1 BROOKHAVEN SCIENCE ASSOCIATES Abstract Magnet and Girder Integration Lewis Doom, NSLS-II Project National Synchrotron Light Source II (NSLS-II) will be a 3-GeV 792-meter circumference 3 rd generation synchrotron radiation facility with ultra low emittance and extremely high brightness. There will be a total of 90 multipole storage ring girder assemblies including machined girder weldments, vacuum chambers, multipole magnets and various pieces of ancillary equipment. A major effort was made to eliminate interferences between components and assure adequate assembly procedures. Topics that will be presented include considerations for designing, interfacing and potential interferences in the development and manufacture of storage ring multipole girder assemblies. Software requirements for the design of large assemblies will be presented along with requirements for access to various components after installation. Alignment requirements and the required fixturing for magnets and vacuum chambers took a significant effort and must be integrated into the overall design of a girder system. These topics will be described in detail. *Work performed under auspices of the United States Department of Energy, under contract DE-AC02-98CH10886

2 BROOKHAVEN SCIENCE ASSOCIATES Magnet and Girder Integration L. Doom Magnet Workshop April 11-12, 2012

3 BROOKHAVEN SCIENCE ASSOCIATES Outline Overview Designing, interfacing and interferences What components will need access later Wiring and utility connections Measuring and adjusting General comments

4 BROOKHAVEN SCIENCE ASSOCIATES Girder Assembly Overview All Primary Girder assemblies are modeled in detail Major assemblies include Girders (150 total required) Magnets (60 Dipoles, 300 Quadrupoles, 270 Sextupoles, 180 Correctors) 210 Vacuum chamber assemblies (150 large aluminum chambers, 30 small aluminum chambers, 30 inconel chambers) Diagnostics (370 vacuum chamber mounted buttons) Water manifolds and connections Electrical enclosures and raceways Girder 4 (30 Required) Girder 2 (30 Required) Girder 6 (30 Required) Dipole Girder (60 required)

5 BROOKHAVEN SCIENCE ASSOCIATES Assembly Specifications 5 Multipole magnet alignment requirements Vertical ±30 microns Transverse: ±30 microns Longitudinal: ±500 microns Roll: ±.5 mrad Pitch: ±1.0 mrad Yaw: ±1.0 mrad Multipole magnet alignment at NSLS-II is done in two stages Preliminary alignment with laser tracker Final alignment with vibrating wire inside temperature controlled room Required specifications should be defined as early as possible along with expected procedure.

6 BROOKHAVEN SCIENCE ASSOCIATES Software Use software to identify interferences between parts Use models that are as accurate as possible Involve all groups in interface and interference checks. Regular meetings and reviews as primary design work is being done. This can take a significant amount of time and should be planned for Use software that can handle very large assemblies – Multipole girder assembly is 8127 files. Dipole assembly is 1666 files – Cell assembly is about 30,000 files – Pentant is about 180,000 files – Storage ring is about 900,000 files – Inventor’s usable limit at about 10,000 files – Navisworks is used at NSLS-II for very large assemblies but is primarily for viewing and has limited interactivity

7 BROOKHAVEN SCIENCE ASSOCIATES Lattice -Make sure Lattice is defined using adequate spacing between magnets -Lattice must include real sizes of components (not just points on a spreadsheet.) Coils and Plumbing may extend beyond expectations

8 BROOKHAVEN SCIENCE ASSOCIATES Lattice As the design develops show real sizes and spacing

9 BROOKHAVEN SCIENCE ASSOCIATES Lattice All components must be shown and evaluated to eliminate interference. Review by all Groups as design progresses

10 BROOKHAVEN SCIENCE ASSOCIATES Splitting Magnets If splitting magnets will be required make sure they are designed to do this easily and test. Splitting water lines at the center would simplify process Water manifold removed Unsupported conductors

11 BROOKHAVEN SCIENCE ASSOCIATES Interfaces Magnet Mounts Make sure there is more adjustment available than required Measuring instruments Fixtures for Vacuum Chambers and Magnets Original configuration Final configuration

12 BROOKHAVEN SCIENCE ASSOCIATES Interfaces Survey Access and Visibility Access in the tunnel will be limited

13 BROOKHAVEN SCIENCE ASSOCIATES Interfaces Ion Pumps (move with expansion of bakeout) Vacuum Chamber Stands Expansion during bakeout (expect over 6mm with aluminum chambers) Vacuum Chambers (2mm is minimum 3mm would be better) Leave more room for coils (4mm)

14 BROOKHAVEN SCIENCE ASSOCIATES Interfaces BPMs Room is need for installation, Survey and wiring Water Connections Water flow requirements and pressure drop across magnets must be clearly specified and understood by the suppliers (All suppliers failed to meet this specification)

15 BROOKHAVEN SCIENCE ASSOCIATES Interfaces Bakeout

16 BROOKHAVEN SCIENCE ASSOCIATES SPECIAL WIDE MAGNETS The beam eventually has to get out If wide magnets are made they should be manufactured from the same vender as standard width magnets Confirm exit requirements as early as possible and lock it in STONE (before magnets are designed) Girder 2 Girder 4

17 BROOKHAVEN SCIENCE ASSOCIATES What components will need access later BPMs Ion pumps Flanges and Bellows Vacuum chamber stands Bake-out heaters and instrumentation Corrector magnets slide out for access to bellows Water connections

18 BROOKHAVEN SCIENCE ASSOCIATES Wiring and Utility Connections Power wires Make sure hardware sizes and spacing are clearly identified and standardized Guards Make sure the requirements are clearly understood Water connections Water connection sizes should be relative to the flow requirements. They may be smaller than you think Ground wires and routing

19 BROOKHAVEN SCIENCE ASSOCIATES Measuring and adjusting Leaves access for instruments and hardware Make room for wrenches Push on center for alignment Vertical, Transverse and longitudinal adjustment and fixtures

20 BROOKHAVEN SCIENCE ASSOCIATES General comments There is more to a magnet than harmonics You learn a lot the first time an assembly is put together. – If prototypes are purchased purchase at least a full girder compliment to test all concepts (assembly procedures, measuring equipment, fixtures, alignment, vibration, wiring and plumbing, survey, …) Safety factors should be applied to specifications because some wont be met. Add enough clearances between parts (the boundary's will be pushed)

21 BROOKHAVEN SCIENCE ASSOCIATES It takes a good team Mechanical Assembly and inspection Electrical measurement and inspection