TF Joint Testing Data Acquisition Special Test Equipment

1
TF Joint Testing Data Acquisition Special Test
Equipment

• Hans Schneider
• with Robert Marsala
• [phone]
• hschneid_at_pppl.gov
• Engineering Operations
• April 2003

2
Resistance Measurement PlanPrototype Insitu
Joints

• Mechanical Prototype Testing
• Electrical Prototype Testing
• Maintenance Insitu Testing
• Commissioning Insitu Testing

3
Resistance Measurement PlanMechanical TF Joint
Test System
MTS Hydraulic Test Stand
4
Resistance Measurement PlanMechanical TF Joint
Test System

• Mechanical Prototype Testing
• Cyclical Mechanical Loads Applied to Prototype
  Joint
• Measure Joint Voltage Drop with 100 Amperes
  Applied
• Voltage Measured at Two Joint Locations
• Automated Test Stand Control Data Acquisition

5
Resistance Measurement PlanMechanical TF Joint
Test System

• Mechanical Prototype Testing
• Cyclical Mechanical Loads Applied to Prototype
  Joint
• Measure Joint Voltage Drop with 100 Amperes
  Applied
• Voltage Measured at Two Joint Locations
• Automated Test Stand Control Data Acquisition
• Joint Voltage Drop Accuracy Factors
• Limited by Cycle Time
• Initial Investigation Indicates 0.5 Should be
  Possible
• Cycle Dwells Could Increase Accuracy to 0.2 or
  Better

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Resistance Measurement PlanMechanical TF Joint
Test System
Flag Joint 0.5u Ohms Nominal
Empro HA-150-50 150A _at_ 50mV Shunt
Agilent 34420A Nano-Volt Meter
-
GPIB Interface
100A
x2
50uV
33mV
GPIB Interface
GPIB Interface Card
Current Control
Hydraulic Test Stand CASS Bld.
Load Control
Kepco ATE 6-100M 100A _at_ 6V
HP 3456 Multi-Meter
Load Displacement Data
IBM PC LabVIEW Software
Current Control
NI 100kS/s 16-Bit Multifunction DAQ Card
7
Resistance Measurement PlanElectrical TF Joint
Test System
Transition Area, TFTR Test Cell basement
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Resistance Measurement PlanElectrical TF Joint
Test System

• Electrical Prototype Testing
• Cyclical Electrical Loads Applied to Prototype
  Joint
• Measure Joint Voltage Drop with gt 70,000 Amperes
  Applied
• Voltage Measured at Up to Eight Joint Locations
• Remote Control of Automated Data Acquisition
  System

9
Resistance Measurement PlanElectrical TF Joint
Test System

• Electrical Prototype Testing
• Cyclical Electrical Loads Applied to Prototype
  Joint
• Measure Joint Voltage Drop with gt 70,000 Amperes
  Applied
• Voltage Measured at Up to Eight Joint Locations
• Remote Control of Automated Data Acquisition
  System
• Joint Voltage Drop Accuracy Factors
• TF Power Supply Current Measurement Accuracy
• Magnetic Field Influences on Measurement Leads
  System
• Unknown Accuracy at This Time

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Resistance Measurement PlanElectrical TF Joint
Test System
Thermocouples x8 (Buy)
SCXI-1001 Chassis And Cards mV, Temp,
Strain Cables, etc. (Buy)
Hallmar Current Sensor X 2
Strain Gages x8 buy
Flag Joint 0.5u Ohms Nominal
Hall Sensors x8 buy
-
TF PWR SUPPLIES
70,000A
x8
35mV
Load Cell (Baker)
Hallmar Signal Conditioner
x4
Fiber (in house)
NI 100kS/s Multifunction DAQ Card (Bought)
Fiber Optic Interface (In House)
Ethernet to Fiber (in house)
SOP/EOP x2
IBM PC LabVIEW Software (In House)
Remote Control PC (in house)
PCI NIC (buy)
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Resistance Measurement PlanInsitu Test Systems
NSTX TEST CELL
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Resistance Measurement PlanInsitu Maintenance
Test System

• Maintenance Insitu Testing
• Permanent Test Cell Installation
• Measure Joint Voltage Drop with /-200 Amperes
  Applied
• Each of 48 Joints Measured at One Joint Location
• Automated Test Cell Data Acquisition System

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Resistance Measurement PlanInsitu Maintenance
Test System

• Maintenance Insitu Testing
• Permanent Test Cell Installation
• Measure Joint Voltage Drop with /-200 Amperes
  Applied
• Each of 48 Joints Measured at One Joint Location
• Automated Test Cell Data Acquisition System
• Joint Voltage Drop Accuracy Factors
• Ambient Electrical Noise Long Joint Cable
  Leads
• Combat with DC Current Reversal Long
  Integration Times
• Unknown Accuracy at This Time

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Resistance Measurement PlanInsitu Maintenance
Test System
FCPC Open Line Ground Switches
24AWG Twisted Pair Teflon (1000V)
12 Upper Joints
Transorbs 450J 50kA 340V 200A
PC LabVIEW
Silicon Rubber Tube (25kV)
1 Ohm 275W
Agilent 6671A 220A _at_ 8V
NO/NC Relay 300A
1N4047 275A 200V
Shunt 50mV 300A
TF Coil 4.5mH 6.3m Ohms 90J _at_ 200A
36 Lower Joints
48 Joints
SCXI Chassis with Multiplexer Cards
Agilent 34420A Nano-Volt Meter
Winchester Connectors
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Resistance Measurement Plan Insitu Commissioning
Test System

• Commissioning Insitu Testing
• Utilizes Maintenance System Wiring
• Measure Joint Voltage Drop with Up to 72,000
  Amperes
• Instrument One, Possibly Two TF Flag Joints
• Data Collected via 908 or 3232 Transient Digitizer

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Resistance Measurement Plan Insitu Commissioning
Test System

• Commissioning Insitu Testing
• Utilizes Maintenance System Wiring
• Measure Joint Voltage Drop with Up to 72,000
  Amperes
• Instrument One, Possibly Two TF Flag Joints
• Data Collected via 908 or 3232 Transient
  Digitizer
• Joint Voltage Drop Accuracy Factors
• TF Power Supply Current Measurement Accuracy
• Magnetic Field Influences on Measurement Leads
  System
• Unknown Accuracy at This Time

17
Resistance Measurement PlanInsitu Commissioning
Test System
FCPC Closed Line Ground Switches 72,000A, 1000V
24AWG Twisted Pair Teflon (1000V)
12 Upper Joints
MDS PLUS
Silicon Rubber Tube (25kV)
Transient Digitizer
TF Coil 4.5mH 6.3m Ohms 90J _at_ 200A
36 Lower Joints
Isolation Amplifier
Instrumentation Amplifier
1 of 48 Joints
Marsala Isolation Amplifier (5kV)
Winchester Connectors
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Software

• LabVIEW Graphical Programming Language
• Seamless integration with associated hardware
• Reduced development, deployment and maintenance
  efforts

Code
Front Panel
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Voltage Tap Location

• Two tap options
• Red Option attach under shear shoe
• Blue Option attach at flag end
• Red Option is preferred
• Advantages
• reduced linked flux
• excludes flag resistance
• wiring at common potential, not crossing over hub
  assembly

Tap wire twisted along water tube and covered
with heat shrink insulation
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Measured Resistance vs. Tap Locationvs. Contact
Resistance

• From ANSYS Finite Element Model...
• R(Vtap-Vtube)/I
• DV from bottom to top of flag is not significant

m?/in2
Micro-Ohms Measured
Range of Interest
Distance from Bottom of Flag (inch)
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Resistance Measurement PlanPrototype Insitu
Joints

• Mechanical Prototype Testing
• Electrical Prototype Testing
• Maintenance Insitu Testing
• Commissioning Insitu Testing