1. October 4-5, 2010 1 Electron Lens Superconducting Solenoid Michael Anerella October 4, 2010 Electron Lens

2. October 4-5, 2010 2 Outline Outline of Presentation Technical Overview Cost & Schedule Risk Management Value Management Project Team ESSH/Quality Assurance Configuration Management Summary

3. October 4-5, 2010 3 Project Scope Design, Build and Test 2 eLens Solenoid Magnets: (under 2 AIP Projects) Magnetic, mechanical, electrical requirements as specified by C/AD Conduct ongoing communications & meetings to significantly clarify scope, improve design and performance Maintain cost control Deliver 1 st magnet by November 2011, 2 nd magnet by March 2012

4. October 4-5, 2010 4 Magnetic Design – solenoids Integrated Main Solenoid / Trim Solenoid / Fringe Field Solenoid / Anti-Fringe Field Solenoid / Dipole Correctors provide - Performance + Versatility - 5 x 10 -3 field uniformity from 3T to 6T ± 50 microns field axis straightness over ± 1050mm from 3T to 6T (Fringe Field solenoid (needed to address field between Solenoid and adjacent magnets) / Correctors (formerly room temperature) all added after “job award”, during design phase) SC solenoid Copper magnets Fringe solenoid Trim solenoid Main solenoid

5. October 4-5, 2010 5 Magnetic Design – slotted correctors Performance improved by block design –Greater efficiency by placing turns closer to midplane –Smaller losses between 0.5m patterns by placing adjacent coils closer together Radial space conserved by using 45° patterns and placing vertical and horizontal dipoles at same radial position

6. October 4-5, 2010 6 Mechanical Design – Coils (1) Goal 1 To support the 1700 psi radial force at 6T Method: –Provide a 6mm stainless steel support sleeve –Expand the sleeve at assembly by heating to 80°C (0.3mm interference); 36000 psi tensile stress in sleeve –Taper the sleeve to coil (G10) mating surface by 8 mm to facilitate installation

7. October 4-5, 2010 7 Mechanical Design – Coils (2) Goal 2 To transmit the 133,000 LB. axial force from each outer coil section around the main coil body. Method –Separate the outer coil sections with a spacer, but continuously wind inner and outer sections –designed to transmit the load through the compression sleeve and the support tube.

8. October 4-5, 2010 8 Mechanical Design - Magnet 15 separate circuits / power lead pairs: 1 main solenoid 2 fringe field solenoids 5 0.5m vertical correctors 5 0.5m horizontal correctors 1 2.5m vertical corrector 1 2.5m horizontal corrector Quench protection via cold diodes Helium vessel cooled by liquid bath from RHIC supply Outer heat shield actively cooled from 4K boil-off, inner shield conductively cooled RHIC support posts / cryostat

9. October 4-5, 2010 9 Parts, Magnet Fabrication (“Make/Buy Plan”) Many components are available in stock, e.g.: –Corrector/Fringe field solenoid Superconductor –Stainless steel helium vessel –cryostat All remaining major components and materials to be purchased, e.g.: –Aluminum (corrector) and stainless (solenoid) support tubes Some parts to be fabricated in BNL machine shops, e.g.: Corrector tube machining All tooling to be fabricated in BNL machine shops (subcontracted as needed) All subassembly work to be done at BNL All coil fabrication, magnet assembly and testing to be performed at BNL

10. October 4-5, 2010 10 Coil Fabrication Test wind: feasibility + time study Tube end insulation time study Corrector Coils – “slotted tube” Expected benefits: Cost savings Time (schedule) savings Reliable (proven) construction Improved magnetic design Smaller axial “gaps” reduce dips in field Blocks near midplane are more efficient → less turns Decouples corrector construction from Direct Wind machines Main solenoid – “direct wind” Expected benefits: accurate conductor placement using precision solenoid gantry developed for BEPC-II program Uniform spacing improves field axis straightness, lessens demands on correctors Reliable (proven) construction BEPC-II coil winding

11. October 4-5, 2010 11 Testing All coils undergo mechanical, electrical and magnetic inspections throughout the construction process as part of QA Coil and Yoke Assembly is cold tested in a vertical test dewar for quench performance before welding into cold mass vessel Cold mass vessel is pressure tested and leak checked before being installed into cryostat Magnet is measured magnetically at room temperature after cold test and surveyed at that time

12. October 4-5, 2010 12 Schedule Summary Critical path shown in red Superconductor paces work fringe, corrector coils not on critical path Meets 4/12 need date

13. October 4-5, 2010 13 Schedule Status Preliminary design - complete Final design – 90% complete, working out final details to optimize magnetic performance Coil Fabrication: –Corrector Coils:  Superconductor available; purchase order for insulating with Kapton placed, first shipment due end of October  Aluminum support tube purchase order placed, tubes fabricated & being shipped now  Mechanical model / drawing for machined coil blocks in tube complete, order being placed with BNL machine shop –Solenoid coils:  Superconductor order placed, delivery 12/2010  Support tube order placed  Machined tube model /drawing complete, order to be placed with BNL machine shop –Fringe field solenoid coils:  Same superconductor as corrector coils  Final strength & proximity to main solenoid being finalized; parts to be made by SMD immediately thereafter

14. October 4-5, 2010 14 Cost Details Cost Estimate Methods: Material: –Actual cost for similar parts on previous programs –Vendor quotes on key items Labor: –Time studies for critical activities (coil winding, insulating, etc.) (see W. Fischer talk for other program costs)

15. October 4-5, 2010 15 Risk Management Coils are on critical path: –Early design specified direct wind of corrector coils; competed for resources with solenoid coils. –Redesign of correctors as hand-wound block coils saved schedule and cost, PLUS enabled work to be completed in parallel by alternate personnel

16. October 4-5, 2010 16 Value Engineering Use existing designs, materials, etc. wherever possible –Existing spare RHIC CQS cryostat –Surplus IsaBelle stainless steel helium vessels –Stock RHIC Ultem support posts Incorporation of Fringe Field Solenoid, Corrector Coils into superconducting magnet system: –Increased Solenoid costs, but reduced other eLens program costs (i.e. change is cost neutral) and improved eLens performance

17. October 4-5, 2010 17 Project Team Scientist, Magnetic Design – Ramesh Gupta Mechanical Engineer, Magnet – Steve Plate Mechanical Engineer, Coils – Andy Marone Mechanical Engineer, Design – Paul Kovach Electrical Engineer, Coils – John Escallier Electrical Engineer, Tooling – Piyush Joshi Scientist, Magnetic Measurements – Animesh Jain Scientist, Cold Test – Joe Muratore

18. October 4-5, 2010 18 Environmental, Safety, Security, and Health (ESSH) Assigned ESSH representative – Steve Moss Regular Safety inspections of Shop Floor Safety review and approval on all drawings and work procedures Weekly safety meetings with staff

19. October 4-5, 2010 19 Quality Assurance Assigned QA representative – Ed Perez QA review and approval on all drawings, work procedures and purchase orders Incoming inspection on all parts –BNL (Magnet Division or Fabrication Services Division) –At vendors before shipment or with delivery Test / inspection points throughout the construction process: –Mechanical –Electrical –Magnetic

20. October 4-5, 2010 20 How is Work Controlled? PICS - Part and Inventory Control System Developed at BNL Superconducting Magnet Division Windows-based software and database Configuration Management Features: Inventory control, including Lot or Serial #’s and location Creation, approval and control of written work procedures with Revision control Kitting of parts for work orders End item documentation, including as-built configuration All QA, testing and safety precautions built into documentation sample traveler

21. October 4-5, 2010 21 Summary The magnet requirements are challenging but achievable. Performance objectives reflect a good continued communication between SMD and C/AD; magnet is much better than original specification Work is started and is progressing in support of the Project Budget and Schedule Experienced personnel (RHIC AGS Snake, RHIC Helical, BEPC-II, LHC, etc.) are available and working