MECO Magnet System Ongoing Work

1. MECO Magnet SystemOngoing Work Presentation to NSF Review Committee Bradford A. Smith (MIT-PSFC) MECO Magnet Subsystem Manager January 20-21, 2003 Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

2. Outline • Advancing the Magnet Conceptual Design • Preparation of the Magnet Statement of Work (SOW) and Technical Specification • Preparation of the Magnet RFP • Plan to Magnet Procurement Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

3. Advancing the Conceptual Design • Industrial studies • Design changes since the CDR • Capture BNL safety requirements • Development of interface specifications • Development of an integrated magnetic verification and tolerance study Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

4. Industrial Studies • Industrial studies advance the conceptual design and reduce risk prior to procurement • Technical • Cost • Schedule • Study areas were recommended by MIT at the conclusion of the CDR and endorsed by the review committee. • Subcontracts resulting from industrial responses to the studies RFP Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

5. Insulation System Study • Contract has been placed withCryogenic Materials, Inc. (Boulder, CO) • Study content: • Coil insulation • Recommend a coil impregnation resin suitable for use in the MECO radiation environment (30 Mrad). Provide specs, unit costs, and viscosity-time-temperature curves. • Provide a protocol for the resin transfer process with sketches, including time-temperature/pressure profile and controls, resin preparation and transfer procedure, coil preparation and resin-cure procedures. • Suggested equipment development or procurement including broad specifications and sketches of proposed equipment. • Joint insulation • Check solder data base for liquidus/solidus temperature higher than 93 C of Indalloy #8 • Determine resin and glass-insulation system to be used with Kapton that conforms to the temperature limitations, minimizes the through thickness and optimizes radiation resistance. • Conduct laboratory trial lay-ups • Final report due in Mar03 • Parallel contract has been placed with General Atomics (La Jolla, CA) Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

6. Refrigerator/liquefier Study • Contract has been placed with Applied Cryogenic Technologies (Ovilla, TX) • Study content • Evaluate the status of the CTI-M4000 refrigerator/liquefier at BNL and the effort required to refurbish/upgrade it to meet the MECO requirements. • Draft a mini-specification for a new refrigerator/liquefier that will meet the MECO requirements and incorporate MECO MDMG technical review comments. • Obtain cost estimates from commercial supplier(s) against the draft refrigerator/liquefier specification. • Submit draft followed by a final report with recommendation to refurbish or procure by mid-Apr03 • Parallel contract has been placed with General Atomic (La Jolla, CA) Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

7. Magnet Fabrication Study Introduction Objectives: • Evaluate an appropriate arrangement of winding lines and impregnation stations for all coils to achieve the desired tradeoff between cost, schedule and ability to provide adequate quality control over all operations. • Provide a budgetary cost estimate and schedule for magnet assembly. Rationale: • Provide independent industrial corroboration to the CDR finding that the winding and impregnation costs are overall magnet system cost drivers. • Quantify cost/schedule tradeoff sensitivity • Corroborate the CDR magnet assembly cost estimate Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

8. Magnet Fabrication Study • Contract has been placed with General Atomics • Study content: • Study is phased to accept input from GA’s own insulation studies as well as those from Cryogenic Materials. • Develop a reference approach for winding and impregnation of all 94 coils of the Conceptual Design. • Estimate the complete schedule and cost for magnet fabrication. • Provide an estimate of the cost sensitivity to schedule changes. • Final report (Apr03) on all studies is 2-4 weeks after completion of the insulation study Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

9. Capture BNL Safety Requirements • A series of telephone conferences have been held with the relevant safety committees at BNL as the first step of familiarizing the committees with MECO features. • Accelerator Systems Safety Review Committee (ASSRC) • Experimental Safety Review Committee (ESRC) • Radiation Safety Committee (RSC) • ALARA (as low as reasonably achievable) Committee (radiation controls) • Cryogenic Safety Committee (CSC) • A matrix of safety topics for further presentation by MECO to the above BNL committees has been prepared. • Safety committees will be briefed by MECO next month. • Safety requirements will be summarized and incorporated in the Draft Magnet Specification and SOW. Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

10. Design Changes Since the CDR • Coil layouts and counts have been revisedto accommodate,without internal joints, the now known lengths of SSC cable that have been inventoried and set aside for MECO with DOE concurrence. • Iron return frame added around the PS cryostat for ground water shielding (safety requirement). • Field specification is to be updated to reflect the fringe fields from the PS and DS into the TS. Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

11. Magnet Interfaces • Magnet interfaces can be finalized in a set of interface control documents by Oct03, prior to magnet baseline. • MIT and other institutions require funding for this activity. Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

12. Development of Integrated Magnetic Verification and Tolerance Study Mission • Refine the design basis structural and em models to accommodate static and dynamic loads and include design changes since the CDR. • Demonstrate that the field specification can be achieved with reasonable and customary component tolerances, manufacturing and verification methods. • Provide a methodology template for final design. • Reduce final manufacturing risk and possible cost and schedule impacts. Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

13. Development of Integrated Magnetic Verification and Tolerance Study Basic approach • Update the ANSYS structural models to match the present coil and iron designs. • Extract from the structural models the changes in coil positions from their warm, manufactured assemblies to their cold, energized assemblies. • Recalculate the cold coil positions based on adjustment- at-installation capability provided to the design. • With em models updated to the present design, calculate the combined impact of non-adjustable coil positions and a set of assumed manufacturing tolerances on the magnetic field. • Iterate the allocation of allowable coil displacements to 1) non-adjustable positional changes at installation and 2) manufacturing tolerances. • Converge the iteration in a set of component, sub-assembly and assembly specification drawings. MIT requires funding for this activity – also exploring doing some of this off-project Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

14. Preparation of Magnet SOW and Specification • SOW and Spec are being prepared simultaneously by MIT with current funding. • A rough draft was completed in Oct02, based on the CDR, and was distributed to UCI. • The next steps are to gather results from ongoing work and modify the draft document in two steps: • Next draft (for draft RFP) • Updated field specification • Industrial study results • Draft interface documents • BNL safety committee feedback regarding design for safety (ongoing). • Final draft (for final RFP) • Final interface documents • Integrated magnetic verification and tolerance study results • Items leading to final draft completion require new MIT funding.This is time critical and can start when new money is available. Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

15. Preparation of the RFP • MAP has recommended MECO proceed now with the development of a draft RFP to acquire the magnet system on a fixed price basis in accordance with the following steps. • Update the field spec • Specify the magnet interfaces • Complete industrial studies • Obtain an independent cost estimate • Finalize the magnet spec and SOW • Initiate the procurement Agency • Draft the magnet acquisition plan • Draft the RFP • Complete program reviews • Obtain vendor comments on the draft RFP • Obtain Government authorization to issue the RFP • A MECO project plan is in place providing a path to procurement that is consistent with the MAP recommendation. Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

16. WBS 1.4 – Solenoids Schedule – 1 Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

17. WBS 1.4 – Solenoids Schedule – 2 Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

18. WBS 1.4 – Solenoids Schedule – 3 First need for additional funds Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

19. WBS 1.4 – Solenoids Schedule – 4 Draft RFP Released 7/2/03 Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work

20. WBS 1.4 – Solenoids Schedule – 5 Subsystem Baselined 11/6/03 Final RFP Released 12/11/03 Engineering Design Commences 7/1/04 Brad Smith NSF Review of RSVP MECO Magnet System Ongoing Work