1 brookhaven science associates sr magnet status satoshi ozaki, manager, sr magnet production 8 th...

1 BROOKHAVEN SCIENCE ASSOCIATES

SR Magnet Status

Satoshi Ozaki, Manager, SR Magnet Production

8th ASAC meeting for NSLS-II Project

May 10-11, 2011


SR Magnets (Types and Numbers)Mgt Type Code Description Part No. Maker QuantityQuadrupole Type A Single-coil, Short & Wide 9801 BINP 30

Type B Single-coil, Short & Narrow 9802 BINP 30Type C Double-coil, Long & Narrow 9804 BINP 30Type C' Same as above, with Cutout 9807 BINP 30Type D Double-coil, Short & Narrow 9809 Tesla 90Type E Double-coil, Short & Wide 9812 Tesla 30Type F Large Aperture, Short & Narrow 9815 BLS 60

Sub Total 300Sextupole Type A Single-coil, Short & Narrow S-9801 Danfysik 150

Type B Single-coil, Short & wide S-9802 IHEP 60Type C Large Aperture, Short & Wide 9816 BSL 30

Sub Total 240Dipole Type A Dipol-35 mm 3500 BSL 54

Type B Dipole 90 mm 9000 BSL 6Sub Total 60

Corrector Type A Corr-100 mm 1000 Everson 90Type B Corr-100 mm with Skew Quard 1001 Everson 30Type C Corr-156 mm 1560 Everson 60Type F Corr-Fast 2002/3 90

Sub Total 270Total 16 Types 916


Typical Challenges in Magnet Production

Tight field quality specs call for• Careful design• Tight specs on raw materials• Specialized tooling & machining• Tightly controlled manufacturing & assembly process • High quality magnetic field measurement capability

To be paid attention by vendor:• purchasing right quality of steel & copper• availability of qualified manpower• adequacy of manufacturing process and toolingChallenges for Vendors:• adequacy of field measurement capability• reproducibility of field quality in each magnet • production capacity and competition with other customers

Have to meet field quality and reproducibility specification


Variety Manufacturing Techniques

Each vendor with unique expertise, tooling, and favorite manufacturing techniques. For example:

• Sextupoles (IHEP, Danfysik): Stamping Laminations, stacking yokes, EDM of poles on complete yokes

• Quadrupoles (TESLA): Stamping laminations, stacking yokes, machining half yokes

• Quadrupoles (Budker): Stamping, fine blanking laminations, stacking half yokes and shaping/reinforcing yokes with chromium-copper bars

• Large Aperture Quads and Sexts (Buckley): Laser cutting laminations, stacking yokes, EDM completed yoke

• Dipoles (Buckley): Laser cutting laminations, stacking machining

• Correctors (Everson): stamping, stacking

TESLA: machining

Buckley: EDM

BINP: Fine planking


There are general recognitions that the production of these magnets have been significantly behind schedule

Many contributing factors, some minor and some significant for this delay:

• Procurement• Formulation of the procurement strategy• Development of bid package• Approval of the package• Bid and proposal selection

• The First Article development• Prohibition to favor the prototype producer• Tightness of the initial field quality tolerance• Requirement for the field quality reproducibility on reassembly of the magnet

halves for the girder assembly with vacuum chamber• Apparent shortage of experienced magnet design and production engineers

at the contractor site • Approval of series production (PRR authorization)

SR Magnet Production Overview


Other Schedule Mitigation Actions• Satoshi Ozaki was appointed as the manager for magnet production to provide full-time,

focused and dedicated management oversight.• Enhanced vendor oversight:

• Assign dedicated engineers for each of 6 production sites• 2 additional consulting contracts placed to provide technical and managerial oversight at

Buckley and Budker• Proactive technical guidance in spite of the fact that these are performance spec procurements

• Relaxation of field quality tolerances based on re-evaluation of the requirement:• A major re-evaluation based on a reduction of momentum acceptance from 3.0% to 2.5%

• Established flexible schedule: • Optimize sequencing of girder integration & installation according to magnet availability• Added a new measurement stand• Additional fixture and tooling designed, produced and tested• Required staff has been augmented and trained

• High precision magnet alignment process formulated: • Prepared to allow installation of single magnet with acceptable precision in the tunnel• Prepared to install dipole magnets after multipole girders are installed

• Additional schedule mitigation• Build additional environmental room• Add shift(s) for magnet-girder integration and increase peak staffing

• Flexibility in PRR authorization, including a conditional approval


Buckley Systems Ltd. (BSL) Frank DePaola

BSL Large Aperture Quadrupole

BSL Large Aperture Sextupole

Large aperture multipoles:• First Articles Q1, Q2 and S1 tested at BNL with promising results • Quad production is now fully turned onto be turned on this week• Sextupole hopefully in May, subject to receiving one more First Article unit


Buckley Systems Ltd. (BSL) Frank DePaola• 90 mm dipole:

• First Article that was air shipped (13,000 lb) and to be tested soon. Getting ready for PRR• 35 mm dipole:

• Although the first of First Article was acceptable quality, the dipole No. 2, 3. and 4 developed cracks on the bonded core, which caused the core production to stop

• Making progress in understanding the cracks on yokes• In parallel, manufacturing design of an enlarger, the dipole yoke as a back- up to mitigate this

technical issue is in progress BSL is a major magnet builder in New Zealand,

which built entire magnet for the Australian Light Source.

A Large firm with 220 employees and annual business volume ~$100 M (90% in magnet business),

At one point, after ALS work, the company lost quality manufacturing expertise due to economic downturn, but is recovering in recent months,

Also expanding its capability with a lease of a large building across the street for manufacturing of lamination magnets 90 mm Dipole Magnet


Tesla Quadrupoles Charles Spataro• Since the awarding of the contract, dealing with them has

been slow and un-satisfactory, • April visit by Ferdinand, Charles, et al • With this visit, Tesla must have realized the seriousness of

our stance toward their tardiness, and began to show signs of improvement

• They finally admitted the machining error that caused 50 μm asymmetry

• Reversed their position for an improvement of their measuring stand that was recommended by BNL

• Agreed to expedite test yoke production on EDM prove out process

• Providing, for now, daily reports on the progress towards the May 20 PRR for full production

• For two of those magnets measured at BNL, their field quality is acceptable, and field reproducibility is good, in spite of the machined poles be not symmetric

Tesla Quad Narrow

Tesla Quad Wide 9812


BINP Quadrupoles Sushil Sharma• BINP uses a Cu bar wedged between two

poles upper and lower • Short quadrupole has been in the

production phase • Long quad PRR was also approved for

full production• A request was made for their proposal

to manufacture the type of quadrupoles that are being made by Tesla

Short & Narrow

Short & Wide

Long & Narrow

Long & Kinked

• They promised to deliver five magnets in the next two weeks• A snag with the Russian export control issue• Have already made many yoke and coils under their own risk


IHEP Beijing Sextupoles John Skaritka

• Reputable magnet producer that supplied equipment to many projects around the world

• They are in the production phase• Sextupole #11 was measured at BNL

and found to be in acceptable range• Back-up source for the Large Aperture

multipoles• began with tooling design and

lamination laser cuttingIssues:• Initially, we suffered from some cultural issues involving the manufacturing• The magnet manufacturing without following a written procedure• Poor communications between scientific/engineering and people at the work shop• After many negotiations, the manufacturing procedures have been put in place

gradually and now normal manufacturing procedures and traveler exist, and are being used on the shop floor in most cases

• Exception to this has bean for the yoke assembly, where a technician appeared to have assembled and tighten the bolts in his own way, making it difficult to achieve the reproducibility of the field


DANFYSIK Sextupoles Lewis Doom

• Danfysik was the first one to enter into the full production mode of operation• A little over 25% of the magnets have been delivered to date with nominal

delivery rate of ~14 per month• Production, however, had been halted for about two months while tooling

upgrades are in progress• Should resume delivery in May• ECR to remove C-shaped pole clamp


Trends with Danfysik Sextupoles

0.824

0.826

0.828

0.830

0.832

0.834

0.836

0 5 10 15 20 25 30 35 40 45 50

LT-S68 Serial Number

(B"L

)/I

(T/m

/A)

Danfysik Data BNL Data

-0.5

-0.4

-0.3

-0.2

-0.1

0.0

0.1

0.2

0.3

0 5 10 15 20 25 30 35 40 45 50


Rol

l Ang

le (

mra

d)

Danfysik (As Reported) BNL Data

Sign of Danfysik data is as reported by Danfysik, but is opposite of that computed from reported (a 3,b 3).

-3

-2

-1

0

1

2

3

4

0 5 10 15 20 25 30 35 40 45 50


b4 (

unit

s; 2

5 m

m)

Danfysik (Sign Corrected) BNL Data Spec. Limits

-2

-1.5

-1

-0.5

0

0.5

1

1.5

0 5 10 15 20 25 30 35 40 45 50


a4 (

unit

s; 2

5 m

m)

Danfysik (Sign Corected) BNL Data Spec. Limits


Everson Correctors George Rakowsky

• Everson continues to manufacture the corrector magnets at a satisfactory rate

• Everson has been notified about Hi-Pot failure between the coil leads and a corner of the corrector yoke

• Recommendation for the way to prevent such a break down was given to the company

100 mm Corrector

100 mm Corrector with Skew Quad 156 mm Corrector


The SR Magnet Production at a Glance

Quad-SC-S-W 9801 Type A Budker 30 24-Mar-11 16 16 9 16 2 2 2 2 2 2 2 3 (1)Quad-SC-S-N 9802 Type B Budker 30 21-Apr-11 15 15 7 16 2 2 2 2 2 2 2 3 (1)Quad-DC-L-N 9804 Type C Budker 30 21-Apr-11 10 7 7 10 3 3 3 3 2 2 2 3 (1)Quad-DC-L-N 9807 Type C' Budker 30 4-Apr-11 6 6 3 11 3 3 2 2 2 1 1 3 (2)Quad-DC-S-N 9809 Type D TESLA 90 21-Apr-11 6 3 3 2 2 2 2 2 2 2 2 3 (1)Quad-DC-S-W 9812 Type E TESLA 30 21-Apr-11 6 2 2 2 2 2 2 2 2 2 2 2Sext-S-S-N S-9801 Type A Danfysik 169 06-Apr-11 54 54 54 48 47 47 47 3 47 44 44 58 (14)Sext-S-S-W S-9802 Type B IHEP 75 21-Apr-11 35 10 9 9 7 7 6 6 6 6 3 4 (1)Quad-LA Back-up IHEP 4 21-Apr-11 4Sext-LA Back-up IHEP 6 21-Apr-11 6Quad-LA 9815 Type F Buckley 60 20-Apr-11 9 3 3 3 3 3 3 3 3 2 2 3 (1)Sext-LA 9816 Type C Buckley 30 20-Apr-11 9 3 2 2 1 1 1 1 1 1 1 2 (1)Dipol-35 3500 Type A Buckley 54 20-Apr-11 3 3 3 3 3 3 na na 3 0 0 0Dipole 90 9000 Type B Buckley 6 20-Apr-11 1 1 1 1 1 1 na na 1 1 0 1 (1)Corr-100 1000 Type A Everson 102 21-Apr-11 26 24 13 20 10 10 na na 11 11 11 14 (3)Corr-100-SQ 1001 Type B Everson 30 20-Apr-11 8 8 4 4 4 4 na na 4 4 4 5 (1)Corr-156 1560 Type C Everson 60 21-Apr-11 20 20 10 13 8 8 na na 7 7 7 9 (2)

SUMMARY 836 234 175 130 160 98 98 70 26 95 87 83 113 (30) 0

One of each to be returned after repair

72 last monthApril 27, 2011


Risks and Mitigation

• Possibility of an extensive delay in production• More intense monitoring of the production process• IHEP Back-up for large aperture multipoles from Buckley• Plan B for TESLA to give directed change in yoke machining (outsourcing)• Begin First Article process for TESLA quadrupoles at BINP• Work more intensely with BSL and in-house assembly of dipoles with locally

manufactured components ?• Keep the possibility of DANFYSIK for TESLA/BINP back-up (high cost!) ?

• Single point of failure in production tools:• Plant with a single Electrical Discharge Machining (EDM) facility

– Encourage to add another EDM machine• Supplier with single or inefficient field measuring facility

– Help supplier improve their measuring capabilityBINP setting up the 2nd measuring standTesla responded to our recommendation

– Prepare BNL to step in to perform the measurements


Summary

• Our supplier can build acceptable multipole magnets, and multipole magnet productions are either in progress or about to begin

• Although some of the manufactures, Danfysik, Everson, and possibly BINP are already in the routine production, a few more months of ramp-up time is anticipated for others to reach a routine production and delivery stage

• Next critical issue remains with 35 mm dipole production at Buckley• Our receiving and in-house measurement has been overloaded with

many special tests, but is poised to deal with the increased flow of magnets to come

• Manufacturing quality issues at some of the suppliers require continued surveillance

• Until the routine production is in place, very frequent visits by our staff, and/or consultants are essential

1 brookhaven science associates sr magnet status satoshi ozaki, manager, sr magnet production 8 th...

Documents

field quality reproducibility

magnet production capacity

mm3500bsl54 type bdipole

mm1000everson90 type

stamping laminations

production engineers

magnet halves

shapingreinforcing yokes