Procurement status of SR main magnets

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

2. Agenda • reports and specifications • main contracts and schedule • CERN sextupole pre-series pole tip profiles TAC Nov. 2012 presentation Attilio Milanese

3. REPORTS & SPECIFICATIONS Attilio Milanese

4. 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. placeholder structure for deliverables of the EC project CESSAMag Attilio Milanese

5. Reports and specifications • Combined function bending magnets • 1279692 Design Report under approval • 1279694 Technical Specification released • 1280708 Technical Questionnaire released • Quadrupoles • 1257123 Design Reportreleased • 1257262 Technical Specificationreleased • 1280709 Technical Questionnairereleased • 1279686 Technical Specification Coilsreleased • Sextupoles / correctors • 1257260 Design Reportreleased • 1290345 Technical Specification Coilsreleased • 1279686 Technical Specification under preparation Attilio Milanese

6. 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. 2013 gave some tentative values, no fully discussed and detailed with beam dynamics arguments Tentative values from Feb. meeting with Erhard at CERN and Maher A. analyses • target ∫ field quality dipoles: 5∙10-4 for -30 ≤ x ≤ 30 mm, y = 0 QF quadrupoles: QD quadrupoles: sextupoles (correctors off): ai, bi are of ∫ harmonics of B at R= 24 mm • magnet-to-magnet reproducibility, as maximum deviation between each couple of magnets in the same family (peak-to-peak) dipoles,reproducibility of ∫ central G: 1∙10-2 QF: 2∙10-3 , QD: 10∙10-3 , sextupoles 20∙10-3 • position of the magnetic axis for quadrupoles and sextupoles: 0.1 - 0.2 mm rms? • alignment of the bending magnet? • magnet-to-magnet alignment on the girder? 10∙10-4 10∙10-4 0∙10-4 Attilio Milanese

7. 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 • 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. Attilio Milanese

8. MAIN CONTRACTS Attilio Milanese

9. Main contracts Attilio Milanese

10. 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. 2013 (before awarding the contract), visiting both TESLA and the subcontractor for the punching, Midland Tool & Design • contractual schedule • Manufacturing File 25 Nov. 2013 • 1 pre-series dipole 25 Jul. 2014 • 4 series dipoles 19 Dec. 2014 • 4 series dipoles 25 Mar. 2015 • 4 series dipoles 25 Jun. 2015 • 4 series dipoles 25 Sept. 2015 Attilio Milanese

11. 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 (isovac1400-100A high perm with EB549 coating, from VoestAlpine, Austria), delivery to puncher expected beginning of Mar. 2014. • TESLA has ordered 11 t of hollow copper conductor (from Luvata, Finland), first conductor delivery expected mid-Feb. 2014. • The punching tooling is also in preparation, the first laminations are expected mid-Mar. 2014. • next visit on 25 Nov. 2013, for reviewing the Manufacturing File Attilio Milanese

12. 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. 2013 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 QF 12 Mar. 2014 • 8 series QD + 8 series QF 27 Jun. 2014 • 8 series QD + 8 series QF 7 Nov. 2014 • 8 series QD + 8 series QF 18 Feb. 2015 • 8 series QD + 8 series QF 14 Apr. 2015 Attilio Milanese

13. Quadrupoles • direct involvement of the technical director, Julio Lucas • the drawing of the lamination is approved • ELYTT has ordered the electrical steel (M1300-100A 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. 2013 CAD model of ELYTT (work in progress) Attilio Milanese

14. Quadrupole coils • 140 QF and 140 QD coils • CERN provides the hollow copper conductor (from Luvata, Finland), insulated with 2×50 mm of polyimide with epoxy layer + 3×130mm of glass fiber (wrapping performed by Sofilec, France) • review of Manufacturing File 10 Oct. 2013 at CERN, we had already visited them in Turkey for a contract of spare coils • schedule • Manufacturing File 11 Oct. 2013 • 10 pre-series QD and 10 pre-series QF coils13 Dec. 2013 • 40 series QD and 40 series QF coils 28 Mar. 2014 • 40 series QD and 40 series QF coils 25 Jul. 2014 • 50 series QD and 50 series QF coils 29 Nov. 2014 Attilio Milanese

15. 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 QD mould QF mould QD winding mandrel QF test coils Attilio Milanese

16. 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. 2013 • schedule • 20 pre-series coils21 Feb. 2014 • 100 series coils 30 May 2014 • 100 series coils 1 Aug. 2014 • 100 series coils 17 Oct. 2014 • 100 series coils 19 Dec. 2014 Attilio Milanese

17. 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 32 + 1 magnets. • A company in Cyprus (CNE Technology Center) has been selected for supplying the other 32 +1 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. Attilio Milanese

18. Schedule for main contracts • schedule broken down according to supply of batches • contractual schedule for dipole, quadrupoles, quadrupole coils and sextupole coils • estimated schedule for sextupoles I II III IV I II III IV IV 2014 2015 Attilio Milanese

19. 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 Attilio Milanese

20. 1st assembly of CERN sextupole pre-series (electric and hydraulic circuits in test configuration) correctors circuits view main sextupole view (already in an accelerator tunnel, the ISR!) Attilio Milanese

21. Field quality of CERN sextupole pre-series ∫b9 = 0 and with no end pole chamfer thanks to a biased b9 in 2D b9,2D = 12.8 Opera-2D model ∫b9 = 0 Opera-3D model center Lmagn Liron multipoles in 10-4 @ R = 24 mm  The allowed harmonics are extremely good: the pole profile is confirmed.  a6 = 0.9 due to a solenoidal loop on the lead side: avoiding that would lower a6 to 0.3 (tried experimentally).  The other non allowed harmonics (octupole and decapole), can be further reduced by improving the symmetry of the assembly. allowed Rotating coil measurements allowed Attilio Milanese

22. CERN pre-series correctors (in sextupole) vertical dipole horizontal dipole skew quadrupole • 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. Attilio Milanese

23. A precisely punched lamination • 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. Attilio Milanese

24. 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 Attilio Milanese

25. Stacking tooling: 5 ready (for series yokes) Attilio Milanese

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

27. TO CONCLUDE Attilio Milanese

28. A wide effort Attilio Milanese

29. Special thanks to • the EC for the CESSAMag funds, FP7 contract 338602 • 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) teşekkürederimתודה (toda) Attilio Milanese