NCSX NCSX Trim Coil Peer Review 11/6/07 1 Tom Brown Art Brooks Raki Ramakrishnan Mike Kalish NCSX Trim Coil Peer Review

NCSX NCSX Trim Coil Peer Review 11/6/07 2 Objective Achieve Consensus on Trim Coil Requirements Show How Requirements Are Met Through Trim Coil Design Approach and Design Tradeoffs To Date Establish Path Forward Design is in Development This is the Time for Feedback!

NCSX NCSX Trim Coil Peer Review 11/6/07 3 Outline How Field Error Correction Requirements Evolved Trim Coil Configuration Requirements (Art Brooks) Optimization of # of Turns Power Supplies (Raki Ramakrishnan) Cooling requirements and analysis Structural Support Requirements Coil Manufacturability Schedule Cost Path Forward Summary

NCSX NCSX Trim Coil Peer Review 11/6/07 4 Evolution of Coil Set Configuration- 144 to Coil Set Analysis provided the optimum subset of 12 coils Actual Enclosed Area of Coil Les than %50 of Initial Layout Forced Increase in Amp-Turns Bottom Top 2 4 Near Midplane Bottom

NCSX NCSX Trim Coil Peer Review 11/6/07 5 Evolution of Coil Set Configuration- 72 to Coil Set Subsets of 72 Coil Set Explored Evolved into Final 36 Coil Set (24 Effective Coils) 36 Coil Set

NCSX NCSX Trim Coil Peer Review 11/6/07 6 Art’s Presentation Field Error Correction Requirements and Performance

NCSX NCSX Trim Coil Peer Review 11/6/07 7 Determination of the # of Turns Original Design = 4 Turns –Minimized Coil Cost –Heat Transfer OK Optimized Design =121 Turns (or more) –Power Supply Costs Drop –More turns – Higher Voltage Lower Current Less than 600V incurs no penalty in power supply cost Decreases current requirement from 5000Amp to 165Amp –allows for 11x11 build with reasonable 2mm conductor size –Four Twisted 10AWG (.109”x4) wires can be used for buss connections Note: 121 Turns requires response time be greater than 32 ms

NCSX NCSX Trim Coil Peer Review 11/6/07 8 Coil, Bus, Power Supply Cost Comparison 4 Turns vs 121 Turns 4 Turns121 TurnsDelta Coil Costs Cable M&S5112 Cable Installation 6532 Day One Cost$565K$714K+$148K Power Supply Upgrade Cable M&S Upgrade Cable Install Upgrade Final Cost$3454K$1817K-$1637K Increases Coil Costs Decreases Power Supply Costs Decreases Final Bus Work Material Cost Decreases Bus Work Installation Cost 24 Connections Out of Cryostat and 2 Connections to Basement

NCSX NCSX Trim Coil Peer Review 11/6/07 9 POWER SUPPLIES FOR TRIM COILS SELECTION OF POWER SUPPLIES THERE ARE 36 COILS TO BE CONFIGURED IN 24 CIRCUITS IN EACH CIRCUIT FOLLOWING IS NEEDED: –H BRIDGE & ASSOCIATED CONTROLS –DISCONNECT AND GROUND SWITCHES –VOLTAGE & CURRENT TRANSDUCERS –CABLING –ALL 24 H BRIDGES WILL BE FED FROM ONE DC LINK PROPOSE TO USE EXISTING 500V 5KA(PULSED) PEI SUPPLY FORCING VOLTAGE TO BE AS HIGH AS POSSIBLE BUT BELOW 450 VOLTS SELECT NUMBER OF TURNS ACCORDINGLY IF 4 TURNS ARE CHOSEN THE CABLING WILL BE 4/C 2/0- TWO CONDUCTORS IN PARALLEL IN EACH POLE. IF 128 TURNS ARE CHOSEN THE CABLING WILL BE 4/C #12 TWO CONDUCTORS IN PARALLEL IN EACH POLE. NOTE THAT 4/C#12 WILL BE THE MINIMUM CABLING SIZE THAT WILL BE CHOSEN INDEPENDENT OF INCREASE IN NUMBER OF TURNS Raki

NCSX NCSX Trim Coil Peer Review 11/6/07 10 COST OF POWER SUPPLIES & ASSOCIATED EQUIPMENT  IF 4 TURNS ARE CHOSEN COST WILL BE NEARLY 2.5 MILLION DOLLARS  IF 128 TURNS ARE CHOSEN COST WILL BE NEARLY 1 MILLION DOLLARS POWER SUPPLIES FOR TRIM COILS Raki

NCSX NCSX Trim Coil Peer Review 11/6/07 11 Extract from Art’s # of Turns volts amps amps CW (2s/900s) Coil IR Lead IR39.1 Coil I2R L/R (Coil)0.18 coil resistance (N2) ohms coil Inductance henries E Lead resistance per Art Lead cabling#2 cable*2#6 *2#8*2#12*2 Resistance of 100' Total Coil & Cabling resis Circuit L/R Circuit IR Ckt I^2*R Raki

NCSX NCSX Trim Coil Peer Review 11/6/07 12 Raki

NCSX NCSX Trim Coil Peer Review 11/6/07 13 Coil Cooling Requirements – Comfortable Design Margins With Convection Cooling, Risk Low Margin Available –Doubling the current to 40 amp turns –Temperature increase per pulse is only approx.= 10.3 C –Equilibrium at Temperature Rise approx.= 35C –Equivalent Average Power of 107 watts Requirement –2 second pulse every 15 minutes –20 Kamp Turns –Fit in 1.25” square cross section For 121 Turn Coil With 2mm Conductor (11X11) –Temperature increase per pulse is only approx.= 2.6 C –Equilibrium at Temperature Rise approx.= 9C –Equivalent Average Power of 27 watts

NCSX NCSX Trim Coil Peer Review 11/6/07 14 Structure- Design Margin is Questionable, Concept in Development, Risk Higher Coils Mounted to MCWF Coils Stepped off of Structure Force varies linearly with #amp turns Design Requirement = 20KAmp Turns Highest Loading approx 75lb/in Design Will Trade off Coil Structure For # of Supports Coil May be Wound Into Supporting Case? Magnetic Permeability Requirement Increases Cost

NCSX NCSX Trim Coil Peer Review 11/6/07 15 Coil Manufacturability- Conventional, Risk Low Similar Coil built by Everson-Tesla (2x20 bent the hard way) Conductor Pre-Insulated with Kapton is available as a catalogue item Bending Out of Plane and Winding Inward Increases Difficulty Everson Supplied Budgetary Estimates

NCSX NCSX Trim Coil Peer Review 11/6/07 16 Trim Coil Schedule Resource loading extends schedule Preliminary schedule has last trim coil delivered by 5/09 Coil over port start of station 5 drives schedule

NCSX NCSX Trim Coil Peer Review 11/6/07 17 Coil Estimate Materials Estimated Separately Coil Fabrication Costs Based on Budgetary Estimate from Everson Cost escalated due to design uncertainty Coil Cost = $670K

NCSX NCSX Trim Coil Peer Review 11/6/07 18 Structure and Installation Estimate Installation Hardware Estimate Based on Simple Support Scheme – Costs Will be Escalated Installation Estimate Includes Metrology Installation Manpower Estimate = $387K

NCSX NCSX Trim Coil Peer Review 11/6/07 19 Coil, Bus, Power Supply Estimate $$$ K Cable M&S12 Cable Installation 32 Day One Cost$44K Power Supply Upgrade 1000 Cable M&S Upgrade 16 Cable Install Upgrade 87 Final Cost$1147K Power Supply Cost Approx. 35K per Coil with Lower Current Requirement Bus Cable is 4 Twisted 10 Gauge Wires 24 Connections Out and 2 Connections to Basement (should change requirement?) Total Day One Job Cost Including Engineering is now $2240K

NCSX NCSX Trim Coil Peer Review 11/6/07 20 Priorities Headed for PDR Areas of Design Which are Low Risk –Coil Size, Shape, # of Turns, #coils, and cost –Convection Cooling OK –Bus Work simplified with increase in # of turns –Power Supply Costs Minimized Areas of Design with lower maturity needing work up front –Finalize layout – eliminate interferences –Modify layout so that coil is wound in tension –Determine best support plan to minimize complexity and cost –Structural Analysis –Determine assembly method

NCSX NCSX Trim Coil Peer Review 11/6/07 21 Summary- Requirements 20 KAmp Turns 36 Coil Configuration Mounted to Modular Coils At least 121 Turns (and less than 169) Response Time Greater Than 32 ms Installation at Start of Station 5 Small Coils Jumped in Series for effective 24 Coils All Coils Brought to Cryostat Junction Box. Only Two Cables Brought to Basement for Day One?