Thomas Jefferson National Accelerator Facility Pg. 1 SHMS Status Hall C Users Feb Paul Brindza

Thomas Jefferson National Accelerator Facility Pg. 2 SHMS Construction Feb 13, 2014

Thomas Jefferson National Accelerator Facility Pg. 3 SHMS Outline HB magnet construction Q1 magnet construction Dipole magnet construction Q2Q3 magnet JLAB magnet components Hall C Infrastructure

Thomas Jefferson National Accelerator Facility Pg. 4 HB Construction Coils complete and LHE tested Helium vessel assembly underway –Helium vessel backbone complete –Coil 1 installed, shimmed and welded in –Coil 2 installed, shimming underway LN2 shield sub-assemblies underway Warm Yoke complete Vacuum vessel components complete Assembly of helium, vessel around coils has taken longer than expected- current ETA is April 2014 Delivery to JLAB – August 2014 Monthly visits by JLAB to MSU to keep up pressure

Thomas Jefferson National Accelerator Facility Pg. 5 Status of HB Manufacturing First coil inserted in helium vessel (covered by middle plate) Thermal shield test-fit onto Helium vessel.

Thomas Jefferson National Accelerator Facility Pg. 6 Top vessel view in vertical position Wiring from bottom through conduit to top, 5 mil kapton sheet between coil ends and retainers. HB Helium Vessel

Thomas Jefferson National Accelerator Facility Pg. 7 Status of HB Manufacturing Hi-pot test at V with back plate clamped Lead out insulated

Thomas Jefferson National Accelerator Facility Pg. 8 Status of HB Manufacturing Back plate tack welded Vessel repositioned for bottom coil shimming (bottom coil up)

Thomas Jefferson National Accelerator Facility Pg. 9 HB Schedule

Thomas Jefferson National Accelerator Facility Pg. 10 Bore of Q1 Magnet

Thomas Jefferson National Accelerator Facility Pg. 11 Q1 Magnet Status Coils- complete and tested Yoke- complete Cold mass assembled and tested Warm field mapping complete Cryostat Components(Helium, LN2, Vacuum) complete Helium vessel assembly around cold mass underway LN2 shield and Vacuum vessel assembly TBD Factory testing Delivery to JLAB – July 2014

Thomas Jefferson National Accelerator Facility Pg. 12 Yoke Containment Shells

Thomas Jefferson National Accelerator Facility Pg. 13 Q1 He Vessel

Thomas Jefferson National Accelerator Facility Pg. 14 Q1 LN2 Shield

Thomas Jefferson National Accelerator Facility Pg. 15 Q1 OVC Vessel

Thomas Jefferson National Accelerator Facility Pg. 16 Q1 Schedule

Thomas Jefferson National Accelerator Facility Pg. 17 Q1 Magnet - Summary Construction well-advanced. Schedule risk being carefully monitored. –60% of sub-contract is complete. –Good performance for the last 8 months. –Using incentives to advance delivery date. No known technical risks: –Typical manufacturing tasks and workmanship remain. –QA and vendor oversight processes in place.

Thomas Jefferson National Accelerator Facility Pg. 18 Dipole Q2Q3 Highlights Oct Feb 2014 Site SigmaPhi Oct,Nov,Dec, Jan, Feb….. near continuous presence by JLAB engineers Q2Q3 FDR complete with punch list Oct 2013 Production Consolidation Equipment Operational Dipole Prototype VPI completed Dec 13 Second winding station complete Second source of coil spacers delivering ~ 1 layer per week( see the video) Conductor properties 300K and 4 K results including shear measurements exceed requirements

Thomas Jefferson National Accelerator Facility Pg. 19 Production Coil winding

Thomas Jefferson National Accelerator Facility Pg. 20 Production coil 1 st segment and spacer installed

Thomas Jefferson National Accelerator Facility Pg. 21 Dipole Construction Underway First dipole production coil winding started Feb 17 First segment (25 turns) and spacer installed today Second dipole production coil wind start March 12 Dipole cryostat at Chastigny and ASME overlay at APAVE proceeding well 4 K measurements of conductor compression modulus excellent results 4 K 300 K improved measurements with extensometer demonstrate that the initial “soft strain” was a measurement artifact. This makes the coil preload much easier and reduces the interference required. Shear measurements in reasonable agreement with JLAB/Hall B/Torus

Thomas Jefferson National Accelerator Facility Pg. 22 Prototype Coil Results Winding –Techs, equipment and winding went well –late delivery of spacers caused delays resolved with the second source –Coil Resistance and ringing tests results all OK –Equipment is sensitive to single shorted turn VPI –Equipment worked OK except for mold leaks which allowed air intrusion causing some voids. Leaks were found and cause (rusty mandrel)eliminated. –Mold release on coil spacers worked as planned –VPI process improvements to preclude a repeat Confidence high so proceed to production!!!!

Thomas Jefferson National Accelerator Facility Pg. 23 Prototype in VPI Mold

Thomas Jefferson National Accelerator Facility Pg Dipole prototype coil

Thomas Jefferson National Accelerator Facility Pg VPI improvement Objective N°1: Improve the impregnation quality Modifications implemented: 1.Replace G10 sheet 0.2 mm by fiber glass cloth for easier resin flow 2.Increase the number of holes in the G10 sheet (0.3 mm thickness) 3.Sand blast mold for better vacuum seal 4.Tilt the mould (20-30°) to favor the resin flow in between the conductors 5.Install the resin mixer above the mold to trap the air bubbles inside the feed pipes 6.Keep more pressure above the resin inside the malaxer to slow down the impregnation 7.Sequential injection 8.Increase the curing duration to about 30h (cold point at 120°C hot point at 135°C) Objective N°2: Make the resin less sensitive to cracking Modifications Implemented: 1.Improve the injection geometry: larger draft (30 degrees tilt) 2.Add flexibilizer to the resin

Thomas Jefferson National Accelerator Facility Pg. 26 Conductor testing Compressive stress strain results demonstrate that ALL dipole conductors have near identical properties- no need to sort conductor 300 K results from UBS lab using an extensometer demonstrate that the initial “soft strain” is a measurement artifact arising from surface defects and using platen travel- more good news! 4 K results demonstrate average compressive yield at 148 MPA as compared to 100 MPA stress levels at 11 Gev - adequate margin at operating current. Shear results to date indicate adequate margin. More measurements planned. Good agreement with JLAB measurements.

Thomas Jefferson National Accelerator Facility Pg. 27 Compression 300K

Thomas Jefferson National Accelerator Facility Pg. 28 Test Instron at UBS with LVDT’s and Extensometer

Thomas Jefferson National Accelerator Facility Pg K Conductor compression results from CEA/Saclay Youngs Modulus(Gpa)Yield (MPA) original K K K22148

Thomas Jefferson National Accelerator Facility Pg. 30 Production consolidation equipment 30 meters per hour

Thomas Jefferson National Accelerator Facility Pg. 31 Production winding lines at SigmaPhi

Thomas Jefferson National Accelerator Facility Pg. 32 Prototype in production oven

Thomas Jefferson National Accelerator Facility Pg. 33 Dipole Schedule

Thomas Jefferson National Accelerator Facility Pg. 34

Thomas Jefferson National Accelerator Facility Pg. 35 Summary- SigmaPhi Magnets Production coil winding –coil 1 started Feb 17 –coil 2 March 12 Coil spacer delivery solved by second source delivery now one set per week First double layer of production coils 1 and 2 will be separately impregnated to verify VPI. Dipole conductor mechanical property measurements excellent results confirm adequate margins Dipole delivery June 2015 Q2Q3 delivery Aug/Oct 2015

Thomas Jefferson National Accelerator Facility Pg. 36 Magnet Components by JLAB HB/Q1/Q2/Q3/Dipole Conductor Cryogenic Control Reservoir (5 magnets) Warm Yoke Steel (3 magnets); Q1 cold yoke by SMI; HB by MSU DC Power Systems (5 magnets) Instrument and Controls (5 magnets) Stands and Mounts (5 magnets)

Thomas Jefferson National Accelerator Facility Pg. 37 Magnet Components by JlAB-complete ContractVendorCost K$ DeliveryStatusInstallation assembly DC SystemDanfysik 922Jan/Apr 2013CompleteMarch 2014 CryoReservoirMeyer Tool1,067Jan 2012CompleteAt mag vendors Current LeadsAMI 94Feb 2010CompleteAt mag vendors Controls & Software JLAB 1,009Oct 2013Complete Testing Underway April 2014 Yoke CastingsNingbo- Jansen 1,298Oct 2012CompleteNA Yoke Machining Craft Machine 125June 2013CompleteApril 2014 SC CableSSC surplus NA CompleteNA SC Cable Testing BNL 91Nov 2007CompleteNA Copper Channel FMM 266Feb 2012CompleteNA Redraw Channel FMM 15Feb 2012CompleteNA Wave solderAES 284Oct 2012CompleteAt mag vendors Magnet supports Various 154Oct 2012CompleteInstalled

Thomas Jefferson National Accelerator Facility Pg. 38 SHMS Cryo System Re-use G0 transfer line- Mods by Hall C Complete Re-use G0 flex gas return lines- Ready to install New flex cryo-line support – Installation March 2014 New SHMS transfer line- Installed Feb 2014 New U-tubes,L-tubes magnet connections complete, delivered and tested at JLAB Warm gas return system manifolds- complete Warm gas return system- installation underway

Thomas Jefferson National Accelerator Facility Pg. 39 SHMS Installation Rails and mounts complete Steel Structure complete Shield House concrete – last pour Friday Feb 14, 2014 Equipment deck 99% complete Magnet stands installed SHMS transfer line installed Target access platform contracted Shield house interior shielding contracted Shield house raised floor- bids in-award soon Electrical and LCW installation underway

Thomas Jefferson National Accelerator Facility Pg. 40 SHMS Summary All magnets in production Delivery of last magnet (Q3) still very tight Issues with conductor properties resolved JLAB magnet components all complete and delivered or installed or awaiting installation SHMS Cryo system all components on site and tested transfer line installed SHMS assembly in Hall C proceeding very well First magnet delivery July 2014 and we will be ready

Thomas Jefferson National Accelerator Facility Pg. 41 Happy Days!!!