Coil Parts Task Force Video Mtg G. Ambrosio 11

HQ/LHQ Coil Parts Task Force

January 6, 2012

BNL - FNAL - LBNL - SLAC

Coil

Coil PHA01

PHA01 F,F PHA02PHA02 F,F PHB01

PHB01 F PHB02

PHB02 F,F, F LE ILEndshoe

LE IL Endshoe

F,F,F,L

LE OL Endshoe

F,F,S,F

S S F,L,L,LF,F

RE ILEndshoe

RE IL Endshoe

F

RE OL Endshoe

L L,F L,S,S,F,S

Island S,S

F: Failure (current jumps > 1 mkA)L: Current rises continuously, to > 1mkAS: Short (few W – tens of kW)

HQ, LQ

HQ/LQ HiPot Failures before the test

Coil

Coil PHA01

PHA01 F, F PHA02PHA02 F PHB01

PHB01 S PHB02

PHB02 S LE ILEndshoe

LE IL Endshoe

LE OL Endshoe

RE ILEndshoe

RE IL Endshoe

RE OL Endshoe

Island S, S

OL RE Spacer

S

F: Failure (damage)S: Short

HQ, LQ

HQ/LQ coil failures during/after the test

Coil Parts Task Force Video Mtg G. Ambrosio 44

Issues and Remedies - I

Endshoes to coil/endshoe/heaters BNL (LQ) OL instrumentation procedure Replace saddles and extensions after HT with

insulated parts• What insulation (adhesive Kapton, coating, …)?• What to do with available parts (remove some mills from

selected surfaces, …)?

Short term: add 2 mil Nomex, and reduce S2_layer on OD (coil #15)Mid term: remove 10mil from OD, and add coating on OD and cable surface (#17)Long term: new parts with less material on all surfaces, rounded edges, and coating on all surfaces

Action Items:- Set specifications for coating- Explore coating at 3 labs- Decide coating material and thickness

Coil Parts Task Force Video Mtg G. Ambrosio 55

Issues and Remedies - II

Heaters to coil Reinforce insulation under heaters

• How much?– Quick check of QP

• How much can fit the present HQ design?

Change heater design in order to avoid critical areas

Short term: add 2 mil Kapton, and reduce S2_layer on OD (coil #15)Mid term: … + new heater design (#16)Long term: after test results assess if 2 layers of Kapton are OK (if not: 3mil E-glass/ other materials)

Action Items:- Design and procure new heaters

Coil Parts Task Force Video Mtg G. Ambrosio 66

Issues and Remedies - III Island and spacers to coil

Reinforce insulation around ramp• How to do it (part modification, …)?

Coating/anodization/…• Start from island because of 2 times higher voltages, more

likely to see quenches

Winding around end parts• Meeting with techs

Short term: - NA -Mid term: remove ?? from parts (?), and/or add coating Long term: new parts with less material on all surfaces, rounded edges, and coating on all surfaces- Including wedges?

Coil Parts Task Force Video Mtg G. Ambrosio 77

Coating Specs

Two options re HT: Heat treatment resistant (up to 700 C in Argon) No HT resistant (back up)

Cooldown resistance Down to 2 K

Voltage breakdown > 1 kV

Compatible with potting Epoxy, Cynate_Ester, Matrimid

Good bonding strength after several thermal cycles 2 – 300 K

ESH compliant

Coil Parts Task Force Video Mtg G. Ambrosio 88

Coil Parts Task Force Video Mtg G. Ambrosio 99

Other suggestions

By Maxim: Trace layer thickness: study how it affects heat

transfer vs electrical integrity Shoe-to shoe: thicker insulation is needed Voltage tap traces may be shorting to LE OL Endshoe Heater may be punched by Endshoes edges

Add “Rounding of edges” to drawings and travelers

Other suggestions?

Coil Parts Task Force Video Mtg G. Ambrosio 1010

S. Caspi, LBNL

Coils Assembly and Alignment

11

Alignment Keys

Collars

Coil & heater

LARP DOE review, FNAL June 1-2, 2011