EIC-NCMAG-RFI-002 - RFI for ESR Magnet Coils.pdf

EIC NC Magnets

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Request for Information (RFI) ESR Magnet Coils Document Number: EIC-NCMAG-RFI-002 Creation Date: 20 July 20, 2026

Revision Number: -

Author: Chase Dubbe’ Project: EIC - ESR

EIC - ESR Magnets

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Table of Contents 1 Acronyms 3

2 Introduction 3

3 Scope 3

4 Magnet Functional Specifications 3

4.1 Quadrupole & Sextupole Coil Types and Quantities 3

4.2 Corrector Coil Types and Quantities 4

5 Fabrication and Material Requirements 4

5.1 Quadrupole & Sextupole Magnet Coils 4

5.1.1 Copper Conductor 4

5.1.2 Water Fittings 4

5.1.3 Coil Electrical Insulation 4

5.1.4 Coil Vacuum Impregnated Epoxy 4

5.1.5 Coil Vacuum Infusion Tooling 5

5.2 Corrector Magnet Coils 5

6 Quality Assurance, Contractor Required Testing 5

6.1 Quality System 5

6.2 Responsibility for Conformance 5

6.3 Configuration Management 5

6.4 Measuring and Test Equipment (M&TE) Calibration 5

6.5 Responsibility for Inspections and Tests 6

6.6 Contractor Acceptance Tests 6

7 Contractor Responsibility, Planning and Reports 6

7.1 Contractor Responsibilities 6

7.2 Information Provided to Contractor 7

8 Procurement Plan, Procurement Options 7

8.1 Magnet Procurement Specifications and Drawings 7

8.2 Procurement Plan and Procurement Options 7

9 Delivery Schedule 7

9.1 Magnet Delivery 7

10 Preparation for Delivery 8

10.1 Packaging 8

10.2 JLAB Delivery Address 8

11 Release and Revision History 8

12 Approvals 8

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1 Acronyms

Use this section to define any acronyms that are in the document

• JLAB – Thomas Jefferson National Accelerator Facility (Jefferson Lab)

• BNL – Brookhaven National Laboratory

• EIC – Electron Ion Collider

• RFI – Request for Information

• SOW – Statement of Work

• LCW – Low Conductivity Water

• ESR – Electron Storage Ring

2 Introduction

The purpose of this Request for Information (RFI) is to gain understanding of possible cost and schedule for the quantity of different magnet coil types for use in Electron Storage Ring (ESR) of the Electron Ion Collider

(EIC) which will be installed at Brookhaven National Laboratory (BNL). The magnet coils would be procured either by build to print per technical drawings, or per technical specifications.

3 Scope

This document provides basic information as follows:

1. The magnet coil types and quantities to be procured in support of the ESR

2. Magnet Coil Performance and design requirements: Coil dimensions, details, insulation, and testing requirement.

3. Requirements of Request for Proposal

4 Magnet Functional Specifications

4.1 Quadrupole & Sextupole Coil Types and Quantities

Table 4-1 below gives the basic specifications and quantities for the ESR Quadrupole and Sextupole magnet coils. Additional specifications and details are in the Coil Drawings referenced in this table.

Magnet Coil ID Coil Drawings Qty Turns Conductor Size (mm x mm)

Conductor ID (mm)

Coil Dimensions

L x w (in)

Conductor Length (ft)

Q50 - LH MAG-005-0025-0001-01 100a 33 11 x 11 5 22.9 x 6.57 139 Q50 - RH MAG-005-0025-0002-01 100a 33 11 x 11 5 22.9 x 6.57 139 Q60 - LH MAG-005-0025-0001-02 50 33 11 x 11 5 26.83 x 6.57 161 Q60 - RH MAG-005-0025-0002-02 50 33 11 x 11 5 26.83 x 6.57 161 Q80 - LH MAG-005-0025-0001-03 50 33 11 x 11 5 34.71 x 6.57 206 Q80 - RH MAG-005-0025-0002-03 50 33 11 x 11 5 34.71 x 6.57 206

QN80 MAG-005-0026-0004 80 24 10 x 10 6.5 34.65 x 7.72 150 QLA TBD 40 40 14 x 14 11 444 SA 310103-00166-03 80 42 5 x 7.5 1.8 x 4.2 4 x 12.185

Table 4.-1: Quadrupole and Sextupole Coil Specifications.

Note a: Initial quantities of 4 of each Q50 coil type shall be ordered as part of an engineering verification unit.

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4.2 Corrector Coil Types and Quantities

Magnet Coil ID Coil Drawing Number Quantity Turns Conductor Size

(AWG)

Coil Dimensions L x W (in)

Conductor Length (ft)

TH MAG-002-0027-0003 400b 231 12 Heavy Build Square 10.92 x 7.81 607 TV MAG-002-0028-0003 400b 390 10 Heavy Build Square 14.58 x 7.67 1225

TLA TBD 20 286 10 Heavy Build 1500 Table 4.-2: Corrector Coil Specifications.

Note b: Preliminary quantity of 2 TH and 2 TV coils would be ordered as part of an engineering verification unit.

5 Fabrication and Material Requirements

5.1 Quadrupole & Sextupole Magnet Coils

The quadrupole magnet coils shall be Oxygen-Free High Conductivity (OFHC) copper coils. The coils shall be electrically insulated turn to turn and coil to ground with a fiberglass/vacuum impregnated epoxy system as described herein.

The Contractor is responsible for designing and fabricating all the tooling necessary and developing the methods needed to consistently wind the coils and to install the water fittings and plugs.

5.1.1 Copper Conductor

The quadrupole coil conductors shall be hollow oxygen-free electrolytic copper (OFHC), with an annealed electrical conductivity of 101% of IACS 20C in accordance with ASTM-B170-99. The quadrupole coil conductor cross-section and centered water-cooling hole shall be as defined in Table 4-1, and the corrector coil wire gauge size shall be as defined in Table 4-2 for the respective magnets.

5.1.2 Water Fittings

The quadrupole and sextupole magnet copper coils shall use threaded stainless-steel pipe thread fittings brazed into the copper coil ends or sides near the coil ends. The fittings shall be brazed with a braze metal alloy and flux specific to copper to stainless steel joints.

5.1.3 Coil Electrical Insulation

The turn-to-turn insulation shall consist of glass fiber tape, amino-silane treated pure E-glass tape or approved equivalent, half-lap wound during the coil winding process. The final wrapped turn- to-turn tape insulation shall be a minimum of 0.5 mm (0.020") thick.

The completed wound coil shall have an additional outer wrapping of glass fiber tape, amino- silane treated pure E-glass tape or approved equivalent, half-lap wound to provide ground insulation. This additional outer layer shall be a minimum of 1.0 mm (0.040") thick. Additional fiberglass roving or G10 filler blocks shall be used to eliminate any voids/un-reinforced epoxy only volumes at the transitions between the coil layers or near the coil end termination lead transitions or other locations before the final ground insulation winding.

5.1.4 Coil Vacuum Impregnated Epoxy

After wrapping with fiberglass, the magnet coils shall be vacuum infused with a heat/high temperature activated epoxy that will allow time for vacuum degassing of the epoxy and complete infusion of the epoxy into the coil insulating material. This system shall provide a cured monolithic coil assembly with excellent bonding between the copper, epoxy, and fiberglass. There shall be no voids, cracks, or unreinforced epoxy

ESR Magnet RFI Page 5 of 8 resin volume in the completed coil assembly. The completed coils shall not be painted and no pigments are to be used in the epoxy. The epoxy shall be translucent to allow internal inspection after curing.

From previous experience, a mixture of DER 332 (Dow Chemical/Olin Epoxy) DGEBA Resin and DER 736 (Dow

Chemical/Olin Epoxy) Polyglycol Flexible Resin cured with NMA (Allied Chemical Company) Nadic Methyl

Anhydride and DMP-30 (Rohm & Haas) Tridimethyl Amino Methyl Phenol has been proven acceptable for magnet coils. Contractors may propose and use alternate epoxies (after approval by EIC) that have equal or better physical properties and resistance to nuclear radiation at a minimum exposure of 1 x 10

Gy than the specified system.

5.1.5 Coil Vacuum Infusion Tooling

The Contractor is responsible for developing the infusion procedures and designing and fabricating the epoxy degassing system, plumbing, and coil form potting fixture. The coil form potting fixture shall be designed to withstand the cure vacuum/pressure cycle necessary and to provide completed coils that meet the specified coil dimensions. Epoxy curing and coil sizing shall be performed simultaneously.

5.2 Corrector Magnet Coils

The corrector coils shall be made of a single piece length of heavy build square copper wire, wet wound in the dimensions as specified in the referenced technical drawings. The conductor shall be wet wound with epoxy EPON 81C with EPIKURE 3140, or a Jefferson Lab approved alternative. The coil and epoxy shall be cured at the temperature recommended by the epoxy manufacturer. The finished coil shall be wrapped with

.0025 thick Kapton tape under tension, with a 50% overlap.

The Contractor is responsible for designing and fabricating all the tooling necessary and developing the methods needed to consistently wind the coils.

6 Quality Assurance, Contractor Required Testing

6.1 Quality System

The Contractor shall maintain a documented quality assurance (QA) system, which provides the processes to ensure that each magnet produced for acceptance conforms to the requirements of the applicable technical specifications. It is preferred that the QA system meets the requirements of ISO-

9001. The Contractor shall create and maintain a system of travelers for the magnet manufacturing, materials certifications, testing, and inspection. These records shall be part of certificate of conformance provided with each delivered magnet.

6.2 Responsibility for Conformance

The quality requirements set forth in a future purchase order shall become part of the Contractors overall inspection/test program. Acceptance of articles under the test provisions shall not relieve the

Contractor of the responsibility of ensuring that the magnets meet the design requirements and comply with all requirements of the contract or purchase order.

6.3 Configuration Management

The Contractor shall establish and maintain a system to assure that all magnet coils are of the proper configuration, and that all approved configuration changes are documented and incorporated at the specified affected points.

6.4 Measuring and Test Equipment (M&TE) Calibration

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The Contractor shall calibrate any M&TE used for the fabrication, testing, or inspection of the magnets that are traceable to national standards such as the National Institute of Standards and Technology

(NIST).

6.5 Responsibility for Inspections and Tests

The Contractor shall be responsible for inspections and tests listed herein using their own equipment and facilities. EIC may repeat some of these inspections and/or tests after delivery to assure that the magnet coils meet EIC requirements.

6.6 Contractor Acceptance Tests

The following acceptance tests and inspections shall be performed at the Contractor’s facility prior to shipping each magnet to verify that they meet the EIC requirements. The tests shall be documented in the Contractor traveler system:

1. Coil dimensional measurement and visual inspection to confirm the coil bus cross-section, the coil turns, overall cured coil size, and the coil lead location meet the drawing requirements within specified tolerances.

2. Coil test during fabrication to verify that the water passage has not diminished due to poor extrusion quality, coil winding, or the installation of brazed joints.

3. Coil water passage leak check prior to coil epoxy infusion and after infusion to verify that the material, brazed joints, water end fittings, and end plugs are leak tight. This test shall be performed at a water pressure >150 psi.

4. Coil water flow rate test after infusion.

5. Coil ground insulation test after epoxy infusion and cure. The high field magnet coils shall be tested to 2.5 kV between the copper bus and the outer epoxy insulated surface.

6. Coil turn-to-turn insulation test performed by ringing or pulsing the coil and checking the wave form.

Good wave form Poor wave form

7. Coil resistance verification from lead end to lead end.

7 Contractor Responsibility, Planning and Reports

The Contractor shall furnish all equipment, materials, tools, inspection equipment, facilities and labor to perform the work necessary to manufacture, inspect, and ship the magnet assemblies.

7.1 Contractor Responsibilities

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1. Manufacturing planning, staff and equipment planning, and all material procurement.

2. Design and fabrication of manufacturing, inspection, and testing fixtures and tooling.

3. Fabrication of the magnet coils that meet the EIC requirements.

4. Status reports (bi-weekly), status meetings, and in-process inspection reports.

5. Inspection and testing.

6. Packaging and delivery of the magnet coils and traveler/inspection/ test reports to EIC.

7.2 Information Provided to Contractor

1. Magnet design and analysis.

2. Detailed fabrication drawings and specifications for magnet procurement.

3. Timely response to vendor suggestions, participation in status meetings, on-site vendor meetings, and on-site visits for component and testing witness points.

4. Timely inspection, magnetic measurement, magnet analysis of first article magnets for approval or possible adjustments if needed.

5. Timely inspection, testing, and acceptance upon delivery of production magnets coils

8 Procurement Plan, Procurement Options

8.1 Magnet Procurement Specifications and Drawings

Magnet procurement for EIC will be through either:

1. Detailed Build to Print with EIC Provided Drawings with detailed fabrication drawings for all component parts provided with dimensions, dimensional tolerances, material requirements, and supporting specifications which are similar but more detailed than those provided in this

RFI document. or

2. Build to Specification. The coil will have detailed coil design requirements and a supporting coil drawing with tolerances. The Contractor will submit information and drawings during design reviews for approval by the EIC technical representative.

8.2 Procurement Plan and Procurement Options

The different magnet coil types described herein may be procured separately, each with dedicated requests for proposals with technical and contractual procurement packages. All procurements will be for first article magnet coils with follow-on procurement options for the production quantities after successful testing of the first articles. EIC may procure first article magnet coils from more than one

Contractor to allow the option of more than one contract for production due to the large quantity of magnet coils needed.

The second stage will be the production magnet coil contract based on contract option pricing received during the initial RFP bid. EIC will request bid pricing based on different quantities for the production contract and may choose to place production contracts with multiple Contractors based on cost and/or schedule.

9 Delivery Schedule

9.1 Magnet Delivery

Delivery of Magnet coils to JLAB would be 12 to 18 months ARO

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10 Preparation for Delivery

10.1 Packaging

Vendor shall protect all magnet coils and documentation packages from damage by appropriate packing or crating. Crates or pallets shall be built to allow handling with slings from overhead cranes and for forklift transport. Packaging shall protect the coils from damage in transit and from weather during transit and outdoor storage.

10.2 JLAB Delivery Address

Use the following format for the delivery address labeling:

Jefferson Lab

12000 Jefferson Ave

Newport News

VA, 23606, USA

11 Release and Revision History

Rev # Major Changes Approval Date:

Draft Initial version

12 Approvals

This document is approved in Document Control. The Project Engineer is required as an approver. The TR may select other Subject Matter Experts and technical reviewers as checkers and approvers.

Approved by: Name: Signature: Date:

Author Chase Dubbe’ 7/20/2026

Subject Matter

Expert Robin Wines

7/20/2026

Project Engineer Sarin Philip 7/20/2026