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

Attilio Milanese2 Agenda reports and specifications main contracts and schedule CERN sextupole pre-series pole tip profiles TAC Nov presentation

23 Nov. 2013Attilio Milanese3 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. 23 Nov. 2013Attilio Milanese4 placeholder structure for deliverables of the EC project CESSAMag

Reports and specifications Combined function bending magnets  Design Reportunder approval  Technical Specificationreleased  Technical Questionnairereleased Quadrupoles  Design Reportreleased  Technical Specificationreleased  Technical Questionnairereleased  Technical Specification Coilsreleased Sextupoles / correctors  Design Reportreleased  Technical Specification Coilsreleased  Technical Specificationunder preparation 23 Nov. 2013Attilio Milanese5

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 gave some tentative values, no fully discussed and detailed with beam dynamics arguments 23 Nov. 2013Attilio Milanese6 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 23 Nov. 2013Attilio Milanese7 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.

23 Nov. 2013Attilio Milanese8 MAIN CONTRACTS

23 Nov. 2013Attilio Milanese9 Main contracts supplycontractorcountrycomment 16+1 bending magnetsTESLAUKcontract signed 32+1 QF and 32+1 QD quadrupoles ELYTTSpaincontract signed 140 QF QD quadrupole coils STSTurkeycontract signed 420 sextupole coil packages SEFFrancecontract signed 32+1 sextupolesCNECypruspilot order issued 32+1 sextupolesPAECPakistanprotocol 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 (before awarding the contract), visiting both TESLA and the subcontractor for the punching, Midland Tool & Design contractual schedule  Manufacturing File25 Nov  1 pre-series dipole25 Jul  4 series dipoles19 Dec  4 series dipoles25 Mar  4 series dipoles25 Jun  4 series dipoles25 Sept Nov. 2013Attilio Milanese10

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 A high perm with EB549 coating, from VoestAlpine, Austria), delivery to puncher expected beginning of Mar TESLA has ordered 11 t of hollow copper conductor (from Luvata, Finland), first conductor delivery expected mid-Feb The punching tooling is also in preparation, the first laminations are expected mid-Mar next visit on 25 Nov. 2013, for reviewing the Manufacturing File 23 Nov. 2013Attilio Milanese11

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 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 QF12 Mar  8 series QD + 8 series QF27 Jun  8 series QD + 8 series QF 7 Nov  8 series QD + 8 series QF 18 Feb  8 series QD + 8 series QF 14 Apr Nov. 2013Attilio Milanese12

Quadrupoles direct involvement of the technical director, Julio Lucas the drawing of the lamination is approved ELYTT has ordered the electrical steel (M A 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 Nov. 2013Attilio Milanese13 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  m of polyimide with epoxy layer + 3×130  m of glass fiber (wrapping performed by Sofilec, France) review of Manufacturing File 10 Oct at CERN, we had already visited them in Turkey for a contract of spare coils schedule  Manufacturing File11 Oct  10 pre-series QD and 10 pre-series QF coils13 Dec  40 series QD and 40 series QF coils 28 Mar  40 series QD and 40 series QF coils 25 Jul  50 series QD and 50 series QF coils 29 Nov Nov. 2013Attilio Milanese14

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 23 Nov. 2013Attilio Milanese15 QD mould QF mould QD winding mandrel QF 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 schedule  20 pre-series coils21 Feb  100 series coils 30 May 2014  100 series coils 1 Aug  100 series coils 17 Oct  100 series coils19 Dec Nov. 2013Attilio Milanese16

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 magnets. A company in Cyprus (CNE Technology Center) has been selected for supplying the other 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. 23 Nov. 2013Attilio Milanese17

Schedule for main contracts 23 Nov. 2013Attilio Milanese18 IIIIVIIIIIIIVIII 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 23 Nov. 2013Attilio Milanese19

23 Nov. 2013Attilio Milanese20 1 st assembly of CERN sextupole pre-series (electric and hydraulic circuits in test configuration) (already in an accelerator tunnel, the ISR!) correctors circuits view main sextupole view

Field quality of CERN sextupole pre-series 23 Nov. 2013Attilio Milanese21  The allowed harmonics are extremely good: the pole profile is confirmed.  a 6 = 0.9 due to a solenoidal loop on the lead side: avoiding that would lower a 6 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 R = 24 mm ∫b 9 = 0 and with no end pole chamfer thanks to a biased b 9 in 2D b 9,2D = 12.8 allowed Opera-2D model Opera-3D model Rotating coil measurements ∫b 9 = 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) 23 Nov. 2013Attilio Milanese22 vertical dipolehorizontal dipoleskew quadrupole

A precisely punched lamination 23 Nov. 2013Attilio Milanese23 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 preparation 23 Nov. 2013Attilio Milanese24

Stacking tooling: 5 ready (for series yokes) 23 Nov. 2013Attilio Milanese25

Sextupole, steel is on the move 23 Nov. 2013Attilio Milanese26 electrical steel on its way to be punched electrical steel after being punched stacking tooling ready to be shipped to a magnet manufacturer

23 Nov. 2013Attilio Milanese27 TO CONCLUDE

A wide effort 23 Nov. 2013Attilio Milanese28

23 Nov. 2013Attilio Milanese29 Special thanks to the EC for the CESSAMag funds, FP7 contract 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 شكرا (shukran) eυχαριστώ (efharistó) ممنون (mamnoon) شكريه (shukriya) teşekkür ederim תודה (toda)