1. Review of Modular Coil Winding Pack Configuration David Williamson March 19, 2004

2. 2 Outline Conductor / insulation layout Allowance for twist and keystoning Cooling and leads configuration Winding pack performance Summary

3. Coil Type A 20 Turns Coil Type B 20 Turns Coil Type C 18 Turns 93 71 60 in. 68 67 79 Winding Pack Geometry Coil lengths = 291, 283, 263-in Min coil-coil dist = 6.1-7.6 in, Max dist = 27-36 in Min coil-plas dist = 8.1-9.0 in, Max dist = 20-28 in Max coil current = 818, 831, 730-kA 3

4. Prelim Design Configuration Parameters at PDR- Coil Envelope = 2 x 1.675 x 4.671-in Current / Coil = up to 831-kA- turns Number of turns = 20, 20, 18 Conductor size =.391 x.350-in Copper packing fraction = 78% Insulation = 2 half-lapped layers, 0.004 glass Groundwrap = 0.030-in glass, 0.008-in Kapton Max Current / Turn = 41.6-kA Max Cu Current Density = 15.1-kA/cm2 4

5. Final Design Configuration Copper specification- OFHC Copper, 34-ga Wire 12x5/54/34 cable, 3240 strands Clean mfg process Insulation specification- S-2 glass with reactive amino silane finish,.004 in center and.007 at edge, (avg=0.0055-in) thick Four harness satin weave 0.391 +/- 0.010 0.350 +/- 0.010 0.413 REF 0.372 REF 0.004-in Nylon Serve Copper Strands 0.011-in Glass (2 x 0.0055) 5

6. Winding Process – Type C Winding Form 6

7. Slip Plane / Electrical Insulation 2 x 0.0035-in Kapton 7

8. Inner Chill Plates 0.040 x 2-in wide copper plate 8 Radius TBD

9. Ground Wrap Insulation 2 x 0.0065 Kapton HN 3 x 0.010 glass 9 Note: Kapton grade CR preferred over HN but performance not verified at LN temp Kapton- 5 mil thk + 1.5 mil adhesive

10. Conductor Layer #1 Lateral Shim 0.014-in nom 10

11. Layer to Layer Shim Radial shim 0.035-in nominal thk 11

12. Complete Winding Pack Component dimensions- Tee insulation = 0.007-in (kapton) Chill plate = 0.040-in (copper) Groundwrap = 0.043-in (glass/kapton) Turn insul = 0.011-in (glass) Conductor = 0.35w x 0.391h (copper) Lateral shim = 0.014-in (glass) Radial shim = 0.035-in (glass) 4.123-in REF 1.588-in REF 12

13. Allowance for Twist and Keystoning Keystone measurements made by winding conductor on 5-in dia pipe Change in height proportional to width x (width / radius) Results vary with conductor strand size, pitch, insulation, etc 2 x 0.007-in insulation 2 x 0.0055-in insulation 13

14. Winding Pack “Swelling” due to Twist Brad Nelson, 3/6/04 14

15. Outer Chill Plates / Cooling Cooling Tube.375-in Dia Chill Plates.040-in Copper Structural Clamp Asm Leads Arrangement 15 Outer Chill Plate 0.040-in thk Spacer 0.19-in nom Clamp Vert Bar Insulation layer between inner/outer chill plates

16. Thermal Performance Transient conduction/convection model has been updated for four-in-hand winding S.S. Tee Winding Cable Cu Cooling Plates Insulation Convective Cu/Kapton Boundary Layer (0.04” thick) Temp at End of PulseAnalysis Model 16

17. 3 minutes 7 minutes 15 minutes Temperature During Cooldown 17

18. Same Scale as above cases at 15 mins Automatic Scale at 15 mins Temperature At 15-Min 18

19. Temperature After 10 Cycles Temperature profile at this node 130.7 129.4 19

20. Summary The winding pack layout is acceptable conductor dimensions are maximized insulation adequate and can be wound shims provided for twist, keystoning cooling scheme is feasible 20