 .TOC-2}

## [1.2 Scope 1](#scope) {#scope-1 .TOC-2}

# [2 APPLICABLE DOCUMENTS 1](#applicable-documents) {#applicable-documents-1 .TOC-1}

## [2.1 Codes and Standards 1](#codes-and-standards) {#codes-and-standards-1 .TOC-2}

# [3 REQUIREMENTS 2](#requirements) {#requirements-2 .TOC-1}

## [3.1 Winding Form Definition 2](#winding-form-definition) {#winding-form-definition-2 .TOC-2}

## [3.2 Characteristics 3](#__RefHeading___Toc31517476) {#characteristics-3 .TOC-2}

[3.2.1 Performance 3](#performance)

[3.2.1.1 Mechanical and Physical Properties of Casting Alloy
3](#mechanical-and-physical-properties-of-casting-alloy)

[3.2.1.2 DELETED 4](#__RefHeading___Toc31517479)

[3.2.1.3 DELETED 4](#__RefHeading___Toc31517480)

[3.2.1.4 Electrical Properties of the Poloidal Electrical Break
4](#electrical-properties-of-the-poloidal-electrical-break)

[3.2.1.5 Surface Finish 5](#surface-finish)

[3.2.1.6 Relative Magnetic Permeability
5](#relative-magnetic-permeability)

## [3.3 Design and Construction 5](#design-and-construction) {#design-and-construction-5 .TOC-2}

[3.3.1 Production Drawings 5](#production-drawings)

[3.3.2 Standards of Manufacture 6](#standards-of-manufacture)

[3.3.2.1 Heat Treatment 6](#heat-treatment)

[3.3.2.2 Repairs 6](#repairs)

# [4 Quality Assurance Provisions 6](#quality-assurance-provisions) {#quality-assurance-provisions-6 .TOC-1}

## [4.1 General 6](#general) {#general-6 .TOC-2}

[4.1.1 Responsibility for Inspection 7](#responsibility-for-inspection)

## [4.2 Quality Conformance Inspections 7](#quality-conformance-inspections) {#quality-conformance-inspections-7 .TOC-2}

[4.2.1 Verification of Mechanical and Physical Properties of Casting
Alloy
7](#verification-of-mechanical-and-physical-properties-of-casting-alloy)

[4.2.2 DELETED 8](#__RefHeading___Toc31517494)

[4.2.3 DELETED 8](#__RefHeading___Toc31517495)

[4.2.4 Verification of the Electrical Properties of the Poloidal Break
8](#verification-of-the-electrical-properties-of-the-poloidal-break)

[4.2.5 Verification of Surface Finish
8](#verification-of-surface-finish)

[4.2.6 Verification of Relative Magnetic Permeability
8](#verification-of-relative-magnetic-permeability)

[4.2.7 Dimensional Inspection 8](#dimensional-inspection)

[4.2.8 Visual Inspection 8](#visual-inspection)

[4.2.9 Liquid Penetrant Inspection 9](#liquid-penetrant-inspection)

[4.2.10 Inspection for Internal Defects
9](#inspection-for-internal-defects)

# [5 Preparation for delivery 9](#preparation-for-delivery) {#preparation-for-delivery-9 .TOC-1}

## [5.1 Marking 9](#marking) {#marking-9 .TOC-2}

## [5.2 Cleaning 9](#cleaning) {#cleaning-9 .TOC-2}

## [5.3 Crating 10](#crating) {#crating-10 .TOC-2}

## [5.4 Shipping 10](#shipping) {#shipping-10 .TOC-2}

# INTRODUCTION AND SCOPE

## Introduction: 

[Stellarators and the National Compact Stellarator
Experiment]{.underline}

Stellarators are a class of magnetic fusion confinement devices
characterized by three dimensional magnetic fields and plasma shapes and
are the best-developed class of magnetic fusion devices after the
tokamak. The stellarator concept has greatly advanced since its
invention by Dr. Lyman Spitzer, the founding director of the Princeton
Plasma Physics Laboratory (PPPL), during the 1950's. A traditional
stellarator uses only external magnetic fields to shape and confine the
plasma. The National Compact Stellarator Experiment (NCSX) is the first
of a new class of stellarators known as "compact stellarators." The
differentiating feature of a compact stellarator is the use of plasma
current in combination with external fields to accomplish shaping and
confinement. This combination permits a more compact device. The NCSX
project is managed by PPPL in partnership with the Oak Ridge National
Laboratory. This Subcontract will be administered by PPPL. Operation of
NCSX is scheduled to begin in July 2007

## Scope 

This specification establishes the manufacturing and acceptance
requirements for the National Compact Stellarator Experiment (NCSX)
Modular Coil Winding Forms. There are total of (18) winding forms: 3
each of Types A, B, and C.

# APPLICABLE DOCUMENTS

## Codes and Standards

**[ASTM (American Society for Testing and Materials )]{.underline}**[^1]

A703/A703M-01 "Specification for Steel Castings".

A800/A800M-01 "Standard Practice for Steel Casting, Austenitic Alloy,
Estimating Ferrite Content Thereof".

A802/A802M--95 "Standard Practice for Steel Castings, Surface Acceptance
Standards, Visual Examination".

A 903/A903/M--99 "Standard Specification for Steel Castings, Surface
Acceptance Standards, Magnetic Particle, and Liquid Penetrant
Inspection".

**[Manufacturers Standardization Society of the Valve and Fittings
Industry, Inc.]{.underline}** [^2]

MSS SP-54-2001: "Quality Standard for Steel Castings for Valves,
Flanges, Fittings, and Other Piping Components; Radiographic Inspection
Method".

# REQUIREMENTS

## Winding Form Definition

The winding forms are austenitic (non-magnetic) stainless steel
structures which are one of the most important components of the modular
coils and the NCSX device. The winding forms perform two very important
functions: (1) the conductors are wound on the winding forms, and are
located in precise position by these forms; (2) the winding forms serve
as their structural support during assembly and operation. There are
three distinct shapes of winding forms; six of each are required for a
total of 18. The winding forms shall be manufactured by casting followed
by machining. A machined winding form is illustrated in Fig. 3.1-1. .

![](media/image1.jpeg){width="3.1166666666666667in"
height="3.8777777777777778in"}

Figure 3.1‑1 A Machined Modular Coil Winding Form. Illustrated is one of
three winding form types.

*NOTE:* *Figure 3.1-1eis illustrative only and not to be used for
manufacture.*

[]{#__RefHeading___Toc31517476 .anchor}Characteristics

### Performance 

#### Mechanical and Physical Properties of Casting Alloy

[Background]{.underline}

The winding form is to be cast with the alloy developed and qualified by
the subcontractor during their Manufacturing Development and Prototype
Manufacture. (Note: This section will be replaced with the exact
chemical composition for the successful offeror prior to the award of
the subcontract).

[Requirement]{.underline}

The prototype winding form shall be fabricated from stainless steel
alloy that meets the following requirements. (Note: This section will be
replaced with the properties of the successful offeror's casting alloy
prior to award of the Subcontract).

0.2% Yield strength: \>180 MPa (\>26 ksi) at room temperature (RT);
\>360 MPa ( \>52 ksi) at 77K.

Ultimate tensile strength: \>360 MPa (52 ) at RT; \>690 MPa (99.7 ksi)
at 77 K.

Elongation: 30% (min.) at RT and 77 ^0^K.

Thermal conductivity: \>9.5 W/m-K at RT; \>7W/m-K at 77K

Electrical Resistivity: \>83 x 10^-8^ Ω−m at RT; \>64 x 10^-8^ Ω−m at
77K

Fracture Toughness: TBD

#### 

#### 

#### Electrical Properties of the Poloidal Electrical Break

The electrical resistance between any bolt to the winding form and the
insulation break mid-plate to winding form shall be \>500 kΩ when tested
at 100 VDC.

#### Surface Finish

All machined surfaces must have a RMS (root mean square) surface finish
\<125 μ-inches. Uniform "scallops" which exceed 125 μ-inches, which may
result from some machining processes, may be acceptable, subject to PPPL
approval.

#### Relative Magnetic Permeability

The local relative magnetic permeability shall not exceed 1.02.

## Design and Construction

### Production Drawings

The Pro/Engineer CAD files listed in Table 3.3-1 shall be used to
manufacture the production winding forms. They reside in a zip file
(se-141-116p.zip) located at the production winding form ftp site (
[ftp://ftp.pppl.gov/pub/ncsx/manuf/producton_winding_form/](ftp://ftp.pppl.gov/pub/ncsx/manuf/prototype_winding_form/)
).

Table 3.3‑1 List of Pro/ENGINEER Models and Drawings

  ------------------------- ----------------- -------- -------------------
  Document Type             File Name         Rev      Description

                                                       

                                                       

                                                       

                                                       

                                                       
  ------------------------- ----------------- -------- -------------------

### Standards of Manufacture

#### Heat Treatment

The castings are to be heat treated per the supplier's approved heat
treatment procedure as defined in their MIT / QA Plan for dimensional
stability and materials property control prior to final measurements of
mechanical properties and relative magnetic permeability. Heat treatment
records shall be prepared and maintained as defined in S21 of ASTM Spec.
A703/A703M , and supplied to PPPL. Test specimens shall be heat treated
together with the castings they represent per Supplementary Requirement
S22 of ASTM Spec. A703/A703M.

#### Repairs

Unacceptable defects must be repaired. Major repairs shall be welded and
documented as defined in Sections S12 and S20 of ASTM Spec. A703/A703M.
Repairs shall be considered major when the depth of the cavity prepared
for welding exceeds 10% of the actual wall thickness or 1", whichever is
smaller, or when the extent of the cavity exceeds approximately 10
in^2^. Non-conformance reports for major repairs (which include in the
disposition the proposed corrective action) shall be prepared for each
major weld repair and will be subject to the prior approval of PPPL.
Weld preparation shall be per Section S10 of ASTM Spec. A703/A703M. Weld
repairs are to be inspected per Sections 4.2.6, 4.2.7, and 4.2.8 of this
specification.

# Quality Assurance Provisions

## General

Tests shall be conducted at the supplier's facility or otherwise
suitable location.

### Responsibility for Inspection

The responsibility for performing all tests and verifications rests with
the supplier. PPPL reserves the right to witness or separately perform
all tests specified or otherwise inspect any or all tests and
inspections.

## Quality Conformance Inspections

### Verification of Mechanical and Physical Properties of Casting Alloy 

Yield Strength: The yield strength at 0.2% elongation for the cast
stainless steel in the as heat-treated condition at room temperature and
77K shall be provided. Tensile test specimen coupons shall be cast with
each winding form in accordance with ASTM A703/A703M-01, Supplementary
Requirement 7.

Ultimate Tensile Strength and Elongation: The ultimate tensile strength
and elongation for the cast stainless steel in the as heat-treated
condition at room temperature and 77K shall be provided. Tensile test
specimen coupons shall be cast with each winding form in accordance with
ASTM A703/A703M-01, Supplementary Requirement 7.

Elastic Modulus: The elastic (Young's) modulus at room temperature and
77K shall be provided for each casting.

Chemical Composition: The material chemical composition shall be
measured and provided for each casting.

Thermal Conductivity: The thermal conductivity of the casting alloy at
room temperature and 77K shall be provided for each casting.

Electrical Resistivity: The electrical resistivity of the casting alloy
at room temperature and 77K shall be provided for each casting.

Fracture Toughness: The K~IC~ and the Paris Constants (C, n) of the
casting alloy at room temperature and 77K shall be provided for each
casting.

### 

### 

### Verification of the Electrical Properties of the Poloidal Break

The insulation resistance of the poloidal break insulator and the
insulation for each bolt shall be measured by performing an insulation
resistance (Megger ) test.

### Verification of Surface Finish

All machined surfaces shall be inspected for compliance with surface
finish requirements specified in Section 3.2.1.3.

### Verification of Relative Magnetic Permeability

All cast surfaces and features shall be checked with a calibrated Severn
Permeability Indicator for compliance with Section 3.2.1.4. Flange faces
and edges shall be checked at locations no greater than 2 inches apart
and at all weld repairs. Relative magnetic permeability measurements on
all other surfaces shall be made at locations approximately 6" apart (to
approximate a 6" x 6" grid). Relative magnetic permeability of any final
machined casting that exceeds 1.02 must be documented on a
nonconformance report and will require approval on a case-by-case basis.
Permeabilty measurements shall be per Supplementary Requirements S24 of
ASTM Spec. A703/A703M and S1 of ASTM A800/A800M, except that the results
shall be expressed as relative permeability, μ, rather than ferrite
content (FN).

### Dimensional Inspection

All cast surfaces and features shall be dimensionally checked using a
Computerized Measureing Machine (CMM). The dimensional inspections shall
be performed with measurements taken to approximate a 4" x 4" grid on
the shell sections and a 2" x 2" grid on the "T" sections and shall be
performed in accordance with the details defined in the approved
Manufacturing/Inspection/QA Plan.

### Visual Inspection

Visual surface inspection and treatment of unacceptable surface defects
shall be performed per ASTM Spec. A703/A703M, paragraph 10.1. Evaluation
criteria shall be per ASTM A802/A802M, Level II using graded reference
comparators available from Castings Technology International[^3].

### Liquid Penetrant Inspection

Each casting shall be examined for surface discontinuities using liquid
penetrant inspection per Supplementary Requirement S6 of ASTM Spec.
A703/A703M. Evaluation criteria shall be per ASTM A903/A903M Level I for
those regions of the winding forms shown shaded in the drawings in
Attachment 1 and Level II for all other areas. Certified test reports
are required per ASTM A903, Supplementary Requirement S1.

### Inspection for Internal Defects

Each casting shall be examined for internal defects as defined in ASTM
Spec.A703/A703M using radiographic inspection per Supplementary
Requirement S5. Acceptance criteria shall be per MSS SP 54 for
radiography.

# Preparation for delivery

## Marking

The prototype winding form shall have a serial number and its weight
engraved or stamped at its outer horizontal centerline with characters
1/4" high.

## Cleaning

The prototype winding form shall be degreased/cleaned using a solvent
which must be able to dissolve grease, oils and other soils, and leave
the casting residue free. .

## Crating

The crate shall protect the prototype winding form from shock and
weather conditions, including precipitation. The crate shall be built
for moving on rollers, handling with slings from overhead cranes, and
transport by forklifts**.**

## Shipping

Subcontractor is responsible arranging shipment, and for the safe
arrival of the prototype winding form at PPPL in Princeton, New Jersey,
USA. Subcontractor's name, shipper, purchase order number, contents and
gross weight shall be marked on the shipping container.

[^1]: Publications are available from
    <http://www.astm.org/cgi-bin/SoftCart.exe/index.shtml?E+mystore>.

[^2]: Publications are available from Manufacturers Standardization
    Society of the Valve and Fittings Industry, Inc., 127 Park Street,
    NE , Vienna, Virginia 22180 . Tel. (703)-281-6613.

[^3]: http://www.castingsdev.com/