NSTX TF Bundle & Center Stack Curing Oven Mike Viola Joe Rushinski Frank Jones April 14, 2003
Dec 28, 2015
4/14/2003 2
NSTX TF Bundle & Center Stack Curing Oven
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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NSTX TF Bundle & Center Stack Curing Oven
• 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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NSTX TF Bundle & Center Stack Curing Oven
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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NSTX TF Bundle & Center Stack Curing Oven
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
Total Duct Loss (inches Water): 0.814Velocity Pressure (inches Water): 0.762
Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Return
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NSTX TF Bundle & Center Stack Curing Oven
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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NSTX TF Bundle & Center Stack Curing Oven
Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Supply 12” x 12” Square
Fluid: Air Duct Type: RECTANGULARDuct Side a Dimension (in): 12Duct Side b Dimension (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): 3936.01Reynolds Number: 245354Flow Region: TurbulentFriction Factor: 0.0183Density at Inlet: 0.041Specific Volume at Inlet: 24.163Specific Heat Ratio: 1.4
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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NSTX TF Bundle & Center Stack Curing Oven
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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NSTX TF Bundle & Center Stack Curing Oven
Duct Pressure Loss and Velocity Pressure ResultsJob Number: TF Bundle Oven Line Number: Oven Body
Fluid: Air Duct Type: RECTANGULARDuct Side a Dimension (in): 40Duct Side b Dimension (in): 40Flow Rate: 2000 SCFM Duct Length (ft): 24Viscosity (cP): 0.018Inlet Pressure (PSIG): 0Temperature (F): 500Duct Material: GALVANIZED METAL Duct Roughness (ft): 0.0005Fluid Velocity (ft/min): 354.24Reynolds Number: 73606Flow Region: TurbulentFriction Factor: 0.0198Density at Inlet: 0.041Specific Volume at Inlet: 24.163Specific Heat Ratio: 1.4
Straight Duct Loss (inches Water): 0.002Hood Entry Type: NoneDuct Exit Configuration: Vertical Discharge, No Loss Exit Configuration Loss (inches Water): 0
Total Duct Loss (inches Water): 0.002Velocity Pressure (inches Water): 0.004
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NSTX TF Bundle & Center Stack Curing Oven
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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NSTX TF Bundle & Center Stack Curing Oven
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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NSTX TF Bundle & Center Stack Curing Oven
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
NSTX TF Bundle & Center Stack Curing Oven