Electron Lens

Electron Lens Superconducting SolenoidElectron Lens Superconducting Solenoid

Overview of Magnet ProjectOverview of Magnet Project

Michael Anerella

October 20 2010October 20, 2010

October 20, 20101

Outline

Outline of Presentation

Technical Overview Technical Overview Cost & Schedule Risk Management Value Management Value Management Project Team ESSH/Quality Assurance Configuration ManagementConfiguration Management Summary

October 20, 20102

Project Scope

Design, Build and Test 2 eLens Solenoid Magnets:

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

• Conduct ongoing communications & meetings to significantlyclarify scope, improve design and performanceM i t i t t l • Maintain cost control

• Deliver by April 2012

October 20, 20103

Scope (continued)

Simple? NO.

This is a VERY challenging magnet.• Forces are large, in both radial and axial directions, for

main solenoid and fringe field solenoids.ma n soleno d and fr nge f eld soleno ds.• Tolerances are tight for field uniformity and straightness• Cost must be tightly controlled.• Schedule is very aggressive.• Scope was not initially completely defined

→ SMD has designed an efficient, effective magnet to meet all requirements

October 20, 20104

Magnet Mechanical Design Overview

17 separate circuits / max. current:

• 1 main solenoid / 460A

•2 fringe field solenoids / 47A2 fringe field solenoids / 47A

•2 anti-fringe field solenoids / 33A

•5 0.5m vertical correctors / 26A

5 0 5 h i t l t / 26A•5 0.5m horizontal correctors / 26A

•1 2.5m vertical corrector / 34A

•1 2.5m horizontal corrector / 34A

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 s pp t p sts / st t

October 20, 20105

RHIC support posts / cryostat

magnet section - coil locations

f i fi ld l idcorrectors

fringe field solenoid

anti-fringe field solenoid main “trim” solenoid

main solenoid

October 20, 20106

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

• Many components are available in stock, e.g.:– Corrector/Fringe field solenoid Superconductor

S i l l h li l– Stainless steel helium vessel– cryostat

• All remaining major components and materials to be purchased, e.g.:Aluminum (corrector) and stainless (solenoid) support tubes– 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 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 20, 20107

Testing

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

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

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

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

Additi l ld t ti ill b d h i t ll th • Additional cold testing will be done horizontally on the completed magnet after final ring installation – field axis straightness measurements done at this time

October 20, 20108

Schedule Summary

Critical path shown in redEarly schedule:1st meeting 1/10N ti ti 2/10 3/10Negotiations 2/10-3/10

Fringe field coils are on critical path

Meets 4/12 need

October 20, 20109

date

Schedule Status

• Final design – 90% complete, working out final details on Fringe Field Solenoids

• Coil Fabrication:– Corrector Coils:Corrector Coils

Superconductor available; purchase order for insulating with Kapton placed, first shipment due end of October

Aluminum support tubes purchased and received Mechanical model / drawing for machined coil blocks in tube order Mechanical model / drawing for machined coil blocks in tube - order

placed with BNL machine shop – promised delivery mid-November– Solenoid coils:

Superconductor order placed, delivery 12/17/2010S t t b d l d Support tube order placed

Machined tube model /drawing complete, order to be placed with BNL machine shop

– Fringe field / Anti-fringe field solenoid coils: Same superconductor as corrector coils Final strengths & locations finalized; engineering complete, parts to

be made by SMD immediately thereafter

October 20, 201010

Cost DetailsCost Details

Cost Estimate Methods:• Material:

– Actual cost for similar parts on previous programs

– Vendor quotes on k it skey items

• Labor:– Time studies for

critical activities critical activities (coil winding, insulating, etc.)

– Engineering Engineering estimates based on recent similar work (AGS Snake, RHIC helical etc )

Note: cost data above does not yet reflect impact of current fringe field / anti-fringe field coil configurations

October 20, 201011

helical, etc.) anti fringe field coil configurations.

Risk Management

All coils are on critical path or near-critical path:– Redesign of correctors as hand-wound block coils (initially

“direct wind” design was planned) saved schedule and cost direct wind design was planned) saved schedule and cost, PLUS enabled work to be completed in parallel with main solenoids by alternate personnel

– Fringe field solenoid coils are to be wound in parallel as well, tili i t il bl bl i l li utilizing two available programmable commercial re-spooling

machines

Note: this represents peak hands-on manpower (4 FTE’s)Note: this represents peak hands on manpower (4 FTE s)

October 20, 201012

Value Engineering

• Use existing designs, materials, etc. wherever possible– Existing spare RHIC CQS cryostat

Surplus IsaBelle stainless steel helium vessels– Surplus IsaBelle stainless steel helium vessels– Stock RHIC corrector superconducting wire– Stock RHIC Ultem support posts

• Use existing equipment e g :Use existing equipment, e.g.:– SMD direct wind machine, BEPC-II precision solenoid gantry– SMD automated take-up spools– C-AD curing oveng

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

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

• Development of fringe field solenoid coils:– Resolved previously unaddressed operational eLens issue

October 20, 201013

p y p

Project Team

• Project / Engineering Supervision – Mike Anerella

• Scientist, Magnetic Design h G

g g– Ramesh Gupta

• Mechanical Engineer, Magnet – Steve Plate

• Mechanical Engineer, Coils g ,– Andy Marone

• Mechanical Engineer, Design – Paul Kovach

• Electrical Engineer, Coils –g ,John Escallier

• Electrical Engineer, Tooling – Piyush Joshi

• Scientist, Magnetic , gMeasurements – Animesh Jain

• Scientist, Cold Test – Joe Muratore

Many other experienced SMD personnel involved at

l l

October 20, 201014

some level

Staffing issues

• Design completion:– 1 SMD designer (fringe field coils)

1 C A d si n n l n (m n t d s f m mpl t d – 1 C-A designer on loan (magnet dwgs from completed models)

– 1 NSLS-II checker on loan• Coil fabrication

– 2 SMD technicians identified1 requisition for technician being filled now– 1 requisition for technician being filled now

– 1 requisition for additional tech by Jan 2011

October 20, 201015

Summary

• The magnet requirements are challenging but achievable.• Performance objectives reflect a good continued communication between 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 Experienced personnel (RHIC AGS Snake, RHIC Helical, BEPC-II, LHC,

etc.) are available and working• Recent scope addition (latest fringe field / anti-fringe field coils) have

had a significant impact (increased design & engineering, added materials & assembly labor, schedule) but are being accommodated& assembly labor, schedule) but are being accommodated

• Design is mature and nearly ready for production but many issues have been identified and are still being finalized, e.g.:– Quench protection– Pressure vessel approval– Pressure vessel approval– Final testing details

October 20, 201016

Backup slides

October 20, 201017

Fringe field, Anti-fringe field labor details

October 20, 201018

Coil Fabrication

Corrector Coils – “slotted tube”Expected benefits:Cost savingsTime (schedule) savings

Main solenoid – “direct wind”Expected benefits:accurate conductor placement using precision solenoid gantry developed for ( ) g

Reliable (proven) constructionImproved magnetic design

Smaller axial “gaps” reduce dips in fieldBlocks near midplane are more efficient → less turns

Decouples corrector construction from Direct Wind machines

p g y pBEPC-II programUniform spacing improves field axis straightness, lessens demands on correctorsReliable (proven) construction Decouples corrector construction from Direct Wind machinesReliable (proven) construction

Test wind: feasibility +

d

Tube end insulation time study

BEP l d

October 20, 201019

ytime study

yBEPC-II coil winding

Environmental, Safety, Security, and Health (ESSH)

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

procedures• Weekly safety meetings with staff

October 20, 201020

Quality Assurance

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

d d h dprocedures and purchase orders• Incoming inspection on all parts

– BNL (Magnet Division or Fabrication Services BNL (Magnet Division or Fabrication Services Division)

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

process:M h ni l– Mechanical

– Electrical– Magnetic

October 20, 201021

Magnetic

H i W k C t ll d?

Configuration Management

How is Work Controlled?• PICS - Part and Inventory Control System• Developed at BNL Superconducting Magnet Division• Windows-based software and database

Features:Inventory control, including Lot or

sample traveler

y , gSerial #’s and locationCreation, approval and control of written work procedures with Revision controlRevision controlKitting of parts for work ordersEnd item documentation, including as-built configurationg

All QA, testing and safety precautions built into documentation

October 20, 201022