Superconducting QXFA Coil Fabrication - MDC No. AUP-160 Rev: … · 2019. 7. 11. · Superconducting Magnet Division Rev Date: Page 1 of 26 Author: Approved: QXFA Coil Fabrication

Superconducting Magnet Division Rev Date:

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QXFA Coil Fabrication - Prep for Impregnation 03/28/2019

04/11/2019J. Schmalzle

MDC No. AUP-160 Rev: B

Head, Project Mechanical Engineering M. Anerella 04/02/2019Head, Technical Support R. Ceruti 03/29/2019Quality Assurance H. Hocker 04/11/2019ES&H Coordinator M. Samms 04/04/2019Project Engineer - Mechanical J. Schmalzle 04/03/2019

Serial No Part No Part P/L ECN Rev P/L ECN Rev P/L

Work Order #: __________________________ Deviation & Waiver: ______________________

OP DRDateName/Life #Description

10 Reference Documents:Reaction Fixture: P/N 25-2033101Impregnation Fixture: P/N 25-2033102Prep Table Assembly: P/N 25-2034006Solder Fixture Assembly: P/N 25-2034005Lead Tinning Fixture Assembly: P/N 25-2034023Lead Support Assembly: P/N 25-2034030Fixture Lifting Assembly: P/N 25-2038002Impregnation Prep Stand Assembly: P/N 25-2039001

15 All lifting and handling operations requiring overhead crane operations shall be performed by personnel having up to date Material Handling Equipment (or Overhead Crane Operations) qualifications as recorded in the training records within BTMS. Operators shall also be instructed in the use of the appropriate lifting device by the Cognizant Engineer or Technical Supervisor. Hard hats, safety shoes and safety glasses with side shields (or goggles) are required during crane operations.

20 The technicians shall be instructed by their cognizant technical supervisor in the operation of the required electrical test equipment and the electrical testing procedures.


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25 "Hipot ("Hypot") and impulse testing pose an electrical hazard. At least two properly trained technicians must be present to perform this testing. When testing, a trained technician shall be stationed at any point where the item under test is accessible to unauthorized people, and barriers shall be set up. In the event controlling area cannot be guaranteed, a suitable insulating barrier or cover must be used and approved by Cognizant Engineer P. Joshi or Cognizant Engineer J. Escallier.

Signs shall be posted reading

"DANGER HIGH VOLTAGE" and warning lights shall be turned on.

"NO UNAUTHORIZED PERSONNEL ALLOWED DURING HI POT TESTING. Contact P. Joshi or S. Dimaiuta"

30 The technician is responsible for notifying the technical supervisor and/or the cognizant engineer of any discrepancies occurring during the performance of this procedure. All discrepancies shall be identified and reported in accordance with SMD OPM 2.15.

Measuring and test equipment used for this procedure shall contain a valid calibration label in accordance with the SBMS Subject Area 'Calibration', where applicable.

35 Eye protection must be worn when removing flux, especially on hot surfaces. If surfaces are above 140F, thermally insulated gloves (such as welder's gloves) must be worn to protect from burns.

40 Ensure excess solder is recycled or disposed of properly.


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60 Enviroshield mold release contains chemicals that can be cause skin, nose, throat and eye irritation. See MSDS for further information.

Apply per manufacturers instructions: apply light coat, wait 1 minute, wipe dry, wait 15 minutes, apply second light coat, wait 1 minute, wipe dry, wait 30 minutes before installing.

Safety glasses with side shields and chemical resistent gloves must be worn when applying this mold release.

Ensure adequate ventilation.

70 Remove the reaction fixture end plates. Take care not to disturb the leads.

80 Install hold down brackets on both ends of fixture and clamp to table.

90 Remove M20 bolts, top plate, side rails and formblocks.

100 Remove sst liner, radial filler, pushers and seals.

105 Remove the mica paper and glass cloth from the coil OD.

110 Visually inspect the coil and insulation for damage. Photograph the coil.


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120 Carefully remove the witness samples and pack them for shipment.

130 Remove the witness sample holder parts. Be careful not to disturb the coil leads.

135 Measure and record outer pole gap sizes (inches):

LE 1: __________ 2: __________

3: __________ 4: __________

5: __________ 6: __________

7: __________ 8: __________

9: __________ 10: _________ NL

145 Measure outer layer coil end lengths. Record on data sheet in OP 910.

150 Measure and record coil resistance. Set power supply to 25 V DC maximum and apply 1 amp to coil. Use DVM to measure voltage (equal to resistance). Contact CE if measurement is outside the limits.

Voltage (mV): __________ (590.00 - 620.00 mV)

155 Measure and record coil inductance and quality factor at a frequency of 20 Hz. Contact CE if measurement is outside the limits.

Inductance - L (mH): __________ (6.20 - 6.60 mH)

Quality - Q: __________ (1.10 - 1.30)


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160 Perform resistance measurement between the coil and the coil parts using a multimeter. Contact CE if reading is something other than OL (Open Loop).

Coil to LE outer layer saddle: ______

Coil to LE inner layer saddle: ______

LE OL saddle to LE IL saddle: ______

Coil to LE outer layer spacer 1: ______



Coil to NL outer layer saddle: ______

Coil to NL inner layer saddle: ______

NL OL saddle to NL IL saddle: ______

Coil to NL outer layer spacer 1: ______

Coil to NL outer layer spacer 2: ______

Coil to pole (check all 11 segments): ______

180 Carefully slide out and remove the last 4 mandrel blocks.

185 Remove the glass sleeve from coil leads. Carefully clean the lead with a SST brush and alcohol.

190 Install the solder fixture .70" from the end of the saddles. Tin the leads using the tinning spacers, Staybrite 96/4 solder ribbon and MOB-39 flux.

195 Trim the leads to length, even with the end of the saddle extension.


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200 Cut four pieces of NiTi coil lead cable. Solder together pairs of leads using the tinning fixture, Staybrite 96/4 solder ribbon and MOB-39 flux.

205 Install the lead support angles on the end of the base plate.

210 Install the lead pairs in the solder fixture with Staybrite 96/4 solder ribbon and MOB-39 flux. Solder the leads.

215 Remove the solder fixtures and clean the soldered leads with alcohol.

220 Solder lead voltage taps flags to the Nb3Sn coil leads just before the start of the splice joints using .15" wide, 3 mil thick copper ribbon. - A2 to inner layer coil lead. - B2 to outer layer coil lead.

225 Solder lead voltage taps flags to the NbTi coil leads just beyond the end of the splice joints (just past the end of the saddle extension) using .15" wide, 3 mil thick copper ribbon.

- A1 to inner layer extension cable. - B1 to outer layer extension cable.

230 Fill the voids bewteen the end saddles and the start of the splice joints with G11.


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235 Insulate the leads with 2 layers of 3 mil Kapton per the sketch below. Extend Kapton .30" beyond the coil end.

240 Reinstall the LE saddle extensions. Ensure that the extensions are aligned with the saddles when the bolts are tightened. Install interlayer glass cloth between the inner and outer saddle extensions.

245 Fill any voids between the coil end parts and the cable turns with glass cloth. Fill any voids between the coil end parts and the wedges with glass cloth.

250 Fill the gaps between wedge segments with glass cloth.

255 Fill the areas where the coil end turns are below the level of the end spacers/saddles with layers of glass cloth.


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260 Fill the threaded and through holes in the pole with silicone putty to allow for access after impregnation.

265 Fill the threaded holes in the saddles and saddle extensions with silicone putty to allow for access after impregnation. Fill the deep counterbored holes in the saddle extensions with Teflon.

270 Fill all the blind holes in pole and saddles with glass cloth.

275 Fill any gaps between pole segments that are .010" or larger with G11 shims.

280 Apply 2 coats of mold release to the keyway in the pole.

285 Apply 2 coats of mold release to and install the pole alignment keys, spanning the joints between pole segments.

290 Apply 2 coats of mold release to and install the keyway fillers at each alignment pin location. Fill the rest of the keyway with Teflon to allow for access after impregnation.

295 Prepare inner and outer layer instrumentation circuits by cleaning the entire circuits with alcohol and mild abrasive scrubbing pad. Tin all solder pads.


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300 Check each instrumentation circuit segment for continuity.

305 Instrumentation circuit hipot, 3800V:

Operator shall wear voltage rated and tested insulating gloves.

CAUTION: Circuit must be discharged after each test before being handled: - Connect ground to conductive foam in contact with circuit conductors. - Connect ground to sheet of aluminum foil and then place foil on back side of Kapton. - Leave both grounds connected for a time period at least as long as voltage was applied to circuit.

Testing: - Place circuit stainless steel side down onto a sheet of .005" Kapton, secure with painters tape. - Clip hipot leads to a strip of conductive foam (not directly to circuit). - Position foam strip under end of circuit and put a small weight on top of the circuit above the foam strip. - Connect the hipot ground to a conductive foam wand. - Power hipot to 1500 V and wipe along the top of the circuit over all the stainless steel areas. - Increase voltage in 1000V steps and repeat checks up to 3500V. - Reposition foam lead strip and repeat the check in the area where the strip had been. - If pin holes are discovered, note location, patch with a piece of 1 mil kapton tape, recheck.

Record leakage current (<1uA): Inner Layer: __________

Outer Layer: __________

310 Place outer layer circuit onto coil. Mark and cut slits for the voltage tap flags.


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315 Install the kapton insulators under the heaters bewteen the trace and the coil end turns.

320 Solder all voltage tap flags to the instrumentation circuit (7 taps on outer layer includng 1 lead tap). Cover each with a small patch of 1 mil Kapton tape.

325 Install a layer of 5 mil glass cloth under the trace in the wiring pocket at each end of the coil.

330 Use small pieces of adhesive transfer tape to secure the trace ends in the wiring pockets at each end.

335 Install the fiberglass cloth wiring pocket fillers over the trace at each end.

340 Solder temporary copper foil flags to quench heaters at LE to provide means of checking resistance after fixture is bolted closed.


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345 Voltage tap checks (outer layer):

- Attach power supply positive(+) lead to inner coil lead, negative(-) to outer coil lead. - Set power supply to 25 V DC maximum and apply 1 amp to coil. - Take voltage readings using DVM. DVM positive(+) lead to inner coil lead, negative(-) to probe.

Contact CE if measurement is outside the limits.

Record Tap voltages (mV):

B1: __________ (590.0 - 620.0 mV)

B2: __________ (590.0 - 620.0 mV)

B3: __________ (405.0 - 430.0 mV)

B4: __________ (265.0 - 285.0 mV)

B5: __________ (260.0 - 280.0 mV)

B6: __________ (260.0 - 280.0 mV)

B7: __________ (255.0 - 275.0 mV)

B8: __________ (255.0 - 275.0 mV)


Voltage (mV): __________ (590.00 - 620.00 mV)



Quality - Q: __________ (1.10 - 1.30)


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370 Measure quench protection heater resistance (outer layer), 4 wire measurement using DVM with built in power supply:

Contact CE if measurement is outside the limits. B01 - transition side, midplane (Ohm): __________ (1.8 - 2.2 Ohm)

B02 - transition side, pole (Ohm): __________ (1.8 - 2.2 Ohm)

B03 - non-transition, pole (Ohm): __________ (1.8 - 2.2 Ohm)

B04 - non-transition, midplane (Ohm): __________ (1.8 - 2.2 Ohm)

375 Install Teflon pieces in each of the windows in the wiring pocket fillers to allow for access after impregnation.

385 Install outer impregnation fiberglass cloth over the pole and the coil.

390 Apply 2 coats of mold release to the .025" stainless radial filler. Install filler over coil.

395 Apply 2 coats of mold release to and install .010" thick x 8.25" wide Mylar over the sst radial filler. Cut holes at the alignment pin locations.

400 Apply 2 coats of mold release to the .020" stainless steel impregnation liner. Install liner over coil.


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405 Apply 2 coats of mold release to the alignment pins, the set screws and to the holes in the eight modified form blocks. Install alignment pins in the modified formblocks, install set screws to seat and secure the pins.

410 Apply 2 coats of mold release to and install pusher washer and EPDM rubber gasket on each alignment pin.

415 Apply 2 coats of mold release to the impregnation form blocks.

420 Install the impregnation formblocks. The blocks are serialized, start with no.1 at the lead end and install in sequential order.

425 Apply 2 coats of mold release to the impregnation top plate. Install top plate. Verify that the base plate, formblocks and top plate are aligned at both ends so that the end plates will seal properly.


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430 Install M20 bolts. Lighty snug bolts and verify that fixture is closing evenly. Torque the bolts to 40 ft-lbs then increase torque to 60 ft-lbs. Measure and record the gap between the blocks and base plate after each step. Contact cognizant engineer if fixture is not closed at 60 ft-lbs.








Coil to quench heater B01: ______





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Voltage (mV): __________ (590.00 - 620.00 mV)



Quality - Q: __________ (1.20 - 1.40)

460 Apply 2 coats of mold release to the impregnation side rails. Install the side rails using M10 bolts and anti-seize compound.

465 Disconnect fixture hold down brackets and the lead support angles.

470 Install NL end plate.

475 Install fixture lifting beams. Lift fixture high enough to allow it to be rotated. Rotate 180 deg (swing LE up) and place back onto support blocks. Remove fixture lifting beams.

480 Install lead support angles on top plate.

485 Remove NL end plate. Install hold down brackets on both ends of fixture and clamp to table.


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495 Remove M20 bolts, base plate, mandrel blocks and coil shims.

505 Remove the mica paper from the coil ID and coil midplane surfaces.

510 Visually inspect the coil and insulation for damage. Photograph the coil.

520 Measure the inner layer, outer layer and max overall coil length, including end saddles and saddle extentions, using Invar rod / micrometer assembly. Indicate which layer is longer on each end. Record on data sheet in OP 910.

525 Measure inner layer coil end lengths. Record on data sheet in OP 910.

530 Measure and record inner pole gap sizes (inches):

LE 1: __________ 2: __________

3: __________ 4: __________

5: __________ 6: __________

7: __________ 8: __________

9: __________ 10: _________ NL


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Voltage (mV): __________ (590.00 - 620.00 mV)



Quality - Q: __________ (1.20 - 1.40)





Coil to LE inner layer spacer 3: ______




Coil to NL inner layer spacer 1: ______

Coil to NL inner layer spacer 2: ______

Coil to pole (check all 11 segments): ______

560 Set the 22 pole alignment pins to a depth of .25"-.27" below the inner pole surface. Fill the void above each pin with silicone putty to allow for access after impregnation.


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565 Fill all the threaded and through holes in the pole with silicone putty to allow for access after impregnation.

575 Fill the threaded holes in the saddle and saddle extensions with silicone putty to allow for access after impregnation.

580 Fill any gaps between pole segments that are .010" or larger with G11 shims.

590 Fill the gaps between wedge segments with glass cloth.

605 Place inner layer circuit onto coil. Mark and cut slits for the voltage tap flags. Mark and punch holes for access to the threaded holes in the pole.

610 Solder all voltage tap flags to the instrumentation circuit (7 taps on inner layer including 1 lead tap). Cover each with a small patch of 1 mil Kapton tape.

620 Install a layer of 5 mil glass cloth under the trace in the wiring pocket at each end of the coil.

625 Use small pieces of adhesive transfer tape to secure the trace ends in the wiring pockets at each end.

630 Install the fiberglass cloth wiring pocket fillers over the trace at each end.


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635 Voltage tap checks (inner layer):

- Attach power supply positive(+) lead to inner coil lead, negative(-) to outer coil lead. - Set power supply to 25 V DC maximum and apply 1 amp to coil. - Take voltage readings using DVM. DVM positive(+) lead to inner coil lead, negative(-) to probe.

Contact CE if measurement is outside the limits.

Record Tap voltages (mV):

A1: __________ (0.0 - 0.2 mV)

A2: __________ (0.0 - 0.2 mV)

A3: __________ (185.0 - 205.0 mV)

A4: __________ (240.0 - 260.0 mV)

A5: __________ (240.0 - 260.0 mV)

A6: __________ (250.0 - 270.0 mV)

A7: __________ (250.0 - 270.0 mV)

A8: __________ (255.0 - 275.0 mV)


Voltage (mV): __________ (590.00 - 620.00 mV)



Quality - Q: __________ (1.20 - 1.40)


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660 Install Teflon pieces in each of the windows in the wiring pocket fillers to allow for access after impregnation.

665 Install inner impreg fiberglass cloth over the pole and the coil.

670 Install a layer of .005" thick x .75" wide G11 shim on the saddles midplane surfaces opposite the coil leads.

675 Install .005" thick x 1.50" wide G11 shim on each coil midplane. Shim will become part of the impregnated coil, sand / scuff to aid bonding, do not apply mold release.

Verify thickness of each shim .0050" +/- .0005": ________

680 Apply 2 coats of the mold release to the two .087" coil midplane shims. Install one shim on each coil midplane surface.

Verify thickness of each shim .087" : ________

685 Apply 2 coats of the mold release to two 005" thick x 1.50" wide Mylar shims. Install one shim on each coil midplane surface outside the stainless steel shims.

Verify thickness of each shim .0050" +/- .0005": ________

690 Apply 2 coats of mold release to the mandrel blocks.

695 Install the mandrel blocks. The blocks are serialized, start with no.1 at the lead end and install in sequential order.


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700 Apply 2 coats of mold release to the impregnation pusher bars. Install longitudinal o-ring seals and pusher bars.

705 Apply 2 coats of mold release to the impregnation base plate.

710 Loosen the side rail mounting bolts to allow the formblocks to align with the mandrel blocks as the fixture is bolted closed.

715 Install base plate. Verify that the base plate, form blocks and top plate are aligned at both ends so that the end plates will seal properly.

720 Install M20 bolts. Lighty snug bolts and verify that fixture is closing evenly. Torque the bolts to 40 ft-lbs then increase torque to 60 ft-lbs. Measure and record the gap between the blocks and base plate after each step. Contact cognizant engineer if fixture is not closed at 60 ft-lbs.


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730 Tignten the side rail mounting bolts.

740 Remove the lead support angles.

745 Tighten the set screws to compress the gaskets at the alignment pin locations.


Voltage (mV): __________ (590.00 - 620.00 mV)



Quality - Q: __________ (1.20 - 1.40)


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795 Tighten longitudinal seal pusher bolts to fully compress the o-ring on each side.

800 Trim the longitudinal o-ring seals flush with the end of the fixture.

810 Fill the voids at each end of the coil with teflon fillers and silicone putty. Insert a piece of 3/16 tube to provide a passage for epoxy flow thru the putty.

815 Apply 2 coats of mold release to the end plates.


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820 Install o-ring seals in the end plates. Apply silicone putty to the ends of the longitudinal o-ring seals. Install the end plates using M10 bolts and anti-seize compound.

825 Fill the holes in the endplate around the leads with silicone putty.

830 Apply 2 coats of mold release to and install lead seal o-rings, flanges and gaskets.

835 Apply vacuum to the closed fixture. Pump down to less than 500 mTorr.

Record vacuum level achieved: __________

840 Install fixture prep stand hanging brackets.

845 Install fixture lifting beams. Lift fixture, move to the prep stand. Rotate to vertical with the lead end up and hang in prep stand. Remove fixture lifting beams.


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910 Coil Length Measurements:

Insert pins in holes, record distance bewteen centers.


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950 Verify All Traveler Operations Complete

960 Revision History:Revision A - September 17, 2018 Initial Release

Revision B - March 28, 2019 Adjusted coil resistance ranges Changed G11 shim from .010" to .005" Changed trace hipot from 3500V to 3800 V Revised length data sheet Removed instrumentation circuit image Added check pole pin depth