1 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Magnet Production Status Satoshi Ozaki, Manager, SR...

1 BROOKHAVEN SCIENCE ASSOCIATES

Storage Ring Magnet Production Status

Satoshi Ozaki, Manager, SR Magnet Production

9th ASAC Meeting for the NSLS-II Project

February 1-2, 2012


Contents

• Comparison with the conclusions from the last ASAC Meeting in May 2011• Magnet production status

• Multipole Magnet Production: Status and Trend Analysis of Magnet Quality• Dipole Magnet Production: Resolution of Difficulties, and Production Status • Correctors: Production Status and the Skew Corrector Issues

• Lessons Learned Workshop• Summary and Conclusions

SR Magnet Procurement Technical Representatives:Sushil Sharma BINP (Russia)John Skaritka IHEP (Beijing, China)Lewis Doom Danfysik (Denmark)Charles Spataro Tesla Engineering (United Kingdom)Frank DePaola Buckley Systems Inc (New Zealand)George Rakowsky Everson/Tesla (USA)


SR Magnets (Types and Numbers)Mgt Type Code Description Part No. Maker QuantityQuadrupole Type A Single-coil, Short & Wide 9801 BINP 30

Type B Single-coil, Short & Narrow 9802 BINP 30Type C Double-coil, Long & Narrow 9804 BINP 30Type C' Same as above, with Cutout 9807 BINP 30Type D Double-coil, Short & Narrow 9809 Tesla 90Type E Double-coil, Short & Wide 9812 Tesla 30Type F Large Aperture, Short & Narrow 9815 BSL 60

Sub Total 300Sextupole Type A Single-coil, Short & Narrow S-9801 Danfysik 150

Type B Single-coil, Short & wide S-9802 IHEP 75Type C Large Aperture, Short & Wide 9816 BSL 30

Sub Total 255Dipole Type A Dipol-35 mm 3500 BSL 54

Type B Dipole 90 mm 9000 BSL 6Sub Total 60

Corrector Type A Corr-100 mm 1000 Everson 90Type B Corr-100 mm with Skew Quard 1001 Everson 30Type C Corr-156 mm 1560 Everson 60Type F Corr-Fast 2002/3 SHI 90

Sub Total 270Total 16 Types 885


Multipole Magnet Production

• The last ASAC Meeting took place when the technical difficulties with the magnet suppliers were just about resolved, and entering into the production phase with all but a few of the manufacturers.

• At that time, I summarized the situation as: • Our supplier can build acceptable multipole magnets, and multipole magnet

productions are either in progress or about to begin.• Although some of the manufactures, Danfysik, Everson, and possibly BINP are

already in a routine production, a few more months of ramp-up time is anticipated for others to reach a routine production and delivery stage.

• Since then, good progress has been made with all of the suppliers, and in some cases, the series production is coming close to an end.


Delivery for the NSLS-II Multipole Magnets

Spec Code Manufa

ctu

rer

Ord

er

Quantity

PR

R D

ate

Sep-1

0

Oct-

10

Nov-1

0

Dec-1

0

Jan-1

1

Feb-1

1

Mar-

11

Apr-

11

May-1

1

Jun-1

1

Jul-11

Aug-1

1

Sep-1

1

Oct-

11

Nov-1

1

Dec-1

1

Jan-1

2

Feb-1

2

Mar-

12

Apr-

12

May-1

2

Jun-1

2

Jul-12

Aug-1

2

Sep-1

2

Oct-

12

tota

l Deliv

ery

Sextupole A Danfysik169 Aug-10 1 2 27 14 7 14 14 14 14 14 14 14 14 6 16952 0 0 4 15 14 14 11 14 14 14 0 17 169

Sextupole B IHEP 75 Apr-11 2 1 1 2 1 4 7 11 11 11 11 13 756 5 0 0 7 10 2 12 11 11 0 11 75

Sextupole C Buckley 30 Mar-12 1 1 1 2 2 2 2 3 3 3 3 3 3 1 303 0 0 2 0 3 5 2 3 3 3 3 3 30

Quad A Budker 30 Apr-12 1 1 1 2 3 3 3 3 3 3 3 3 1 303 0 0 9 0 4 3 3 4 4 30

Quad B Budker 30 Apr-12 1 1 1 2 3 3 3 3 3 3 3 3 1 303 0 0 4 0 4 5 5 5 4 30

Quad C Budker 30 Apr-12 2 1 2 3 3 3 3 3 3 3 3 1 303 0 0 2 0 4 5 5 6 5 30

Quad C' Budker 30 Apr-12 1 2 3 3 3 3 3 3 3 3 3 301 2 0 0 0 3 5 5 6 8 30

Quad D Tesla 90 May-12 3 2 4 2 9 9 9 9 18 9 9 7 903 0 0 1 0 2 4 1 9 9 9 9 9 9 9 9 7 90

Quad E Tesla 30 May-12 1 2 2 1 3 3 3 3 6 2 2 2 301 1 0 0 1 0 2 1 3 3 3 3 3 3 3 3 30

Quad F Buckley 60 Apr-11 1 1 1 2 4 4 4 4 4 6 6 6 6 6 5 603 0 9 8 0 4 11 6 6 4 4 5 60

Total Delivered by Month 75 8 9 21 23 44 53 48 63 61 33 31 32 12 12 12 574Cumu Total Delivered 75 83 92 113 136 180 233 281

Delivery plan as of May 2011 Delivered <June 30, 2011 Actual Delivery and Current Plan

In total, just about one half of the multipole magnets have been already delivered to BNL.


Statistics of Multipole MagnetsEvaluation Based on the Measurements at BNL

• Most of the magnets delivered have passed incoming inspections, which include a visual inspection for any damage, some dimensional checks, water flow in leak tightness checks and high-potting, but some required work such as re-hanging of coils to ensure the vacuum chamber clearance, re-work on the water manifold, etc.

• The sampling rate for the in-house field measurements depends on our confidence in the suppliers capability from the accumulated experiences. The measurement included the magnetic field harmonics and check of their reproducibility after the re-assembly of the magnet yoke.

• Most of magnets perform very well with all or most of the harmonics of the field quality within the specification. Those which are outside of the specifications, were discussed with the Accelerator Physics Representative for the acceptance of the magnets for the girder assembly.

• Some examples of the integrated magnetic field strength of a series of magnets, and harmonics as a function of the excitation current, both as measured at BNL, together with the harmonics specifications and expected operating range (the red box) are shown in a number of slides which follows.

• The entire data on integrated field strength and harmonics that is available to date can be found in the Web site for this presentation.


Summary for Sextupoles

Danfysik (9801):• 43 magnets have been measured• The integrated strength variation within the series is less than 0.5%• A few magnets have large a4, b4, a5, b5, b6 which are slightly out of spec• The remaining harmonics are good for all the magnetsIHEP (9802):• 16 magnets have been measured• The strength variation is ~1%. • a4, b4, a5, b5 and b7 are the main issues, especially b5 and b7• The field harmonics of IHEP sextupoles appear to be more widely spread than

that of Danfysik and are more susceptible to the torques applied to the assembly bolts than others

Buckley (9816):• 11 magnets have been measured• The strength variation is ~1.4%• There are systematic shifts in the a11 and b11harmonics but are deemed to

be acceptable for a small number of magnets


The Sextupoles Strength Comparison

The sextupoles from two vendors will be powered by one circuit. 9802 is stronger than 9801 by about 1%.

1%

IHEP

Danfysik


Harmonics of Danfysik Sextupoles (9801)

Box indicating harmonics tolerance and tuning range


Harmonics of Danfysik Sextupoles (9801)


Harmonics of IHEP Sextupoles (9802)


Harmonics of Buckley Sextupoles (9816)


Summary for Quadrupoles

Quadrupoles are individually powered, and therefore, the variation in the integrated field strength is a matter of little concern.

BINP:• 51 of their magnets in 4 different types have been measured• They all show good field quality, and meet the specificationsTesla:• 9 magnets have been measured • Most of the harmonics data are good but there are difficulties with the systematic shift in

the b6 harmonics, which most likely arises from the pole chamfer size and is correctableBuckley:• 21 magnets have been measured• In general, the harmonics look good, but have some problems with the a5 and a6

harmonics, which are deemed to be acceptable for a small number of magnets


Harmonics of BINP Quadrupoles (9801)


Harmonics of Tesla Quadrupoles (9809)


Harmonics of Buckley Quadrupoles (9815)


Tesla Quadrupole Production: Concerns

• Tesla Engineering reached a routine manufacturing state only in mid-December, 2011, and produced 10 quadrupoles during January 2012.

• Considering that this was right after the holiday vacation period, and at the beginning of the series production, with a reasonable learning curve, we expect that they can reach a required rate of production in the coming months.

• The back-up for the Tesla quadrupole production is BINP, which has a contract with us to build seven first articles of Tesla type quadrupoles with an option to build additional quintiles (e.g. 30 magnets).

• Due to the fact that the BINP quadrupoles have the poles narrower than that of Tesla’s, this back-up quadrupole is longer by a few cm than that of Tesla, in order to achieve similar integrated gradient strength. This led the Accelerator Physics requirement that these quadrupoles not to be mixed arbitrarily with the Tesla quadrupoles, giving a constraint to the number of magnets of each type to install.

• The proper timing for exercising this option is approaching, if the delivery of the back-up magnets are to be completed by late summer of 2012. Incidentally, the option of 30 quadrupoles from BINP will cost ~$730K.

• We will carefully monitor the progress at Tesla for the next several weeks, and make a decision on this option before the end of February 2012.


Dipole Magnet Production

• The difficulty Buckley Systems, Inc. had with the bonding of the 35 mm dipole yoke was overcome by building a new jig that is much stronger and sturdier, and with more than twice as many tie rods to apply higher bonding pressure more uniformly over the laminations.

• Since the dipoles will be mounted on their own girder, their assembly and alignment on the girders is simple. In fact, the dipoles will be delivered directly to the ring building, where the incoming inspection, assembly, alignment will take place before being installed in the tunnel.

• This permits us to allow the last delivery of the dipoles to be delayed until the end of 2012 or early 2013.

• The field quality of the dipoles, both the 35mm gap and the 90mm gap types, are acceptable, and the integrated vertical fields of the dipoles are uniform within the required tolerance.


Spec Code Man

ufac

ture

r

Ord

er

Qua

ntity

PR

R D

ate

Sep

-10

Oct

-10

Nov

-10

Dec

-10

Jan-

11

Feb

-11

Mar

-11

Apr

-11

May

-11

Jun-

11

Jul-1

1

Aug

-11

Sep

-11

Oct

-11

Nov

-11

Dec

-11

Jan-

12

Feb

-12

Mar

-12

Apr

-12

May

-12

Jun-

12

Jul-1

2

Aug

-12

Sep

-12

Oct

-12

Nov

-12

Dec

-12

Jan-

13

Feb

-13

Mar

-13

tota

l Del

iver

y

35mm Dipole Buckley 54 Sep-11 1 1 1 3 4 4 4 4 4 4 4 4 4 4 4 4 54Published Delivery Plan 1 1 1 1 2 2 4 4 4 4 5 5 5 5 5 5 54Aggressive Delivery Plan 1 1 1 2 4 4 4 4 6 6 6 6 6 3 54

90mm Dipole Buckley 6 Jun-11 1 1 1 1 1 1 6Published Delivery Plan 1 1 1 1 1 1 6Aggressive Delivery Plan 1 1 1 2 1 6

Delivery Plan as of May 2011 Delivered <June 30, 2011 Actual Delivery and Current Plan

The 90 mm dipole stacking and bonding jig was designed to work on the 35 mm dipole also. The mutual understanding between Buckley Systems, Inc. and the NSLS-II Project, is that the monthly production rate of the 35 mm dipoles will be enhanced from four to five per month, or more aggressively from four to six per month, the latter depending on the Buckley’s own V100 Machining Center.

Delivery for the NSLS-II Dipole Magnets


Spec Code Man

ufac

ture

r

Ord

er

Qua

ntity

PR

R D

ate

Sep

-10

Oct

-10

Nov

-10

Dec

-10

Jan-

11

Feb

-11

Mar

-11

Apr

-11

May

-11

Jun-

11

Jul-1

1

Aug

-11

Sep

-11

Oct

-11

Nov

-11

Dec

-11

Jan-

12

Feb

-12

Mar

-12

Apr

-12

May

-12

Jun-

12

Jul-1

2

Aug

-12

Sep

-12

Oct

-12

Nov

-12

Dec

-12

Jan-

13

Feb

-13

Mar

-13

tota

l Del

iver

y

Corr X/Y 100 Everson 60 Oct-10 2 3 2 7 8 5 6 5 5 5 5 5 2 6022 5 6 7 1 6 3 5 5 60

Corr X/Y 156 Everson 102 Oct-10 2 4 5 14 8 9 12 8 8 8 8 8 8 10233 9 12 11 0 13 12 8 4 102

Corr X/Y/Skew Everson 30 Oct-10 1 1 2 2 4 2 0 4 2 2 2 2 4 2 3010 2 0 0 0 0 0 0 0 4 4 4 4 2 30

Delivery Plan as of May 2011 Delivered <June 30, 2011 Actual Delivery and Current Plan

Delivery for the NSLS-II Corrector Magnets

Production of the X/Y Correctors, both the 100 mm and the 156 mm length is coming to an end with an expectation that the delivery of the last magnet will be at the end of January 2012.

Production of the Correctors with skew corrections coils is presently on hold as described in the nest slide.


Skew Corrector Magnet Issue

• During the last summer, it was discovered that there is a very large a4 (skew octupole) term generated by the skew quadrupole coil assembly that will be mounted on 30 of the 100 mm X/Y Correctors.

• Re-design of the skew coil assembly is complete and the contract modification will be made soon.

• A prototype of the new design will be available in six weeks after the contract modification is signed and the production of the new skew corrector coils will follow soon after.


Fast Correctors

Integrated Air-core X&Y Coil Pair Assembly

• Orthogonality tolerance: 15 mrad• Max. horizontal bending angle: 14 rad• Max. vertical bending angle: 15 rad • Max. phase shift without vacuum chamber* @10 kHz: 5 • Max. phase shift with vacuum chamber* @1 kHz: 5

*: Vacuum chamberPipe material: Inconel 625Flange material: Type 304L or 316L Stainless

Steel

A contract negotiation is in progress with a local manufacturer “Sag Harbor Industries” for production of 90 units.

The Fast Corrector will be mounted on the vacuum chamber near its flange after the girder assembly and alignment are completed.


The SR Magnet Production at a Glance

January 13, 2012

Magnet Production Summary

Man

ufac

ture

r

Uni

ts to

be

built

last

upd

ated

yoke

s sta

cked

asse

mbl

ies

rece

ived

read

y fo

r gird

er

% C

ompl

ete

Quad-SC-S-W Budker 30 1/13/12 30 29 19 13 91.2%Quad-SC-S-N Budker 30 1/13/12 30 24 16 11 86.3%Quad-DC-L-N Budker 30 1/13/12 30 24 14 7 83.3%Quad-DC-L-N Budker 30 1/13/12 30 24 13 8 83.3%Quad-DC-S-N TESLA 90 1/13/12 44 14 9 9 27.6%Quad-DC-S-W TESLA 30 1/13/12 15 6 5 5 30.9%

Sext-S-S-N Danfysik 169 1/5/12 125 118 100 43 69.8%Sext-S-S-W IHEP 75 1/5/12 69 40 32 12 68.7%

Quad-LA Buckley 60 1/13/12 67 51 41 21 94.1%Sext-LA Buckley 30 1/13/12 36 23 15 11 93.3%Dipol-35 Buckley 54 1/13/12 9 6 3 1 12.3%

Dipole 90 Buckley 6 1/13/12 2 1 1 0 20.0%Corr-100 Everson 102 1/5/12 102 85 91 71 89.3%

Corr-100-SQ Everson 30 1/5/12 16 12 12 2 43.7%Corr-156 Everson 60 1/5/12 51 48 53 47 83.3%

SUMMARY 826 1/19/12 656 505 424 261 67.0%

> 50% Received


NSLS-II SR Magnet Production Workshop

• One of the action items from the last DOE Review of the NSLS-II Project, was to produce a document for the lessons learned in the procurement and manufacturing of the SR Magnets from the industries.

• In order to collect the information from all of those involved, a workshop is being organized and is scheduled to be held on April 11 – 13, 2012.

• In addition to those NSLS-II Staff members, we intend to invite the magnet suppliers and other interested parties if they wish to participate in this workshop at their own expense.


Summary and Conclusions

• Good progress has been made since last May • As of today, a little more than half of the magnets have already been

delivered to BNL• The mix of multipole magnets being delivered is in general

satisfactory to support the two-girders per week assembly rate that will be later discussed by Lewis Doom

• Although not all of the magnets received from our suppliers are perfect, their quality, by and large, is acceptable for the NSLS-II’s precision storage ring

• With the current agreed upon delivery schedule, even with the delivery of the last 35mm dipoles in March 2013, the SR Magnet deliveries should not impact the commissioning schedule

• Never-the-less, continued close monitoring of the suppliers is imperative for the timely completion of this job, particularly at Tesla

1 BROOKHAVEN SCIENCE ASSOCIATES Storage Ring Magnet Production Status Satoshi Ozaki, Manager, SR...

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