1. EFREMOV INSTITUTE SAINT PETERSBURG RUSSIA
Development, Manufacturing and Testing of Magnets with Resistive (“Warm”) Coils
EFREMOV INSTITUTE
SAINT PETERSBURG
RUSSIA
Victor Varentsov
on behalf of
EFREMOV INSTITUTE
SAINT PETERSBURG
RUSSIA
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2. Collaboration of Efremov Institute with FAIR
The Council of the FAIR GmbH has agreed to the collaboration between FAIR GmbH and the Efremov Institute regarding the design, production and delivery of:
Electromagnets with resistive “warm” (not superconducting) coils
for the
Work Package WP PSP 2.3.2
- FAIR High Energy Beam Transport System (HEBT).

3. Collaboration of Efremov Institute with FAIR
There are three basic groups of the HEBT magnets : Dipoles, Quadrupoles and Correctors.
Magnets
Quantity
Dipoles
73 of 18 types
Quadrupoles
173 of 4 types
Steering
92 of 2 types
TOTAL
338 of 24 types

4. Technical parameters of the magnets4
Technical parameters of the magnets
Dipole magnets
Name
Quantity
Effective
Length,
Gap
Inom
Average
losses
Bmax
Field
quality
∆B/B
Weight m A kW T
[×10-3] kg
dip1s_0 1
1.472
0.080
535
40.8
1.6 4
7200
dip1f_0 11
1.473
1115
38.9
9640
dip1f_1 2
1.197
34.5
7730
dip1f_2
1.068
30.9
7000
dip1f_3
1.308
35.2
8600
dip2_0
2121
53.38
13000
dip2_2
1.769
45.68
10800
dip13_0 28
3.231
0.073
2250
81.66
1.8
15000
dip13_1
2.692
71.2
12500
dip13_2
2.586
69.125
12000
dip14
0.756
25.95
5200

5. Technical parameters of the magnets5
Technical parameters of the magnets
Dipole magnets
Name
Quantity
Effective
Length,
Gap
Inom
Average
losses
Bmax
Field
quality
∆B/B
Weight m A kW T
[×10-3] kg
dip13high 4
3.228
0.093
751
127.1
1.8
20000
dip15_0
1.961
0.080
1115
47.86
1.6
12300
dip15_1 1
2.260
53.35
14500
dip16
2.937
67.1
18000
dip17_0
3.907
89.2
23000
dip10 6
3.232
0.073
2400
81.63
25500
Dip13_0
(with special yoke; dip13_3) 3
3.231
2275
83.49
15600

6. Technical parameters of the magnets6
Technical parameters of the magnets
Quadrupole magnets
Name
Quantity
Effective
Length,
Aperture
Inom
Average
losses
Gmax
Field
quality
∆B/B
Weight m A kW
T/m
[×10-3] kg
quad2 81 1
0.130
271
17.7 10 5
2470
quad10 11
0.75
0.170
873
45.3
3210
quad11 69
1.2
0.105
455
16.77 15
3500
quad12 12
467
17.1
9970

7. Technical parameters of the magnets7
Technical parameters of the magnets
Steering magnets
Name
Quantity
Effective
Length,
Gap
Inom
Average
losses
Bmax
Field
quality
∆B/B
Weight m A kW T
[×10-2] kg
Steerer HEBT100 43
0.58
0.170
400
16.8
0.35 4
577
Steerer HEBT18 44
0.389
0.205 93
2.14
0.1
150
(large aperture) 5
0.3 -

8. Magnets delivery
The magnets will be delivered in batches in accordance with an installation plan of the FAIR GmbH.
Last magnet delivery is foreseen in the first quarter of 2017.

9. Composition of the Batch 19
Composition of the Batch 1
PSP-Code
(Costbook V6.09)
Magnet type
Quantity for
Primary
beams
Secondary
Total
Quantity
dip1s_0 1 -
dip1f_0 11
dip1f_1 2
dip1f_2
dip1f_3
dip2_0
dip2_2
dip13_0 26
dip13_1
dip13_2
dip14 47 4 51

10. Composition of the Batch 2 Steerer HEBT18 (large aperture)10
Composition of the Batch 2
PSP-Code
(Costbook V6.09)
Magnet type
Quantity for
Primary
beams
Secondary
Total
Quantity
dip13high 4 -
dip15_0
dip15_1 1
dip16
dip17_0
dip10 6
quad2 22
quad10 11
quad11 57
quad12 12
Steerer HEBT100 31
Steerer HEBT18 34 10 44
Steerer HEBT18 (large aperture) 5
184 15
199

11. Composition of the Batch 3 dip13_0 (with special yoke; dip13_3)11
Composition of the Batch 3
PSP-Code
(Costbook V6.09)
Magnet type
Quantity for
Primary
beams
Secondary
Total
Quantity
dip13_0 2 -
t.b.d
dip13_0 (with special yoke; dip13_3) 3
quad2 37 22 59
quad11 12
Steerer HEBT100 66 88

12. Milestones for the FAIR project12
Milestones for the FAIR project
List of some major milestones for the FAIR project
Name
All major
contracts closed
for building and
Infrastructure
All contracts
closed for
major
component
component series
production started
Building and
infrastructure
ready for
assembly
All components
installation
(incl. testing)
Assembly and
alignment
finished
commissioning
Commissioning
without beam
HEBT (primary beams) -
Q2/2016
Q2/2018
Magnets (primary beams)
Q2/2013
Q4/2014
Q4/2016
Q4/2017
Diagnostics (primary beams)
Q4/2013
Q1/2014
Q1/2017
HEBT (secondary beams)
Magnets (secondary beams)
Q2/2014
Q4/2015
Q1/2018
Q4/2018
Q1/2016

13. Efremov Institute Cooperation13
Efremov Institute Cooperation
Many years Efremov Institute works in cooperation with European physical centers (e.g. GSI and DESY) in the field of design, engineering and manufacture of different electromagnets for accelerating facilities and experimental physical equipment.

14. Efremov Institute Cooperation14
Efremov Institute Cooperation
Cooperation with GSI
In 1990 the magnet yoke for the 4π detector by weight of 100 t for the SIS/ESR project was manufactured and delivered.
In dipole magnets (14,5° and 7,5°) for the HADES Experiment were manufactured and delivered.
In dipole magnets (7,5°) for the beam line from SIS accelerator to the HHT experimental area were manufactured and delivered.
In quadrupole magnets of the spectrometer VAMOS designed by GSI were manufactured and delivered to GANIL, Caen, France.

15. Dipole (slow), dip1s_0, PSP 2.3.2.1.1.1
Maximum field – 1.6 T
Gap mm
Bending angle deg
Bending radius m
Effective length mm
Current A
Power kW
Weight kg
Year , 2003

16. Dipole (slow), dip1s_0, PSP 2.3.2.1.1.1

17. Half yoke of Dipole (slow),
dip1s_0, PSP

18. Quadrupole Q2 of the spectrometer VAMOS for GANIL, Caen, France
Aperture radius – 250 mm
Pole length – 0.7 m
Current – 850 A
Voltage drop – 134 V
Weight – kg
Number of magnets - 2
Year

19. Manufacturing of magnet yokes
The laminated dipole magnet yokes are produced from magnetic steel ones from 1-mm-thick steel sheet of "Power Core A" type (DIN EN /1996) covered with Stabolit 70 on both sides.
The quadrupole magnet yokes consists of laminated iron quadrants produced from 1-mm-thick steel sheet of "Power Core A" type (DIN EN /1996) covered with Stabolit 70 on both sides.
All magnets can be easily deassembled in the horizontal plane for subsequent installation of the vacuum chamber.

20. Requirement to magnet coils
The conductor for all coils should be made of oxygen-free electrolytic copper (OF-Cu according to DIN 1787) with a specific resistance not exceeding 1.72 x 10-8 Ω×m at 20°C. The coils should behave as rigid bodies with mechanical strength sufficient to withstand the electromagnetic forces and thermal stresses (which can occur cyclically) without developing cracks. All conductor parts should be insulated and impregnated with waterproof compound free of entrapped air.
Electric strength of insulation between the conductors and the yoke should be tested at an effective voltage of 1.5 kV at 50 Hz applied for 1 minute.
One of the coils produced (for each type of magnet) is to be subjected to 500 thermal cycles between 30 °C and 60 °C and after thermocycling tested before the series production continues.

21. Manufacturing of magnet coils

22. Manufacturing of magnet coils

23. Manufacturing of Magnet XBB for XFEL project
All 14 XBB magnets are manufactured. Six of them have been measured. One of them is now at DESY for verifying results of the magnetic measurements, which have been done at the Efremov Institute.
Homogeneity of magnetic field in the XBB should be about 1×10-4. So, to reach this accuracy magnetic calculations for the pole profile were required.
Magnetic testing
Special partial disassembling

24. Manufacturing of Magnet Type XQF (90 pieces) for XFEL project
Three magnets has been assembled. For this quadrupoles the magnetic measurements have been carried out. The measurement results are analyzed now by specialists of DESY and Efremov Institute.

25. Manufacturing of Magnet Type XQH (35 pieces) for XFEL project
Three magnets has been assembled.

26. Manufacturing of Magnet Type XQE (43 pieces) for XFEL project
16 quadrupole magnets XQE are manufactured. For 15 magnets the magnetic measurements have been carried out. Now the measurement results are analyzed by DESY and Efremov Institute specialists.

27. Manufacturing of Magnet Type XSC (17 pieces) for XFEL project
17 sextupoles XSC are manufactured.

28. Thank you for your attention!