October 4-5, 20101

Electron LensSuperconducting Solenoid

Michael Anerella

October 4, 2010

Electron Lens

October 4-5, 20102

Outline

Outline of Presentation

Technical Overview Cost & ScheduleRisk ManagementValue Management Project TeamESSH/Quality Assurance Configuration ManagementSummary

October 4-5, 20103

Project Scope

Design, Build and Test 2 eLens Solenoid Magnets:

(under 2 AIP Projects)

• Magnetic, mechanical, electrical requirements as specified by C/AD

• Conduct ongoing communications & meetings to significantly clarify scope, improve design and performance

• Maintain cost control • Deliver 1st magnet by November 2011, 2nd magnet by March

2012

October 4-5, 20104

Magnetic Design – solenoids

Integrated Main Solenoid / Trim Solenoid / Fringe Field Solenoid / Anti-Fringe Field Solenoid / Dipole Correctors provide

- Performance + Versatility -• 5 x 10 -3 field uniformity from 3T to 6T• ± 50 microns field axis straightness over ± 1050mm from 3T

to 6T• (Fringe Field solenoid (needed to address field between

Solenoid and adjacent magnets) / Correctors (formerly room temperature) all added after “job award”, during design phase)

SC solenoid

Copper magnets

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Trim

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ain

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noid

October 4-5, 20105

Magnetic Design – slotted correctors

• Performance improved by block design– Greater efficiency by placing turns closer

to midplane– Smaller losses between 0.5m patterns by

placing adjacent coils closer together• Radial space conserved by using 45°

patterns and placing vertical and horizontal dipoles at same radial position

October 4-5, 20106

Mechanical Design – Coils (1)

Goal 1• To support the 1700 psi radial force at 6T• Method:

– Provide a 6mm stainless steel support sleeve– Expand the sleeve at assembly by heating to 80°C

(0.3mm interference); 36000 psi tensile stress in sleeve– Taper the sleeve to coil (G10) mating surface by 8 mm to

facilitate installation

October 4-5, 20107

Mechanical Design – Coils (2)

Goal 2• To transmit the 133,000 LB. axial force from each outer coil

section around the main coil body.• Method

– Separate the outer coil sections with a spacer, but continuously wind inner and outer sections

– designed to transmit the load through the compression sleeve and the support tube.

October 4-5, 20108

Mechanical Design - Magnet

15 separate circuits / power lead pairs:

• 1 main solenoid

• 2 fringe field solenoids

• 5 0.5m vertical correctors

• 5 0.5m horizontal correctors

• 1 2.5m vertical corrector

• 1 2.5m horizontal corrector

Quench protection via cold diodes

Helium vessel cooled by liquid bath from RHIC supply

Outer heat shield actively cooled from 4K boil-off, inner shield conductively cooled

RHIC support posts / cryostat

October 4-5, 20109

Parts, Magnet Fabrication (“Make/Buy Plan”)

• Many components are available in stock, e.g.:– Corrector/Fringe field solenoid Superconductor – Stainless steel helium vessel– cryostat

• All remaining major components and materials to be purchased, e.g.:– Aluminum (corrector) and stainless (solenoid) support tubes

• Some parts to be fabricated in BNL machine shops, e.g.:• Corrector tube machining

• All tooling to be fabricated in BNL machine shops (subcontracted as needed)

• All subassembly work to be done at BNL• All coil fabrication, magnet assembly and testing to be performed

at BNL

October 4-5, 201010

Coil Fabrication

Test wind: feasibility + time study

Tube end insulation time study

Corrector Coils – “slotted tube”Expected benefits:Cost savingsTime (schedule) savingsReliable (proven) constructionImproved magnetic design

Smaller axial “gaps” reduce dips in fieldBlocks near midplane are more efficient → less turnsDecouples corrector construction from Direct Wind machines

Main solenoid – “direct wind”Expected benefits:accurate conductor placement using precision solenoid gantry developed for BEPC-II programUniform spacing improves field axis straightness, lessens demands on correctorsReliable (proven) construction

BEPC-II coil winding

October 4-5, 201011

Testing

• All coils undergo mechanical, electrical and magnetic inspections throughout the construction process as part of QA

• Coil and Yoke Assembly is cold tested in a vertical test dewar for quench performance before welding into cold mass vessel

• Cold mass vessel is pressure tested and leak checked before being installed into cryostat

• Magnet is measured magnetically at room temperature after cold test and surveyed at that time

October 4-5, 201012

Schedule Summary

Critical path shown in red

Superconductor paces work

fringe, corrector coils not on critical path

Meets 4/12 need date

October 4-5, 201013

Schedule Status

• Preliminary design - complete• Final design – 90% complete, working out final details to optimize magnetic

performance• Coil Fabrication:

– Corrector Coils: Superconductor available; purchase order for insulating with Kapton

placed, first shipment due end of October Aluminum support tube purchase order placed, tubes fabricated &

being shipped now Mechanical model / drawing for machined coil blocks in tube

complete, order being placed with BNL machine shop– Solenoid coils:

Superconductor order placed, delivery 12/2010 Support tube order placed Machined tube model /drawing complete, order to be placed with

BNL machine shop– Fringe field solenoid coils:

Same superconductor as corrector coils Final strength & proximity to main solenoid being finalized; parts to

be made by SMD immediately thereafter

October 4-5, 201014

Cost DetailsCost Details

Cost Estimate Methods:• Material:

– Actual cost for similar parts on previous programs– Vendor quotes on key items

• Labor:– Time studies for critical activities (coil winding, insulating,

etc.)

(see W. Fischer talk for other program costs)

Superconductor 84

Coil 89

Cold Mass 294

Magnet 636

Total 1103

ARRA funding

$KSuperconducting Solenoid Magnet

October 4-5, 201015

Risk Management

Coils are on critical path:– Early design specified direct wind of corrector coils;

competed for resources with solenoid coils.– Redesign of correctors as hand-wound block coils

saved schedule and cost, PLUS enabled work to be completed in parallel by alternate personnel

October 4-5, 201016

Value Engineering

• Use existing designs, materials, etc. wherever possible– Existing spare RHIC CQS cryostat– Surplus IsaBelle stainless steel helium vessels– Stock RHIC Ultem support posts

• Incorporation of Fringe Field Solenoid, Corrector Coils into superconducting magnet system:– Increased Solenoid costs, but reduced other eLens

program costs (i.e. change is cost neutral) and improved eLens performance

October 4-5, 201017

Project Team

• Scientist, Magnetic Design – Ramesh Gupta

• Mechanical Engineer, Magnet – Steve Plate

• Mechanical Engineer, Coils – Andy Marone

• Mechanical Engineer, Design – Paul Kovach

• Electrical Engineer, Coils – John Escallier

• Electrical Engineer, Tooling – Piyush Joshi

• Scientist, Magnetic Measurements – Animesh Jain

• Scientist, Cold Test – Joe Muratore

October 4-5, 201018

Environmental, Safety, Security, and Health (ESSH)

• Assigned ESSH representative – Steve Moss• Regular Safety inspections of Shop Floor• Safety review and approval on all drawings and

work procedures• Weekly safety meetings with staff

October 4-5, 201019

Quality Assurance

• Assigned QA representative – Ed Perez• QA review and approval on all drawings, work

procedures and purchase orders• Incoming inspection on all parts

– BNL (Magnet Division or Fabrication Services Division)

– At vendors before shipment or with delivery• Test / inspection points throughout the

construction process:– Mechanical– Electrical– Magnetic

October 4-5, 201020

How is Work Controlled?• PICS - Part and Inventory Control System• Developed at BNL Superconducting Magnet

Division• Windows-based software and database

Configuration Management

Features:Inventory control, including Lot or Serial #’s and locationCreation, approval and control of written work procedures with Revision controlKitting of parts for work ordersEnd item documentation, including as-built configuration

All QA, testing and safety precautions built into documentation

sample traveler

October 4-5, 201021

Summary

• The magnet requirements are challenging but achievable.

• Performance objectives reflect a good continued communication between SMD and C/AD; magnet is much better than original specification

• Work is started and is progressing in support of the Project Budget and Schedule

• Experienced personnel (RHIC AGS Snake, RHIC Helical, BEPC-II, LHC, etc.) are available and working