IS 5067.1983 Power point

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STATUS REPORT ON

VACUUM CHAMBERS(Dipole & Straight)

&

DIPOLE MAGNETS

FOR TL-2 OF CTF3

A.K. JAIN, S.S. PRABHU,S. KOTAIAH

RRCAT, INDORE (INDIA)

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Vacuum Chambers

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Initially, two test vacuum chambers fabricated in aluminum

grade AA 6061 for qualifying machining & welding

procedure. Surface finish < 0.30 microns achieved.

Welding torch manuveres needed to access some portions

of chamber.

For third chamber, design was changed to simplify welding.

Leak rate obtained ~3 x 10-10 Torr ltr / sec.

Dipole Vacuum Chambers :

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DIPOLE VACUUM CHAMBERS

Machined & Welded Prototype Chamber

Initial Trial Final Trial

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1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

E E

F F

NATIONAL INSTITUTE OF NUCLEAR PHISICS

FRASCATI NATIONAL LABORATORY

DRAFTER D ES IG NE R E NG IN EE R APPROVAL

DRAWING N. REVQUALITY ASSURANCE

VACUUM DIAGNOSTIC ACC.PHY. ELEC. ENG.

DATE MATERIAL WEIGHT SCALE

GENERALTOLERANCESUNI EN22768/1-MEDIUM

FINISH NEXT ASSY DWG QUANT. NOTE

A2

CTF3

CAMERA TL

TERZA CAMERA CHICANE

FLANGIA RETTANGOLARE

G. FONTANA

0 8/ 07 /2 00 3 A NT 60 82 T6 1:1

CTF3-013-000 1

CTF3-013-004 A

B B

B-B ( 1 : 1 )

27

27

59,5

59,5

136

18

36

33

3383

96

Sm1X45

A

0,1 A

R12,5

R21,50,05

37

90

55

0,05

C 0,1 B

1080,05

B

0,1 A

3+0,06-0

43

5,5

5,5

45

R35,5

R27

40+0,2+0,1 R14+0,2

+0,1

66

R15,5

8,4 PASS.

Sm 03x45

0,1 A B C

NOTES:

1) ALL MACHININGS MUST BE DONE AS

SPECIFIED

BY DOCUMENT N CTF3-013-SP-A2) ALL INTERNAL SURFACES TO HAVE ROUGHNESS

BETTER THAN 0.4 MICRON

3) ALL EXTERNAL SUFACES TO HAVE ROUGHNESS


4) GENERAL TOLERANCES = 0.3 mm

END FLANGES OF DIPOLE VACUUM CHAMBERS

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Fabrication & Processing :Material:

AA6061T6 is silicon magnesium based aluminium alloy.

(Material is solution heat treated and artificially aged).

Tooling :

High-speed cutters were used. Cutters equipped withperipheral mounting, high positive rake angle (340), coated

carbide inserts with 900 approach angle. One of three

inserts had a wiperinsert to get good surface finish.

Processing :Chemical cleaning-Approved by CERN for aluminium alloy

grade AA6061-T6. After chemical cleaning, jobs were hand

scrapped in the lip area to remove oxide layer just before

welding.

Dipole Vacuum Chambers (Contd)

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TIG WELDING :

Welders were qualified as per section IX of ASME code.

Cleanliness and humidity level of the weld room was maintained using air

conditioners, air curtains and Dehumidifiers.

Base material used:

AA 6061 T6 ( containing Si- 0.6%, Mg 1-1.2%, - Cu - 0.27%)

Filler wire used:

AWS A5.10 ER 4043 (Containing Si5%, Mn 0.05% Fe 0.4% Al rest)

Shielding gas used:

XL grade argon 99.999% as per IS-5760-1983 (Grade - 1) (Impurities -

Oxygen less than 1.5 ppm., Moisture less than 1.0 ppm, total

hydrocarbon NIL)


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Welding Parameters

Peak current 60-70 Amps.

Back ground current 25 Amps.

Pulse frequency 7 Hz. (at high position)

Pulse Ratio 80%

Type of arc Hard Arc

Shielding gas flow rate 8 Ltrs / min

Relative Humidity Less than 35%

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Present Status :

Fabrication and welding procedures qualified.

Raw material AA 6061 T6 procured.

Awaiting CERNs approval of TL-2 optics design & also magnet design.

Final drawings for chamber fabrication to be taken up thereafter.

Total nos. of dipole chambers ~5. Assembly of dipole chamber with

bending magnet has been tried using CAD. There is no problem in the

assembly.

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Straight Chambers :

RRCAT, Indore will deliver these chambers built out of extruded

aluminum grade AA 6061 T6. This will avoid welding of chambers at

the edges and their machining on a CNC vertical milling machine.

Extrusion job already ordered.

Extruded material expected at RRCAT ~April, 2007. Once TL-2 optics

is frozen, material will be cut to required lengths, ends machined to

suit the welding joints with end flanges.

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NATIONAL INSTITUTE OF NUCLEAR PHISICS

FRASCATI NATIONAL LABORATORY

DRAFTER ENGINEER APPROVAL

DRAWING N. REVQUALITY ASSURANCE

VACUUM DIAGNOSTIC ACC.PHY. ELEC. ENG.

DATE MATERIAL WEIGHT SCALE

GENERAL TOLERANCES UNI EN 22768/1-MEDIUM

FINISH NEXT ASSY DWG QUANT. NOTE

Foglio N.

DESIGNER

A3

A A

A-A ( 1 : 4 )

365 360 365

1090

B

B ( 1 : 2 )

C

C ( 1 : 2 )

D

D ( 1 : 2 )

NOTES:

1) ALL MACHININGS MUST BE DONE AS

SPECIFIED

BY DOCUMENT N CTF3-018-SP-A

2) ALL INTERNAL SURFACES TO HAVE ROUGHNESS


3) ALL EXTERNAL SUFACES TO HAVE ROUGHNESS

BETTER THAN 3.2 MICRON4) GENERAL TOLERANCES = 0.3 mm

TIG WELDING TIG WELDING

1,10,05

48,3 0.05

3 4 2 1 2 4 3

A 0,1

1 1 CTF3-018-002

2 2 CTF3-018-0013 2 CTF3-018-003

4 2 CTF3-018-004

Elenco parti

ELE QT NUMERO PARTE DESCRIZIONE NO

B

0,1 A 0,1 B

40 0.05

Straight Chambers

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DIPOLE MAGNETS FOR TL-2

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Specifications

Sr.

No.Parameters

Values (Type-1)

350

Values (Type-2)

17.50

1 Nominal Field 1.3 Tesla 1.3 Tesla

2 Nominal current 340 A 340 A

3 Pole Gap 45 mm 50 micron 45 mm 50 micron

4 Pole width 240 mm 240 mm

5 Coil Pocket size 176 mm (width) X 176 mm (width) X

157.5 mm (height) 157.5 mm (height)

6 Yoke Length 465 mm (235mm)

7 Magnetic Length 518 mm 288 mm

8 Bending Angle 35 17.5

9 Construction Length 920 mm 690 mm10 Core weight 1273 kg 640 Kg

11 Coil weight 860 kg 445 Kg

12 No of Pan Cakes 4 4

13 No of turns 48/pancake 48/pancake

14 Total no of turns 192 192

15 Resistance 60 milli-Ohm 32.5 milli-ohm

16 Voltage 20.4 Volts 11.3 volts

17 Power dissipated 6.8 Kilo-watt (3.8 KW)

18 Cooling water flow 9.5 LPM 9.5 LPM

19 Pressure drop 2.4 ata 1.24 ata

20 No of cooling circuits 4 4

21 Water temperature rise 11 C 5.8 C

22 Quantity Required 2 Nos. 3 Nos.

DIPOLE MAGNET

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Magnet Core Material:

1.5 mm thick low carbon steel sheets supplied by M/s CockrehillSambre.

B/H data and other information :

H in A/m 120 1200 5000 10000B in Tesla 0.7 1.5 1.71 1.81

Variation in B % 15 % 2 % < 2 % 1 %

Coercivity 70 A/m

Carbon content < 0.01 %

Yield Strength 120 N/mm2

Tensile Strength 260 N/mm2

Thickness spread < 1.5 %

Dipole Magnets (Contd)

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Dipole Magnet Bottom Half Block

Dipole Magnet Coil Pan Cake

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DIPOLE MAGNET ASSEMBLY

Overall Mechanical Details of Assembled 35 Dipole MagnetMagnet height 640 mm

Magnet Width 1000 mm (812 + 30 + 158)

Magnet Length 910 mm

Magnet total weight 2200 kg

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03

01

02

CORE BLOCK FOR DIPOLE MAGNET

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Fabrication Stages :

Laser Cutting of Stampings.

Stacking of stampings & pressing to form a

block.

Welding of stampings to get block.

Machining of pole surface & other reference

surfaces.

Assembly of two blocks along with water

cooled coil pancakes.

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Present Status :

Engineering drawings for 350 bending magnet completed;

Sent to CERN, but approval awaited. Quantity required 2 nos.

Fabrication will start only afterCERNs approval of drawing.

Engg drawings for 17.50 bending magnet completed; will be

shortly sent to CERN for approval. Quantity required 3 nos.

Raw material for core & coil procured.

Dipole Magnets (Contd)

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THANK YOU FOR YOUR ATTENTION

Documents

IS 5067.1983 Power point