AGS Department / SNS Ring Systems

BROOKHAVEN NATIONAL LABORATORY

Brookhaven Science Associates

Upton, New York 11973

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height="0.7326388888888888in"}

#### SPEC. SNS-0001

Revision A

December 3, 1998

##### Specification for Radiation Resistant

##### Fiberglass/Epoxy Insulated Magnet Coils

Approvals:

George J. Mahler, Engineer

> Jon Sandberg, Chief E.E.
>
> Joseph Tuozzolo, Chief M.E.

David Passarello, Quality Assurance

This Specification consists of 12 pages, including this cover sheet.

SNS Ring System

BROOKHAVEN NATIONAL LABORATORY

Brookhaven Science Associates, Inc.

Upton, New York 11973

SPEC. SNS Ring Systems-0001

Rev. A October 27, 1998

SPECIFICATION

FOR

RADIATION RESISTANT FIBERGLASS/EPOXY INSULATED MAGNET COILS

**1.0** **SCOPE**

This Specification, in conjunction with associated drawing(s) and other
applicable documents, defines the design requirements, configuration,
materials, quality assurance, inspection, testing, workmanship,
cleaning, and packaging for various magnet exciting coils. Coils
supplied under this Specification will be used to excite magnets that
will guide a beam of charged particles.

**2.0 APPLICABLE DOCUMENTS**

The following documents form a part of this Specification to the extent
specified herein. Unless otherwise specified, the issue date or revision
level shall be that in effect on the date of the Invitation to Quote.
Exceptions must be approved in writing by BNL.

> [Number]{.underline} [Title]{.underline}

# BNL-QA-101 BNL Seller Quality Assurance Requirements

> ASTM-Bl7O-89 Standard Specification for Oxygen-Free Electrolytic
> Copper
>
> Title 29 Federal Regulations, Section 1910.1200 Appendix A & B
>
> 57-295 AIEE Conference Paper

**3.0 REQUIREMENTS**

3.1 Conductor

The conductor shall be oxygen-free electrolytic copper (OFHC), Grade 1,
in accordance with the latest revision of ASTM Standard referred to in
Section 2.0 of this Specification. The minimum electrical conductivity
shall be 101% IACS. The copper shall be delivered in an annealed (dead
soft temper) pancake configuration. The conductor size and tolerance
shall be as specified on the drawing. It is the responsibility of the
Seller to verify dimensional compliance, inspect surfaces, leak check
and ball check the conductor before accepting them from his supplier.

3.1.1 Coil Terminals (Un-insulated Ends)

Coil terminals shall be silver plated on the surface(s) shown on the
drawing. The plating shall be continuous and shall be suitable for a
pressure joint to a similarly silver coated surface. It shall not peel
or crack with joint pressures up to 3000 psi.

3.1.2 Conductor Joints

The coil shall be wound of a continuous conductor if possible. The
number of joints shall be limited to two or less per coil unless
indicated otherwise on the drawing. Joints are allowed only in the areas
specified on the drawing.

3.1.3 Brazed Joints

All joints and connections must be brazed with Handy Harmon \"Sil-Fos\"
brazing material or a BNL approved equal. All copper-to-copper joints
shall be made WITHOUT flux. A thermocouple controlled incandescent
carbon block is the preferred brazing method. Excess brazing alloy shall
be mechanically removed flush with the conductor\'s virgin surfaces. The
Seller shall develop and submit to the Buyer the description of the
brazing cycle together with three (3) sample joints, with the conductor
at least 8 inches long on each side of the joint and (2) two virgin
conductors at least 16 inches long. The brazed joint shall be at least
eighty percent (80%) as strong as the virgin conductor. The fabrication
of production coils must not start prior to testing and approval of the
brazed sample joints by the Buyer. Brazed joints in the formed coil
shall be leak tested before wrapping with insulation tape in accordance
with Section 4.4.2 of this specification. The completed coil must pass
the coil resistance test specified in section 4.5.3 of this
specification.

3.1.4 Corner Buildup

All bends shall be stress-relieved and any key-stoning due to bending of
the conductor shall be mechanically removed by filing or grinding.
Resulting sharp corners shall be radius-ed.

3.2 Insulation

The coil shall be insulated only after it is completely formed, ball
tested (section 4.4.1 herein), leak tested (section 4.4.2 and 4.4.3
herein), flow tested (section 4.4.4 herein) corners dressed, degreased
and sandblasted. If the copper thickness in the bend direction is 5/8
inch or less and the smallest inside bend radius is at least twice the
conductor thickness, then the conductor may be wrapped with insulation
after sandblasting and before forming. The copper surfaces and
insulating materials shall not be contaminated with skin oil, dirt,
grease, etc., after bead blasting. Clean gloves shall always be used to
handle the clean conductor material. After application of the complete
insulating system it must pass the tests in section 4.5 of this
specification.

3.2.1 Turn-to-turn insulation

The conductor shall be wrapped with both Kapton^R^ and Amino Silane
treated glass fiber tape, half-lap wound to the thickness specified on
the drawing referenced to the coil.

3.2.2 Ground Insulation

Ground insulation shall consist of Amino Silane treated glass fiber
tape, half-lap wound to the thickness specified on the drawing. Any
voids in at the transitions between the coil layers or near the
terminations shall be filled with glass roving prior to the ground wrap.
This is to avoid resin rich areas in the coil structure after
impregnation.

3.2.3 Coil Impregnation

The insulation between the bare copper turns and all of the insulation
layers shall be impregnated with bonding resins which shall be cured to
bond the coil and insulation into a monolithic structure with mechanical
strength. No voids shall exist between the conductor and insulation and
between the insulation layers. All insulating materials used shall be
compatible with each other and the copper.

The preferred coil impregnating resin system is as follows:

#DER 332 (Dow Chemical) DGEBA Resin 50 pbw

#DER 736 (Dow Chemical) Polyglycol Flexible Resin 50 pbw

and cured with:

NMA (Allied Chemical Company) Nadic Methyl Anhydride 90 pbw

Acceleration of cure will be through the use of:

DMP-30 (Rohm & Haas) Tridimethyl Amino Methyl Phenol. 1.5 pbw

In lieu of the above, the Seller may submit to the Buyer, for approval,
the exact impregnation epoxy mix formulation and curing cycle
description of an alternate mix. The alternate mix, however, must have
equal or better physical properties and resistance to nuclear radiation
at a minimum exposure of 1 x 10^-8^ Gy as the \"preferred mix\".

3.2.4 Impregnation Form

In order to maintain dimensional tolerances, rigid tooling must be used
for the curing cycle of the epoxy. Sizing and curing operations must be
performed simultaneously. The form shall be designed to withstand the
cure vacuum/pressure cycle used by the seller and to provide completed
coils that meet the specified dimensions.

3.2.5 Impregnation Procedure:

1\. The impregnation form and the coil in it shall be preheated to 120 ±
5 ^o^F (for half an hour before impregnation).

2\. The impregnation form shall be vacuum pumped to 200 microns or less.

3\. The epoxy mix shall be de-aerated and preheated to 120 ± 5 ^o^F in
an appropriate tank. DMP-30 shall be added to the mix 3-5 minutes prior
to potting.

4\. The impregnation form shall be filled with the epoxy mix while under
vacuum, then pressurized to 10 psig for 1 hour with an inert gas (i.e.
nitrogen, argon, helium, etc.).

5\. The epoxy curing cycle recommended by the Seller and accepted by the
Purchaser shall be such as to minimize distortion and cracking of the
surface. The typical curing cycle for the \"preferred epoxy mix\" is:

180 deg ± 5 deg F for 4 hours

260 deg ± 5 deg F for 10 hours

Cooled to 140 deg F in not less than 5 hours to minimize distortion.

3.2.6 Coating

The coil assembly shall be painted with clear Dow Corning R-4-3117
conformal coating to protect the coil from moisture absorption after
impregnation.

3.3 Marking

Prior to shipping, each coil shall be identified by its respective
drawing number, plus a three-digit serial number. The number shall be
painted with white epoxy paint in the size and location shown on the
drawing. No other permanent markings may be applied without the written
approval of the Purchaser.

3.4 Repairs

Cast or impregnated coils shall be free of voids, fissures, cracks, or
other defects. Coils with defective or damaged internal insulation shall
be rejected and may not be repaired. External defects may be repaired,
contingent, in each instance, upon prior Buyer written authorization,
including approval of the procedure and materials to be used in the
repair. The Buyer will not accept any coil assembly that has been
reworked or repaired in whole or in part unless the rework or repair was
authorized in writing by the Buyer.

3.5 Hazardous Materials

Materials that may be defined as hazardous in accordance with Title 29,
Code of Federal Regulations, Section 1910.1200 Appendix A and B
(attached) shall not be used without written approval from BNL.

**4.0 QUALITY ASSURANCE PROVISIONS**

4.1 General

Articles furnished in compliance with this Specification shall be
produced under the controls established herein and as required by the
applicable contract. Additional Quality Assurance requirements are in
accordance with BNL Quality Assurance (QA)-101, Sections 1,2,3
(including 3.1 and 3.1.2), 4.1, 4.3, 4.10, 4.10.1, 4.16, 4.20, and 4.21.

4.2 Responsibility for Inspections and Tests

Unless otherwise specified in the contract or purchase order, the Seller
shall be responsible for the performance of all inspections and tests
specified herein and in referenced specifications. BNL reserves the
right to re-perform any of the inspections and/or tests set forth in
this or referenced specifications where deemed necessary to assure that
supplies and services conform to prescribed requirements. BNL shall be
advised two weeks in advance when tests are to be conducted so that
representatives may be designated to witness or supervise the tests when
so desired.

4.3 Acceptance Tests

Acceptance tests shall be performed to verify that articles supplied
under the contract meet the standards established in Section 3.
Acceptance or approval of material during the course of manufacture
shall not be construed as a guarantee of its acceptance in the finished
product. All articles shall have satisfactorily passed the applicable
acceptance tests prior to delivery. The acceptance test data for each
delivered coil shall be recorded on a "Coil Data Sheet" (attached).
Copies of the Seller certified test results shall be submitted to the
Buyer.

4.  Tests Prior to Coil Insulation

4.4.1 Steel Ball Test

Prior to insulating the coil, the Seller shall blow a polished steel
ball through the cooling passage(s) of the conductor. The ball diameter
shall not be less than 60% of the cooling passage diameter specified on
the drawing. This is to check for braze material or any other
obstruction in the cooling passage. Coils that can not pass the ball
shall be rejected.

4.4.2 Leak Check

Prior to insulating the coil, its water passage shall be thoroughly
washed by flowing water at 180 to 200^o^F for at least 15 minutes,
followed by subsequent washing with water at room temperature for 15
minutes. The water passage shall then be dried by blowing air through
it. When dry, the entire assembly shall be enclosed in a polyethylene
bag or other suitable enclosure and a helium leak test shall

be made on the entire assembly. As a substitute check, a
halogen-sensitive detector may be used by pressurizing the water passage
with a halogen gas compound for 10 minutes minimum at 150 psig pressure.
The joints and entire coil shall be probed for leaks. The leak rate of
halogen gas shall not exceed 0.5 ounce per year.

4.4.3 Hydrostatic Test

Prior to insulating the coil, it shall be filled with water and
pressured to 300 psig. The coil shall be isolated from the pressure
source for a period of 1 hour and any pressure changes shall be recorded
on the Coil Data Sheet at intervals of 15 minutes. Recorded data shall
include the following:

Coil water pressure to the nearest 0.5 psig.

Coil water temperature to within 2 deg F.

The coil shall show no evidence of external leakage or internal pressure
drop other than that resulting from any changes in water temperature.

4.4.4 Hydraulic Flow Test

Prior to insulating the coil, it shall be checked for water flow in
gallons per minute at a pressure differential of 50 psi with a water
temperature range of 60^o^F to 80^o^F. Any coil whose water flow rate
exceeds [+]{.underline} 10% of the average rate for all the coils
produced or does not meet the flow rate specified by the buyer shall be
rejected.

4.5 Tests After Coil Insulation

4.5.1 Ground Insulation

The insulation to ground shall be tested to withstand 5000 volts DC for
one minute applied between the conductor and metal foil wrapped tightly
over the entire insulation surface. Evidence of insulation breakdown or
damage or a leakage current which exceeds 100 microamps at 5000 volts DC
shall be cause for rejection.

4.5.2 Turn-to-Turn Insulation

The turn-to-turn insulation shall be tested either by applying 1600
volts peak-to-peak high frequency for one minute across the coil
terminals or by applying a 2000 volt peak impulse having a rise time of
1 to 5 microseconds. This is done by switching a capacitor across the
terminals of the coil so that a resonant circuit is formed (method
similar to that described in AIEE conference paper No. 57295, \"High
Voltage Surge Tests for Detecting Faults Between Turns of Rotating
Machines\"). There shall be no indication of breakdown between turns, as
indicated by a scope trace of the oscillations (see last page of this
Specification figures 2A and 2B). The actual scope trace for each coil
must be attached to the data sheet.

4.5.3 Coil Resistance

The Ohmic resistance of the coil shall be measured and recorded to four
significant figures, at 70 [+]{.underline}5 ^o^F, by means of a standard
commercial Double Kelvin Bridge. Ohmic resistance readings that exceed
[+]{.underline} 10% of the average readings for all the coils produced
or that does not meet the resistance specified by the buyer shall be
rejected.

4.5.4 Dimensional Compliance

The Seller shall inspect and verify dimensional compliance of the coil
to the drawing.

4.5.6 Visual Inspection

The Seller shall inspect the coil assembly for voids, cracks, fissures,
or other defects before packing and shipping.

4.6 Inspection of BNL Furnished Material (if applicable)

When material is furnished by BNL, the Seller\'s procedures shall
include as a minimum the following:

\(a\) Examination upon receipt to detect damage in transit.

\(b\) Inspection for completeness and proper type.

\(c\) Periodic inspection and precautions to assure adequate storage
conditions and to guard against damage from handling and deterioration
during Storage.

\(d\) Functional testing as required to determine satisfactory
operation.

\(e\) Identification and protection from improper use or disposition.

(f) Verification of quantity.

(g) The Seller shall report to BNL any BNL furnished material found
    damaged, malfunctioning or otherwise unsuitable for use.

Use of BNL furnished material in no way relieves the Seller of the
responsibility to furnish an acceptable product.

**5.0 PREPARATION FOR DELIVERY**

1.  The Seller is responsible for proper packing or crating of coils.

2.  Water shall be completely drained from each coil, and the coolant
    hole dried by blowing air through it. When dry, both ends shall be
    suitably sealed. Flare fittings shall be protected with suitable
    plastic caps that shall also serve to seal off the water passages.

3.  The silver-plated, un-insulated leads shall be protected to prevent
    damage.

4.  Coils shall be packed in completely enclosed containers. Coils shall
    be covered by waterproof shrouding and shall be cushioned and
    blocked to prevent damage by impact. Special attention shall be
    given to protection of coil leads. Containers shall be designed to
    permit stacking one onto another for a height of at least six
    containers.

5.  Containers shall be marked externally so that the particular coil
    inside any container may be identified without opening the
    container.

6.  Fixtures shall be shipped to BNL with the last shipment of coils.

**6.0 NOTES**

6.1 Seller Suggested Modifications

The Seller is encouraged to bring to the attention of BNL any
improvements in design, performance, or reliability that would result
form the use of materials, parts, and processes other than those
specified. A request for approval of such improvements shall be
submitted to BNL for consideration accompanied by complete supporting
information. Changes may be made only with the written approval of BNL.

6.2 Seller Subcontracting

The seller may subcontract all or part of the work defined by this
Specification. However, the seller is responsible for fulfilling all of
the conditions given in the Specification and the requirements of the
Terms and Conditions in the Contract/Purchase Order.

6.3 Defects in Items Already Accepted

When investigation of a failure or non-conformance indicates that like
defects exist or could exist in the items already accepted, the seller
shall so advise BNL, designate the necessary corrections and incorporate
them after approval by BNL.

**BROOKHAVEN NATIONAL LABORATORY**

**COIL INSPECTION DATA SHEET (sheet 1 of 2)**

Manufacturer: Serial No:

Coil Drawing No: Date:

Purchase Order
No.:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

4.4.1 Ball Test By: Date:\_\_\_\_\_\_\_ Ball Dia.\_\_\_\_\_\_\_ \[
\]passed \[ \]failed

4.4.2 Leak Check (Either vacuum leak check or pressurized per
specification).

\[ \] Vacuum By: Date: \[ \]passed \[ \]failed

\[ \] Pressure By: Date: \[ \]passed \[ \]failed

4.4.3 Hydrostatic Test By: Date: \[ \]passed \[ \]failed

+-----------------------+-----------------------+-----------------------+
| ## Interval (min)     | Pressure (psig)       | Temperature (F)       |
+-----------------------+-----------------------+-----------------------+
| 1                     |                       |                       |
+-----------------------+-----------------------+-----------------------+
| 15                    |                       |                       |
+-----------------------+-----------------------+-----------------------+
| 30                    |                       |                       |
+-----------------------+-----------------------+-----------------------+
| 45                    |                       |                       |
+-----------------------+-----------------------+-----------------------+
| 60                    |                       |                       |
+-----------------------+-----------------------+-----------------------+

4.4.4 Flow Test By: Date: \[ \]passed \[ \]failed

+-----------------------------------+-----------------------------------+
| ##                                |                                   |
|                                   |                                   |
| ## Flow (US gpm)                  |                                   |
+-----------------------------------+-----------------------------------+
| ##                                |                                   |
|                                   |                                   |
| ## Pressure (psig)                |                                   |
+-----------------------------------+-----------------------------------+
| Temperature (F)                   |                                   |
+-----------------------------------+-----------------------------------+

**BROOKHAVEN NATIONAL LABORATORY**

**COIL INSPECTION DATA SHEET (sheet 2 of 2)**

Manufacturer: Serial No:

Coil Drawing No.: Date:

Purchase Order
No.:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

4.5.1 Ground Insulation Check By: Date: \[ \]passed \[ \]failed

  ------------------------- ----------------------------- ---------------
  Leakage Current @ 5000                                  microamps
  Volts DC                                                

  ------------------------- ----------------------------- ---------------

4.5.2 Turn-to-Turn Insulation Check By[:]{.underline} Date:

1600 Volts peak-to-peak high frequency or 2000 volt impulse @ 1 to 5
microsecond rise time.

\[ \] Scope Trace Attached \[ \]passed \[ \]failed

4.5.3 D.C. Resistance By: Date: \[ \]passed \[ \]failed

Coil Temperature (F): Resistance (Ohms):

4.5.4 Dimensional Compliance Check By[:]{.underline} Date:

\[ \]passed \[ \]failed
Notes:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

4.5.6 Visual Inspection By[:]{.underline} Date:

\[ \]passed \[ \]failed
Notes:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Figure 2A - Ringing pattern for good coil.

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Figure 2B - Ringing pattern for bad coil.

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