Elena

Magnets Daniel Schoerling on behalf of WP 2.2 and WP 2.16 ELENA Project Review 14th – 15th October 2013 31-3-004 - IT Amphitheatre Daniel Schoerling TE-MSC-MNC 1 Overview A I. Introduction, scope of work package & workflow B I. Challenges and solutions for all required magnet families I. Schedule II. Summary of parameters C III. Procurement strategy IV. Conclusion Daniel Schoerling TE-MSC-MNC 2 A.I Introduction: Magnet System Daniel Schoerling • 51 magnets (incl. spare) of 7 types • Ring magnets + AD-ELENA TL magnets • Normal-conducting magnets • Water and air cooled • Mostly iron-dominated; laminated yokes • Coil cooling designed for DC operation at maximum field TE-MSC-MNC 3 Design phase Functional Specification Design Report Engineering Specification Technical Specification Procurement & Installation A.I Simplified Workflow: ELENA Magnets Tendering & Contract Award • Functional Specifications define all required information for the design. • Design Reports document the design process and the taken design decisions. Contract Follow-Up Incoming Inspection & Certification Magnetic Measurements at CERN Installation Daniel Schoerling • Engineering Specifications define the interfaces to other WPs. • Further changes of parameters will require to issue an Engineering Change Request. TE-MSC-MNC 4 B.I Magnets: ELENA Dipole Magnet Parameter Value Number 6 + 1 (Reference) + 1 (Spare) Field 0.37 T (0.42 T) to 0.05 T Pole iron gap 76 mm Bending angle 60° Radius 927 mm Magnetic length 970 mm Cut angle 13° Ramping speed (up) 0.37 T/s Ramping speed (down) 0.05 T/s Good-field-region ±2⋅10-4, 66 mm (H) x 48 mm (V) Daniel Schoerling TE-MSC-MNC 5 B.I Magnets: ELENA Dipole Prototype Challenge • Excellent and repeatable field quality is requested at very low field. Solution • Selection of high permeability electrical steel M270-50 A HP. • Dilution of electrical steel with non-magnetic stainless steel to increase the magnetic induction in the iron and avoid working in the highly nonlinear area of the BH-curve. Prototype • Manufacturing methods were studied. • Planned magnetic measurements: local and integrated dynamic effects, field homogeneity, hysteresis effects, local effect of dilution. • Concept of shimming will be tested. Comprehensive Design Study to be published as ATS report Daniel Schoerling TE-MSC-MNC 6 B.I Magnets: ELENA Ring Dipoles 10 x 10 Y-position 0 mm -5 Sextupolar + up Sextupole Octupole Decapole 8 Field Homogeneity Status • ELENA dipole prototype measurements are starting. • Magnetic design finished. • Engineering and technical specifications are under approval. Challenges • Production of the curved yoke is challenging and will require a close follow-up. • Shimming of final magnet is expected to be time intensive to achieve the requested field homogeneity of ±2⋅10-4 through out the whole working range. • Eddy currents in vacuum chambers are considered a non-issue and will be measured using the prototype. Measurement • Measurement with flux meter is challenging due to small dBy/dt: long lead item, design and production will start now. 6 4 2 0 -2 -4 -40 -30 -20 -10 0 10 x-position [mm] 20 30 40 Comprehensive Design Report to be published on EDMS #1311860 Daniel Schoerling TE-MSC-MNC 7 B.I Magnets: ELENA Ring & TL Quadrupoles Status • Magnetic design finished. • All documents for call for tender are under approval. • The design provides stable field quality over the whole required range. Challenges • The remanent gradient is only around 2 times smaller than the minimum required gradient: 2𝜇𝜇 𝐻𝐻 𝑙𝑙 𝐺𝐺res = − 0 c2 iron = 9.2 × 10−3 T/m. 𝑟𝑟 • Magnets will have to be powered by using the same cycle. • Prototype is foreseen to validate the above mentioned calculations. Measurement • Magnetic measurement of integral field will be performed with existing rotating coil system. Number of magnet 12 + 3 + 1 Field gradient 0.02-1.45 T/m Mechanical aperture 124 mm Magnetic length 250 mm Good-field-region ±5 ⋅ 10-4 at ∅54 mm Designed good-field-region 1.1 ⋅ 10-4 at ∅54 mm Design Report published on EDMS #1302869 Daniel Schoerling TE-MSC-MNC 8 B.I Magnets: ELENA Ring Skew Quadrupoles Status • Magnetic design finished. • All documents for call for tender are under approval. • Similar design as for normal quadrupole: Yoke is shorter and coils have less windings. Challenges • Same challenges as for normal quadrupole; the prototype will also answer all questions for the skew quadrupole. Measurement • Magnetic measurement of integral field will be performed with existing rotating coil system. Number of magnet 2+1 Field gradient 0.023-0.88 T/m Mechanical aperture 124 mm Magnetic length 150 mm GFR ±1 ⋅ 10-2 at ∅46 mm Designed GFR 9.2 ⋅ 10-5 at ∅46 mm Design Report published on EDMS #1310534 Daniel Schoerling TE-MSC-MNC 9 B.I Magnets: ELENA Ring Sextupole Status • Magnetic design finished. • Functional drawings started. • The design provides stable field quality over the whole required range. Challenges • The dynamic range is unusually large: 330! • The remanent gradient is larger than the minimum required gradient: 6𝐻𝐻𝑐𝑐 𝑙𝑙mag 𝜇𝜇0 T ′′ = 0.23 2 . For same cycles, 𝐵𝐵rem =− 𝑅𝑅 3 m this can be solved by inverting the current direction. Measurement • Magnetic measurement of integral field will be performed with existing rotating coil system. Number of magnet 4+1 Field gradient 0.12 - 40 T/m2 Mechanical aperture 89 mm Magnetic length 150 mm GFR ±2 ⋅ 10-3 at ∅40 mm Designed GFR 1 ⋅ 10-5 at ∅40 mm Design Report published on EDMS #1308783 Daniel Schoerling TE-MSC-MNC 10 B.I Magnets: ELENA Ring & TL H/V Correctors Status • Magnetic design finished. • Functional drawings started. Challenges • No particular challenges, standard design. • Cross-talk and remanent fields will be measured for typical ELENA cycles with a similar available corrector. Measurement • Magnetic measurement of integral field will be performed with existing rotating coil system. Number of magnet 8 (+ 2) + 3 + 2 Integrated field 6⋅ 10-3 Tm Mechanical aperture 124 mm Magnetic length 310 mm GFR ±1 ⋅ 10-2 at ∅44 mm Designed GFR 1.9 ⋅ 10-3 at ∅44 mm Design Report published on EDMS #1308780 Daniel Schoerling TE-MSC-MNC 11 B.I Magnets: ELENA Compensation Solenoids Status • Compensation solenoids and E-cooler should be considered as a design unit. • Parameters (length, integrated field) have to be optimized depending on space required for Ecooler. Challenges • Standard solenoid with moderate field quality requirements should not provoke challenges. Measurement • Measurement will be performed with stretched/vibrating wire measurement system. Possible Design 𝑁𝑁𝑁𝑁 = 23873 A, 𝑁𝑁max = 40 A, 𝑁𝑁 = 600, Acable = 5 x 8 mm2 = 39.14 mm2 , 35 Turns, 17 Layers, 𝑈𝑈DC ≈ 8 V Daniel Schoerling Number of magnet 2+1 Field 0.1 T, TBD Magnetic length 300 mm, TBD Aperture 89 mm TE-MSC-MNC 12 B.I Magnets: TL Bending Magnets Status • Magnetic design finished. • Functional drawings almost finished. Challenges • No particular challenges, standard design. • Laminated to allow for ramping, but pole profile can be machined to ease the manufacturing process. Measurement • Magnetic measurement of integral field will be performed with existing rotating coil system. Number of magnet 2+1 Field 0.67 T Bending angle 40 degree Mechanical aperture 65 mm GFR, straight ±1 ⋅ 10-3 at 68 x 48 mm2 Designed GFR, straight ±3 ⋅ 10-4 at 68 x 48 mm2 Design Report published on EDMS # 1297334 Daniel Schoerling TE-MSC-MNC 13 C.I Summary: Parameters ELENA RING DesignStatus Label Short label Total number of magnets Aperture in mm Goodfield region in mm Integrated field homogeneity Magnetic length in m Mechanica l length in m Maximum field strength Minimum field strength Instrumentation PXMBHEKCWP MBR 8 76 66 (H) x 48 (V) ±2⋅10-4 0.97 1.20 0.42 T 0.05 T None PXMQNLGNAP MQR 13 ∅124 ∅54 ±5⋅10-4 0.25 0.31 1.45 T/m 0.02 T/m BPMs PXMXNADNAP MXR 5 ∅89 ∅40 ±2⋅10-3 0.15 0.16 40 T/m2 0.12 T/m2 None PXMQSABNAP MQS 3 ∅124 ∅46 ±1⋅10-2 0.15 0.17 0.88 T/m 0.023 T/m None PXMCCAYWAP MCR 9 (+2) ∅124 ∅44 ±1⋅10-2 0.31 0.22 6⋅10-3 Tm (integrated) - BPMs PXMLNAFNAC MLR 3 TBD TBD TBD TBD TBD TBD - None Label Short label Total number of magnets Aperture in mm Goodfield region in mm Integrated field homogeneity Magnetic length in m Mechanical length in m Maximum field strength Instrumentation PXMBHCBCWP MBL 3 65 68 (H) x 48 (V) ±1⋅10-3 0.35 0.49 0.67 T None PXMQNLGNAP MQR 3 ∅124 ∅54 ±5⋅10-4 0.25 0.31 1.45 T/m None PXMQNAFNWP QPMA 1 ∅60 ∅20 ±2⋅10-3 0.23 0.30 11.2 T/m None PXMCCAYWAP MCR 4 ∅124 ∅44 ±1⋅10-2 0.31 0.22 6⋅10-3 Tm (integrated) None Element type Bending Magnet, Horizontal Quadrupole, Normal Sextupole, Normal Quadrupole, Skew Corrector H+V Solenoid TL AD to ELENA DesignStatus Element type Bending Magnet, Horizontal Quadrupole, Normal Quadrupole, Normal Corrector H+V Fixed parameters, further changes require a formal Engineering Change Request (ECR) for green and yellow items! Daniel Schoerling TE-MSC-MNC 14 C. II Schedule • Re-optimization of the schedule was necessary to cope with the late delivery of the magnet parameters. • An optimization of the schedule makes a magnet delivery until 15/12/2015 possible. • We will try our best to catch up the remaining delay by trying to accelerate the approval process inside CERN and by performing close follow-up after contract placement. Dipole Schedule: Q4 13 Q1 14 Q2 14 Q3 14 Q4 14 Q1 15 Q2 15 Q3 15 ID Task Name Start Finish Duration 1 Prototype Measurement 15/10/2013 13/12/2013 8w 4d 2 Contract Preparation & Placement 15/10/2013 17/02/2014 18w 3 Pre-Series Production 08/04/2014 17/02/2015 45w 1d 4 Series Production & Acceptance 01/01/2015 01/12/2015 47w 4d 5 Installation Period 04/08/2015 15/12/2015 19w 1d Daniel Schoerling TE-MSC-MNC 15 C.III Procurement Strategy: ELENA Magnets • All magnet families will be procured independently of each other (in total 6 contracts) because all manufacturers are small and have currently many contracts to follow. • Normal and skew quadrupole magnets share the same lamination design and will be therefore procured together. • Bending magnets and quadrupoles are expected to be in the contract class >200 kCHF and require an Invitation to Tender. A Market Survey was performed and 6 companies were qualified. • Four contracts are expected to be in the contract class <200 kCHF and will require no pre-qualification. Qualified companies, and depending on experience new suppliers, will be asked to provide offers. • Electrical steel and stainless steel will be procured by CERN and delivered to the companies to reduce the delay and facilitate the procurement. Daniel Schoerling TE-MSC-MNC 16 C. IV Conclusion The following specifications/activities are finished: • Functional Specifications • Design Reports for all magnets (except solenoids) • Dipole prototype; measurements are starting • Engineering Specification: MQR, MQS, MBR; for other magnets information available • Functional drawings: MQR, MQS, MBR, MBL under approval; MXR & MCR under preparation • Technical Specification: MBR, MQR & MQS approval process started We see the following challenges: • Technical challenges can be addressed with prototypes for the bending magnet and the quadrupole. • Measuring the ELENA dipole magnet requires a dedicated flux meter. • Parameters of the compensation solenoid are required before starting with the design. • To meet the schedule and avoid technical complications design changes should be avoided in the future. • Further changes on the magnet’s parameter will require a formal Engineering Change Request. Daniel Schoerling TE-MSC-MNC 17