superconducting qxfa coil fabrication - mdc no. aup-170 rev: … · 2019. 7. 11. ·...

Superconducting Magnet Division Rev Date:

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QXFA Coil Fabrication - Impregnation 04/10/2019

05/02/2019J. Schmalzle

MDC No. AUP-170 Rev: B

Head, Project Mechanical Engineering M. Anerella 04/10/2019Head, Technical Support R. Ceruti 04/10/2019Quality Assurance H. Hocker 05/02/2019ES&H Coordinator M. Samms 04/18/2019Project Engineer - Mechanical J. Schmalzle 04/12/2019

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:Impregnation Fixture: P/N 25-2033102Coil Lifting Beam: P/N 25-2034004Prep Table Assembly: P/N 25-2034006Impreg Heater Installation: P/N 25-2034040Lead Support Assembly: P/N 25-2034030Fixture Lifting Assembly: P/N 25-2038002Impreg Fixture Hanging Assy: P/N 25-2039003Imprenation Prep Stand Assembly: P/N 25-2039001Shipping Fixture Assy: P/N 25-2040003

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

20 "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"


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25 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.

30 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.

35 Ensure excess solder is recycled or disposed of properly.

40 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.

45 CTD-101K epoxy contains chemicals that can cause severe skin, nose, throat and eye irritation / burns. See 3 part MSDS for further information.

Safety glasses with side shields and chemical resistent gloves must be worn when handling this material.

50 When using epoxy, perform operation under exhaust hood and document quantity of epoxy used on "Epoxy Usage Form".


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60 Attach the vacuum tank top hat to the impregnation fixture. Lift fixture from prep stand and remove hanging brackets.

70 Below the top hat, connect the epoxy supply line to the bottom of the fixture and connect epoxy return line to the top of the fixture.

80 Install the heaters and attach the thermocouples per the sketch in OP 810.

85 Connect heaters wires to the terminal strip per the table in OP 810. Measure and record resistance of each heater circuit.

90 Hang a drip catch pan below the fixture.

95 Install the fixture in the vertical vacuum tank.

100 Place a container to collect epoxy in the epoxy resin trap, install and secure the resin trap lid.

105 Above the top hat, connect the epoxy return line, with a shut off valve (#4), to the center of the resin trap.

110 Connect the vacuum line from the top of the resin trap to the top hat connector that is open to the vacuum tank.


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115 Install the epoxy supply line in the mixing chamber and secure the quick flange clamp.

120 Install the mixing chamber cover.

125 Above the top hat, connect the epoxy supply line to the output line from the epoxy pot. Include a section of Tygon tube, 1/4 OD, 1/8 ID, for use in the peristaltic pump. Include valves (#1 & #3) at each end of the Tygon tube. Do not clamp Tygon tube in pump rollers until after line has been evacuated.

130 Open the valve (#5) in the vacuum line connecting the resin trap to the top hat, to allow the resin trap to be pumped down with the vacuum tank.

135 Open the valve (#4) in the epoxy return line connected to the resin trap to allow the coil to be pumped down with the vacuum tank and resin trap.

140 Open the two valves (#1 & #3) in the epoxy supply line to allow the Tygon tube, supply line and mixing chamber to be pumped down.

145 Open the valve (#2) in the vacuum line connecting the mixing chamber to the vacuum tank, to allow the mixing chamber to be pumped down with the vacuum tank.

150 Close the resin trap vent valve (#6), the mixing chamber vent valve (#7). Close the precision leak valve (#8) by turning the knob clockwise to the stop.


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155 Verify that the vacuum pump outlet is attached to an exterior vent pipe.

160 Turn on the vacuum roughing pump. When vacuum level reaches approximately 14 torr, start the primary vacuum pump.

165 Pump down the vacuum tank, mixing chamber and resin trap to less than 1200 mTorr.

Record vacuum levels before bake out:

- Vacuum tank: __________ mTorr

- Mixing chamber: __________ mTorr

- Resin trap: __________ mTorr

170 Connect the heater control cabinet power cord to wall receptacle. Connect the heater power cords (6) and the thermocouple cables (3) from the top hat to the heater control cabinet. Turn on the power to the heater control cabinet.

175 Login to the computer and start LabView:

Open project "QXFA Coil Impreg Project.lvproj"

Open "QXFA Coil Impreg Real Time Controller.vi" from project menu. - Click "Run" arrow to start real time control program.

Open "QXFA Coil Impreg User Interface.vi." from project menu. - Click "Run" arrow to start the user interface program. - Enter coil number


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180 Verify that impregnation monitoring screen can be viewed on the web.

If not, set up the web publishing option found under the tools menu: - Set mode to "Snapshot" - Set name to "impreg" - Click "Start"

185 Setup heating profile for bake out:

Repeat last step settings for all remaining steps.

When end of profile is reached the system will maintain the temperature of the last set point. Bake Profile shall end with a setpoint of 55 C so that system holds at 55 C until epoxy fill is complete and cure is inititated.

190 Start profile for bake-out by clicking the "Start Profile B" button on the bake-out tab. Engage the heaters by pressing the green button on the heater control cabinet. Indicator light will iluminate to indicate that heaters are engaged.

192 Prepare for impregnation by pre-heating epoxy Part A to 55 C to eliminate any crystalization and restore the material to liquid state.


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195 Verify vacuum levels after bake out are less than 500 mTorr.

Record levels after bake out.:

- Vacuum tank: __________ mTorr

- Mixing chamber: __________ mTorr

- Resin trap: __________ mTorr

200 Working in the vented hood; carefully measure and mix the 3 part CTD 101K epoxy.

Do not use epoxy that is past the expiration date.

- Zero the scale - Place the aluminum mixing pot on the scale. - Press the tare button to zero the scale. - Add Part A to pot to specified weight - Press the tare button to zero the scale - Add part B to pot to specified weight

- Use precision scale to weigh part C - Zero the scale - Place small cup on scale - Press tare button to zero scale - Add Part C to the cup to specifed weight - Pour Part C into the epoxy pot

Record expiration date for each part:

- Part A: 5200 +/- 10 grams Date: __________

- Part B: 4600 +/- 10 grams Date: __________

- Part C: 78 +/- 2 grams Date: __________

Record the amount in grams on the posted epoxy usage sheet.

205 Close the first valve (#1) in the epoxy supply line and the valve (#2) in the vacuum line connecting the mixing chamber to the vacuum tank, to isolate the mixing chamber from the vacuum tank.


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210 Slowly open the vent valve (#7) in the mixing chamber to bring the chamber up to atmospheric pressure. Remove the mixing chamber cover.

215 Remove the quick flange clamp from the epoxy supply port in the side of the mixing chamber to allow the epoxy supply tube to be moved for epoxy pot installaion.

220 Place the epoxy pot on the hot plate in the mixing chamber. Secure the clamps to hold the pot in place while mixing.

225 Insert the epoxy supply tube into the epoxy pot and secure the quick flange clamp.

230 Install the thermocouple in the epoxy pot.

235 Place the cover on the mixing chamber and secure with toggle clamps.

240 Turn on the mixing motor and set to low speed.

245 Turn on the hot plate and set control to hold epoxy at 55 C.


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250 Open the valve (#2) on the vacuum line connecting the mixing chamber to the vacuum tank. Draw vacuum on the pot until the mix is pumped down to less than 600 mTorr.

- Record vacuum level achieved: __________ mTorr

255 Close the second valve (#3) in the epoxy supply line and open the first valve (#1) in the epoxy supply line. Verify that vacuum level in the mixing chamber remains unchanged.

260 Use the precision leak valve (#8) to slowly adjust the vacuum in the tank to achieve a level of 700-800 mTorr. Adjust by turning the knob couter-clockwise, approximately 2 turns are required to start to see change in vacuum level, then only very small changes are required to adjust the vacuum level.

265 Clamp the Tygon tube in the peristaltic pump rollers.

270 Close the valve (#2) on the vacuum line connecting the mixing chamber to the vacuum tank.

275 Slowly open the vent valve (#7) on the mixing chamber to allow atmosphere into the chamber. Epoxy should start to flow into the epoxy supply line and be stopped by the pump rollers.

Record time when epoxy flow is initiated: __________

280 Slowly open the valve (#3) in the epoxy supply line so that epoxy can begin to flow into the coil.


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285 Activate the peristaltic pump in RPM mode. Set pump to 20 rpm.

290 When the epoxy reaches the resin trap and fills to approximately 3" level, close the valve (#4) in the epoxy return line leading to the resin trap.

Record time when epoxy reaches resin trap: __________

Record time when epoxy reaches approx 3": __________

295 Turn off peristaltic pump and release the Tygon tube from the pump rollers so that epoxy can continue to flow freely into the coil as needed.

300 Hold the fixture at 55 C for 12 - 16 hours with vacuum in tank and atmosphere in mixing chamber.


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310 Set up heating profile for the cure cycle:

Repeat last step settings for all remaining steps. When end of profile is reached the system will maintain the temperature of the last set point. Profile for cure shall end with a setpoint of 20 C.

315 Start profile for cure by clicking the "Start Profile C" button on the cure tab.

320 When fixture has cooled to below 50 C, close the valve to isolate the vacuum tank from the vaccum pump. Shut down the vacuum pump and slowly let the vacuum tank up to atmosphere.

330 Stop the data recording program. Shut off and disconnect the heater control cabinet.

340 Remove fixture from vacuum tank, install hanging brackets, hang fixture in the prep stand.


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350 Remove the thermocouple wires, heaters and epoxy lines. Use care to prevent the uncured epoxy in the lines from dripping onto the fixture. Remove top hat.

355 Install fixture lifting beams.

360 Lift and rotate the fixture to the horizontal position, base plate on top. Transfer the fixture to the assembly table and place it onto support blocks. Remove fixture lifting beams.

365 Remove the lead seals and the end plates.

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

385 Remove M20 bolts. Loosen the longitudinal seal pusher bolts. Remove the base plate and mandrel blocks.

390 Remove longitudinal seals and pusher bars.

395 Use custom abrasive tool to carefully sand along the edge of the stainless steel midplane shims to remove epoxy that is bridging between the coil and the shims. This will help to prevent any chipping of the epoxy along the edge when the shims are removed.


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400 Carefully remove any loose epoxy flashing extending beyond the midplane shims on the coil OD. Avoid applying downward pressure as this tends to cause delamination on the coil OD near the midplane edge. Leave remaining flashing in place to be removed when the coil OD is exposed.

405 Remove the stainless steel shims from the coil midplanes. Scrape remaining epoxy flashing from the coil ID along the midplane edges.

410 Visually inspect the coil for damage and for voids in the epoxy. Photograph the coil.

420 Clean out and re-tap the M8x1.25 threaded holes in the inner pole, using a tap made for use in Titanium.

Use only tap intended for use in Titanium - any other tap may bind or break off in the coil.

425 Clean out all the thru holes in the pole.

430 Carefully remove the Teflon fillers from the instrumentation wiring windows at both ends of the coil.

435 Solder 26 AWG Axon HH2619 voltage tap wires and 18 AWG Axon HH1819 heater wires to the trace at each end.

440 Tag each instrumentation wire with an adhesive label.


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445 Mark coil number on coil ID using permanent marker.

450 Voltage tap checks:

- 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)

460 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)

470 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): __________ (6.50 - 6.90 mH)

Quality - Q: __________ (1.20 - 1.40)


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480 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 NL outer layer saddle: ______

Coil to NL inner layer saddle: ______

NL OL saddle to NL IL saddle: ______

Coil to pole (check all 11 segments): ______

485 Perform resistance measurement between the pole segments using a multimeter.

Pole segment to Pole segment: 1-2: _______ 2-3: _______ 3-4: _______

4-5: _______ 5-6: _______ 6-7: _______

7-8: _______ 8-9: _______ 9-10: _______

10-11 (NL): _______

490 Install shrink sleeve over each wire to cover where the wire crosses the end of the saddle or saddle extension.

495 Fill the instrumentation wiring windows with Araldite AV / HV 1580 epoxy putty. Smooth putty so that it is flush or slightly below flush with the surface ot the coil.


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500 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 of the coil and measure the distance it protrudes.

510 Install the coil midplane shims and mandrel blocks.

535 Install the base plate.

540 Install M20 bolts and nuts. Torque the bolts to 40 ft-lbs then increase torque to 60 ft-lbs. Contact cognizant engineer if fixture is not closed at 60 ft-lbs.

545 Install NL end plate.

550 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.

555 Remove NL end plate.


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

565 Remove M20 bolts, top plate, side rails and form blocks.

570 Remove the sst liner, mylar and sst radial filler.

580 Carefully scrape and sand epoxy flashing from the edges of the coil.

585 Visually inspect the coil for damage and for voids in the epoxy. Photograph the coil.

590 Clean out the keyway in the outer pole.

600 Clean out and re-tap the M8x1.25 threaded holes in the outer pole, using a tap made for use in Titanium.

Use only tap intended for use in Titanium - any other tap may bind or break off in the coil.

605 Clean out all the thru holes in the pole.


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610 Clean out and re-tap the M4x0.7 threaded holes in the ends of the LE saddle extensions and the M4x0.7 threaded holes in the ends of the NL saddles.

615 Carefully remove the Teflon fillers from the instrumentation wiring windows at both ends of the coil.

620 Solder 26 AWG Axon HH2619 voltage tap wires and 18 AWG Axon HH1819 heater wires to the trace at each end.

625 Tag each instrumentation wire with an adhesive label..

630 Mark coil number on coil OD and on end of NL saddle using permanent marker.


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635 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)

640 Measure quench protection heater resistance, 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)


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645 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 NL outer layer saddle: ______

Coil to NL inner layer saddle: ______

NL OL saddle to NL IL saddle: ______

Coil to quench heater B01: ______




LE OL Saddle to quench heater B01: ______




NL OL Saddle to quench heater B01: ______




Coil to pole (check all 11 segments): ______

655 Install shrink sleeve over each wire to cover where the wire crosses the end of the saddle or saddle extension.


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660 Fill the instrumentation wiring windows with Araldite AV / HV 1580 epoxy putty. Smooth putty so that it is flush or slightly below flush with the surface ot the coil.

670 Attach coil lifting beam and secure the leads and instrumentation wires. Lift the coil from the impregnation fixture.

675 Transfer the coil to the coil supports on the granite table.

680 Carefully remove any remaining epoxy flashing from the coil edges.


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800 Epoxy impregnation plumbing schematic:


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810 Heater and TC installation: