nstx tf bundle & center stack curing oven mike viola joe rushinski frank jones april 14, 2003

NSTX TF Bundle & Center Stack Curing Oven

Mike ViolaJoe RushinskiFrank Jones

April 14, 2003

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Criteria:• Fit the TF bundle with Hub Assembly

• Oven is 4’ x 4’ x 24’ long

• Controlled heating to 200ºC (392ºF) for epoxy curing and 465ºF for tube soldering

• Oven is capable of 600ºF

• Uniform Heating

• Oven is 384 ft3 @1000 CFM ~ 3 air changes per minute

• Easy access to bundle during curing for bolt tightening

• Oven is split lengthwise with guidepins (no bolts)

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• Reduced size for future storage & handling• Oven is built in three 8’ sections

• Feedthroughs for 12 thermocouples

• Windows for viewing potential problems• 4 windows provided (2 at each end)

• Parts available to the NCSX Autoclave• Heaters (2 @ 12 KW)

• Blower (2000 CFM @ 5 in.; 4000 CFM @ 2 in.)

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Fluid: Air Duct Type: RECTANGULARDuct Side a Dimension (in): 14Duct Side b Dimension (in): 8Flow Rate: 2000 SCFM Duct Length (ft): 14Viscosity (cP): 0.018Inlet Pressure (PSIG): 0Temperature (F): 500Duct Material: GALVANIZED METAL Duct Roughness (ft): 0.0005Fluid Velocity (ft/min): 5159.32Reynolds Number: 280907Flow Region: TurbulentFriction Factor: 0.0184Density at Inlet: 0.041Specific Volume at Inlet: 24.163Specific Heat Ratio: 1.4

Straight Duct Loss (inches Water): 0.248Hood Entry Type: NoneElbow Aspect Ratio 1: 2.0Radius / Duct Diameter 1: 1.0Number Of Elbows 1: 2Elbow Loss Factor 1: 0.21Elbow Loss 1 (inches Water): 0.385Duct Exit Configuration: Expansion within Duct Expansion Taper Angle (Degrees): 30Diameter Ratio: 1.75:1Loss Factor: 0.51Velocity Pressure Outlet (inches Water): 0.097761953Exit Configuration Loss (inches Water): -0.292Equipment Name 1: HeaterEquipment 1 Pressure Drop (inches Water): 0.05Equipment Name 2: HeaterEquipment 2 Pressure Drop (inches Water): 0.05

Total Duct Loss (inches Water): 0.441Velocity Pressure (inches Water): 0.917

Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Supply

Velocity High: 5159.32

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Fluid: Air Duct Type: ROUNDDuct Diameter (in): 12Flow Rate: 2000 SCFM Duct Length (ft): 14Viscosity (cP): 0.018Inlet Pressure (PSIG): 0Temperature (F): 500Duct Material: GALVANIZED METAL Duct Roughness (ft): 0.0005Fluid Velocity (ft/min): 4703.58Reynolds Number: 268213Flow Region: TurbulentFriction Factor: 0.0184Density at Inlet: 0.041Specific Volume at Inlet: 24.163Specific Heat Ratio: 1.4

Straight Duct Loss (inches Water): 0.196Hood Entry Type: NoneElbow Type 1: 4 piece Radius / Duct Diameter 1: 1.50Number Of Elbows 1: 3Elbow Sweep 1 (Degrees): 90Elbow Loss Factor 1: 0.27Elbow Loss 1 (inches Water): 0.617Duct Exit Configuration: Vertical Discharge, No Loss Exit Configuration Loss (inches Water): 0


Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Return

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SCFM Size Area Velocity Duct Loss Pressure

2000 12x14 168 3379 0.225 0.393

2000 14 154 3455 0.374 0.411

2000 12x12 144 3936 0.279 0.534

2000 8x14 112 5159 0.441 0.917

2000 12 113 4703 0.814 0.762

Choose 12x12 Square Supply with 14” round return

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Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Supply 12” x 12” Square


Straight Duct Loss (inches Water): 0.125Hood Entry Type: NoneElbow Aspect Ratio 1: 1.0Radius / Duct Diameter 1: 1.5Number Of Elbows 1: 2Elbow Loss Factor 1: 0.13Elbow Loss 1 (inches Water): 0.139Duct Exit Configuration: Vertical Discharge, No Loss Exit Configuration Loss (inches Water): 0Equipment Name 1: HeaterEquipment 1 Pressure Drop (inches Water): 0.05Equipment Name 2: HeaterEquipment 2 Pressure Drop (inches Water): 0.05

Velocity Pressure (inches Water): 0.534 Total Duct Loss (inches Water): 0.364

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Fluid: Air Duct Type: ROUNDDuct Diameter (in): 14Flow Rate: 2000 SCFM Duct Length (ft): 14Viscosity (cP): 0.018Inlet Pressure (PSIG): 0Temperature (F): 500Duct Material: GALVANIZED METAL Duct Roughness (ft): 0.0005Fluid Velocity (ft/min): 3455.69Reynolds Number: 229897Flow Region: TurbulentFriction Factor: 0.0182Density at Inlet: 0.041Specific Volume at Inlet: 24.163Specific Heat Ratio: 1.4

Straight Duct Loss (inches Water): 0.09Hood Entry Type: NoneElbow Type 1: 4 piece Radius / Duct Diameter 1: 2.50Number Of Elbows 1: 3Elbow Sweep 1 (Degrees): 90Elbow Loss Factor 1: 0.23Elbow Loss 1 (inches Water): 0.284Duct Exit Configuration: Vertical Discharge, No Loss Exit Configuration Loss (inches Water): 0

Velocity Pressure (inches Water): 0.411 Total Duct Loss (inches Water): 0.374

Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Return 14” Round

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Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Body


Straight Duct Loss (inches Water): 0.002Hood Entry Type: NoneDuct Exit Configuration: Vertical Discharge, No Loss Exit Configuration Loss (inches Water): 0


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Heaters:• 480 3Ø• require a minimum of 6 ft/sec @ 650ºF

• Heater duct is 12”x24” min flow required is 750 CFM∴ Blower:

• Radial fan to provide high flow rates @ pressure• Max Temp is 600ºF• 208 3Ø

Insulation: • 2”

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Thickness Temp Watts

1 106 7376

1.5 95 5156

2 89 3977

Temperature

106

95

89

80

85

90

95

100

105

110

1 1.5 2

Insulation Thickness

Temp

Watts

7376

5156

3977

0

1000

2000

3000

4000

5000

6000

7000

8000

1 1.5 2

Insulation Thickness

Watts

INSULATION

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Mass:• TF Bundle 2820 lbs.• Mold 4500 lbs.• Oven 7400 lbs.

Thermal units: Thermal Conductivity Specific Heat BTU/h (ft) ºF BTU/(lb) ºF

• Copper 227 .092• Steel 9.4 .12• Air .018

Heat needed: Q=m Cp ΔT=lb (BTU/lb ºF) ºF• QCopper=2820 (.092) (392-70)=83,540 BTU• QSteel=11900 (.12) (392-70)=459,816 BTU• QTotal=543,356 BTU• 1 KW=3412.14BTU/h

QTot=159 KW-hours for a 9 hours rise=17.7 KW/hour Convection heat transferred: q=h A ΔT

• Initially q=(8 BTU/h (ft2) ºF) 25 ft2 (392-70) = 64,400 BTU/h = 18.8 KW• Final q=(8 BTU/h (ft2) ºF) 25 ft2 (400-392) = 1,600 BTU/h = 1 KW• Plus losses through insulation: 4 KW

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Tinsulation_surface 273K

K

9

5 32 89

deg F Insulation Surface Temperature

Tinsulation_surface 273K 31.6K

Tinsulation_surface dt Toutside

dt

K

9

5 32 51dt 10.6Kdt

Qloss

L

1

2 r h

Lost to convection Qloss 3.977 103 WQloss

Tinside Toutside

RtotL

Thermal Resistance conduction + convectionRtot1

2 r h

lnr

rp

2 k

SA 402.124ft2SA 2 r Lr

pipe_dia 2 thk2

rppipe_dia

2

h 10W

m2

K k .23BTU in

hr ft2 R

h is an avg value of 10 W/m^2K is given for no wind

L 24 ftinsulation thicknessthk 2 in

pipe_dia 60 inTinside 200 273( ) KToutside 21 273( ) K

Calculate Loss from Oven and Insulation Surface Temp

Viola / Kalish 4/7/03

Tinsulation_surface 273K

K

9

5 32 95

deg F Insulation Surface Temperature

Tinsulation_surface 273K 35.2K

Tinsulation_surface dt Toutside

dt

K

9

5 32 58dt 14.2Kdt

Qloss

L

1

2 r h

Lost to convection Qloss 5.31 103 WQloss

Tinside Toutside

RtotL

Thermal Resistance conduction + convectionRtot1

2 r h

lnr

rp

2 k

SA 402.124ft2SA 2 r Lr

pipe_dia 2 thk2

rppipe_dia

2

h 10W

m2

K k .23BTU in

hr ft2 R

h is an avg value of 10 W/m^2K is given for no wind

L 24 ftinsulation thicknessthk 2 in

pipe_dia 60 inTinside 260 273( ) KToutside 21 273( ) K


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nstx tf bundle & center stack curing oven mike viola joe rushinski frank jones april 14, 2003

Documents

duct pressure loss

total duct loss inches

duct material

rectangular duct

air duct type

velocity pressure inches

duct exit configuration

round duct diameter