Procurement status of SR main magnets Attilio Milanese 23 Nov. 2013.

Procurement status of SR main magnets

Attilio Milanese

23 Nov. 2013

23 Nov. 2013 Attilio Milanese 2

Agenda

• reports and specifications•main contracts and schedule• CERN sextupole pre-series

pole tip profiles

TAC Nov. 2012 presentation


REPORTS & SPECIFICATIONS

Reports and specifications• The CERN EDMS (Engineering Data Management System) is used to

archive the magnet reports and specifications: it allows to handle access rights, to track changes, comments and approvals.


placeholder structure for deliverables of the EC project CESSAMag

Reports and specifications• Combined function bending magnets

1279692 Design Report under approval 1279694 Technical Specification released 1280708 Technical Questionnaire released

• Quadrupoles 1257123 Design Report released 1257262 Technical Specification released 1280709 Technical Questionnaire released 1279686 Technical Specification Coils released

• Sextupoles / correctors 1257260 Design Report released 1290345 Technical Specification Coils released 1279686 Technical Specification under preparation


Reports and specifications• Still missing from SESAME a formal specification of field quality,

magnet-to-magnet reproducibility and alignment tolerances• Meeting at CERN on 8 Feb. 2013 gave some tentative values, no fully

discussed and detailed with beam dynamics arguments


• target ∫ field qualitydipoles: 5 10∙ -4 for -30 ≤ x ≤ 30 mm, y = 0

QF quadrupoles: QD quadrupoles:

sextupoles (correctors off): ai, bi are of ∫ harmonics of B at R= 24 mm

• magnet-to-magnet reproducibility, as maximum deviation between each couple of magnets in the same family (peak-to-peak)

dipoles, reproducibility of ∫ central G: 1 10∙ -2 QF: 2 10∙ -3 , QD: 10 10∙ -3 , sextupoles 20 10∙ -3

• position of the magnetic axis for quadrupoles and sextupoles: 0.1 - 0.2 mm rms?• alignment of the bending magnet?• magnet-to-magnet alignment on the girder?

10 10∙ -4 10 10∙ -4

0 10∙ -4

Tentative values from Feb. meeting with Erhard at CERN

and Maher A. analyses

The case of the bending magnet

• An end pole shimming scheme for the bending magnets has been proposed.

• The three stacks can host a variable number of ferromagnetic (1) and non-magnetic (2) shims, to act on:

the ∫ field the ∫ gradient the ∫ sextupole component


• We set up techniques to analyse field maps (both from simulations and from Hall probe mapping) and to infer the linear transfer matrices of the optics, or the equivalent pole face rotation.

• Still, beam dynamics objectives are needed before the pre-series dipole is measured, to define and implement optimal shimming.


MAIN CONTRACTS


Main contracts

supply contractor country comment

16+1 bending magnets TESLA UK contract signed

32+1 QF and 32+1 QD quadrupoles ELYTT Spain contract signed

140 QF + 140 QD quadrupole coils STS Turkey contract signed

420 sextupole coil packages SEF France contract signed

32+1 sextupoles CNE Cyprus pilot order issued

32+1 sextupoles PAEC Pakistan protocol prepared

Bending magnets• 16+1 magnets + a set of spare coils• procurement of all components directly managed by the contractor• kick-off meeting 3-4 Sept. 2013 (before awarding the contract),

visiting both TESLA and the subcontractor for the punching, Midland Tool & Design

• contractual schedule Manufacturing File 25 Nov. 2013 1 pre-series dipole 25 Jul. 2014 4 series dipoles 19 Dec. 2014 4 series dipoles 25 Mar. 2015 4 series dipoles 25 Jun. 2015 4 series dipoles 25 Sept. 2015


Bending magnets• direct involvement of senior management: Ben Leigh, UK

Engineering Director, and Simon Pittard, Director of Magnet Division• parts of the Manufacturing File have already been received and

approved, in particular the coil and the drawing of the lamination• TESLA has ordered 120 t of steel (isovac 1400-100A high perm with

EB549 coating, from VoestAlpine, Austria), delivery to puncher expected beginning of Mar. 2014.

• TESLA has ordered 11 t of hollow copper conductor (from Luvata, Finland), first conductor delivery expected mid-Feb. 2014.

• The punching tooling is also in preparation, the first laminations are expected mid-Mar. 2014.

• next visit on 25 Nov. 2013, for reviewing the Manufacturing File


Quadrupoles• 32+1 QF and 32+1 QD quadrupoles• ELYTT will manage all the procurement, with the exception of the

coils, which will manufactured by STS• kick-off meeting 11 Sept. 2013 at CERN (before awarding the

contract), we had a visit to Spain in July for a similar contract• contractual schedule

1 pre-series QD and QF 12 Mar. 2014 8 series QD + 8 series QF 27 Jun. 2014 8 series QD + 8 series QF 7 Nov. 2014 8 series QD + 8 series QF 18 Feb. 2015 8 series QD + 8 series QF 14 Apr. 2015


Quadrupoles• direct involvement of the technical director, Julio Lucas• the drawing of the lamination is approved• ELYTT has ordered the electrical steel (M1300-100A with STABOLIT

70 coating, from ThyssenKrupp, Germany)• the punching tooling is in preparation with Omedec, the first

laminations are expected for mid-February 2014• the review of the Manufacturing File is scheduled for 29 Nov. 2013


CAD model of ELYTT

(work in progress)

Quadrupole coils• 140 QF and 140 QD coils• CERN provides the hollow copper conductor (from Luvata,

Finland), insulated with 2×50 mm of polyimide with epoxy layer + 3×130 mm of glass fiber (wrapping performed by Sofilec, France)

• review of Manufacturing File 10 Oct. 2013 at CERN, we had already visited them in Turkey for a contract of spare coils

• schedule Manufacturing File 11 Oct.

2013 10 pre-series QD and 10 pre-series QF coils 13 Dec. 2013 40 series QD and 40 series QF coils 28 Mar. 2014 40 series QD and 40 series QF coils 25 Jul. 2014 50 series QD and 50 series QF coils 29 Nov. 2014


Quadrupole coils• direct involvement of the owner and of the management• visit 12 Nov. 2013: first tooling prepared and first test coils wound,

an iteration is being performed to reach the target coil geometry


QD mould

QF mould

QD winding

mandrelQF test coils

Sextupole coils• 420 sextupole coil packages• CERN provides to SEF all the insulated conductor:

– the hollow copper conductor (from Luvata, Finland), insulated with 2×50 mm of polyimide with epoxy layer + 3×130 mm of glass fiber (wrapping performed by Sofilec, France)

– the enamelled copper conductor (from VonRoll, Switzerland)

• kick-off meeting at CERN on 5 Nov. 2013• schedule

20 pre-series coils 21 Feb. 2014 100 series coils 30 May 2014 100 series coils 1 Aug. 2014 100 series coils 17 Oct. 2014 100 series coils 19 Dec. 2014


Sextupoles• CERN provides to the magnet manufacturer

– the impregnated coil packages, with brazed electrical / hydraulic connections– the punched laminations– the stacking toolings– some auxiliary components (supports, cables, thermoswitches, etc)– support for manufacturing procedures and testing

• A protocol between CERN and PAEC (Pakistan) is in preparation for the supply of 32 + 1 magnets.

• A company in Cyprus (CNE Technology Center) has been selected for supplying the other 32 +1 magnets. A pilot order for manufacturing one complete yoke has been placed and the related material is on its way to Cyprus.

• A tentative schedule is given on the next page.


Schedule for main contracts


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

10/2013 12/2013 04/2014 07/2014 09/2014 12/2014 04/2015 07/2015 09/2015 12/2015

Dipoles

Quadrupoles

Quadrupole coils

Sextupole coils

Sextupoles

III IVIII III IVIII

2014 2015

IV

• schedule broken down according to supply of batches• contractual schedule for dipole, quadrupoles, quadrupole coils and sextupole coils• estimated schedule for sextupoles

Acceptance and magnetic measurements• Bending magnets

Acceptance tests and magnetic measurements at ALBA Draft of the measurement procedure already underwent a

couple of iterations, the alignment procedure is being particularly discussed (still pending the alignment tolerances from SESAME)

• Quadrupoles and sextupoles Acceptance tests at CERN Magnetic measurements at SESAME

• Other components Quadrupole / sextupole coils will be qualified at CERN Checks of laminations and other samples at CERN



1st assembly of CERN sextupole pre-series(electric and hydraulic circuits in test configuration)

(already in an accelerator tunnel, the ISR!)

correctors

circuits viewmain sextupole

view

-0.4

-0.3

-0.2

-0.1

0.0

0.1

0.2

0.3

0.4

0 20 40 60 80 100 120

B9[mT]

z [mm]

cent

er

L iron

L mag

n

Field quality of CERN sextupole pre-series


The allowed harmonics are extremely good: the pole profile is confirmed. a6 = 0.9 due to a solenoidal loop on the lead side: avoiding that would lower a6 to 0.3 (tried experimentally). The other non allowed harmonics (octupole and decapole), can be further reduced by improving the symmetry of the assembly.

multipoles in 10-4 @ R = 24 mm

∫b9 = 0 and with no end pole chamfer thanks to a biased b9 in 2Db9,2D = 12.8

-1.2

1.2

-0.7

0.3

0.4

-0.1

1.0

-3.8

0.9 0.8

-0.1

-4.5

-3.5

-2.5

-1.5

-0.5

0.5

1.5

4 5 6 7 8 9 10 11 12 13 14 15

bn

an

allowed

allowed

Opera-2D model

Opera-3D model

Rotating coil measurements

-1.2

1.2

-0.7

0.3

0.4

-0.1

1.0

-3.8

0.9 0.8

-0.1

-4.5

-3.5

-2.5

-1.5

-0.5

0.5

1.5

4 5 6 7 8 9 10 11 12 13 14 15

bn

an

-1.2

1.2

-0.7

0.3

0.4

-0.1

1.0

-3.8

0.9 0.8

-0.1

-4.5

-3.5

-2.5

-1.5

-0.5

0.5

1.5

4 5 6 7 8 9 10 11 12 13 14 15

bn

an

∫b9 = 0

• Results of magnetic measurements considering also coupling between the main sextupole and the different circuits are being analysed by Louis Walckiers.

• Preliminary frequency tests show no measurable attenuation till at least 200 Hz.

CERN pre-series correctors (in sextupole)


vertical dipole horizontal dipole skew quadrupole

A precisely punched lamination


• Omedec (France) delivered the first punched laminations within the specified tolerances at the first iteration.

• Extract from the CERN Metrology report (the red lines are at ± 25 micron) below.

Sextupole toolings / assembly procedures• Winding tooling and impregnation mould for coil packages: drawings

shared with the coil manufacturer, to speed up the procurement

• Stacking tooling for yoke: see next slide• Assembly procedures / quality control

Procedures are being prepared to detail the alignment and curing of the sextants, the precision assembly of the sextupole

Quality controls templates are also in preparation23 Nov. 2013 Attilio Milanese 24

Stacking tooling: 5 ready (for series yokes)


Sextupole, steel is on the move


electrical steel on its way to be punched

electrical steel after being punchedstacking tooling ready to

be shipped to a magnet

manufacturer


TO CONCLUDE

A wide effort



Special thanks to • the EC for the CESSAMag funds, FP7 contract 338602• all the colleagues at CERN working on the procurement of these

magnets, in particular the Magnet Normal Conducting section, the Procurement Office, the Legal Service and the Logistics

• the colleagues at ALBA and other light sources for useful discussions and their availability during the numerous contacts

thank you

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Procurement status of SR main magnets Attilio Milanese 23 Nov. 2013.

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