3. AL-1704-5147A Technical Specification for the ALS-U ATS_STA Dipole Magnets.pdf

Advanced Light Source Upgrade Project

Lawrence Berkeley National Laboratory All officially released LBNL documents are watermarked and contain LBNL Document Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

Technical Specification for the ALS-U ATS/STA Dipole

Magnets

M. Johansson, P. Wehle

Release Date: Mar 25 2024 11:43:46 AM PDT

Document Number: AL-1704-5147 Revision: A

Document Status: Released

Document Type: SPECIFICATION

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TABLE OF CONTENTS

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

2 Coils

2.1 Materials

2.2 Manufacturing methods

2.3 Test reports

3 Yoke

3.1 Material

3.2 Heat treatment

3.3 Inspection

4 Magnet Assembly

4.1 Factory acceptance test reports

5 Applicable Documents

REVISION HISTORY

Rev. CM Number Description of Change

A Initial Release

APPROVALS

Approver Project Role

Ken Chow ALS-U Accelerator Mechanical Systems Lead

Sol Omolayo ALS-U Mechanical Systems Lead

Michael Lerche ALS-U Magnets Control Account Manager

Charles Swenson ALS-U Magnet Design & Integration Technical Lead

Martin Johansson ALS-U Magnet Manufacturing Technical Lead

Windchill Approved / Concurred By majohansson,oomolayo,KPChow,CASwenson,mlerche ci al ly R el ea se d to th e

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ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source

ALS-U Advanced Light Source Upgrade

ASSY Assembly

ATS Accumulator Ring To Storage Ring (transfer line)

CMM Coordinate Measurement Machine

COTS Commercial off the shelf

DC Direct current

FAT Factory Acceptance Test

ID Identification

LBNL Lawrence Berkeley National Laboratory

STA Storage Ring To Accumulator Ring (transfer line)

TBENDJ Transfer Line B1, B2 & B3 Dipoles ~ 9.29 Deg. Angle

TBENDK Transfer Line B4 Dipoles – Vertical Bend ~ 3.81 Deg. Angle ci al ly R el ea se d to th e

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1 INTRODUCTION

This specification document provides the technical requirements for the production of the ALS-U accumulator ring to storage ring (ATS) and storage ring to accumulator ring

(STA) dipole magnets under a build-to-print Subcontract.

There are two dipole magnet types in the ATS and STA transfer lines: TBENDJ and

TBENDK, shown in Figure 1-1 and Figure 1-2. TBENDJ is a horizontal bending magnet and TBENDK is a vertical bending magnet. Key design parameters for the magnet types are listed for reference in Table 1-1. The TBENDJ type is designated as having variants A and B, but from a manufacturing point of view these two variants are identical (the differentiation pertains to their install location).

The magnets are to be produced according to this technical specification and the applicable drawings and documents listed in Section 5.

Figure 1-1 Magnet type TBENDJ, variant A (TBENDJ-A dipole)

Figure 1-2 Magnet type TBENDK, variant A (TBENDK-A dipole) ci al ly R el ea se d to th e

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Table 1-1 Design parameters for the two ATS/STA dipole magnet types.

Parameter TBENDJ TBENDK Unit

Effective Magnetic Length

ID # (S09-02-)

0.800

017001

0.400

018001 m

Bend angle

ID # (S09-02-)

9.294

017005

3.806

018005

Nominal Dipole field

ID # (S09-02-)

-1.3527

017013

-1.1078

018013 T

By Corrector Field

ID # (S09-02-)

±0.0135

017080

- T

2 COILS

The dipole magnet main coils are layer-wound hollow conductor coils of rectangular shape, with different exit lead routing for each magnet half. The TBENDJ coils include trim windings of solid enameled conductor potted together with the main winding.

The coil production drawings are identified in the drawing list (see Section 5), with additional specifications listed in Sections 2.1 – 2.3 below.

2.1 Materials

1. Materials and commercial off the shelf (COTS) parts are specified in the coil drawings.

2. The coil hollow conductor and solid conductor materials are indicated as copper

C10100 in the drawings, but grades C10100 through C10500 are acceptable. The material grade must be the same for all coils for the same magnet type.

3. Material certificates must be provided for the full quantity of conductor material, and traceability to individual coils must be maintained.

4. The coil potting epoxy formula must be proposed by the Subcontractor, subject to

LBNL approval.

2.2 Manufacturing methods

1. All coil windings must be done without internal splices.

2. The coils must be potted in epoxy by vacuum impregnation.

3. Large volumes of pure un-reinforced epoxy in the finished coils are not allowed.

4. Each coil must be indelibly marked with the LBNL drawing number and serial number.

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2.3 Test reports

Test reports for each individual coil must be provided as part of the Factory Acceptance

Test (FAT) report package for each magnet. All results must be for tests performed on the finished coils.

The FAT report for coils must include the following information and test results for both main and trim windings, as applicable:

1. LBNL drawing number, serial number, and subcontract number

2. Conductor material certificate ID(s)

3. Epoxy product information

4. Inspection and test results:

a. Conductor size

b. Number of coil turns

c. Coil mechanical dimensions: interior length and width, exterior length and width, and cross section height

d. Ground insulation resistance, DC 1 minute at specified voltage

e. Main to trim circuit insulation resistance, DC 1 minute at specified voltage

f. Inter-turn insulation

g. Resistance between coil terminals, corrected to 20°C

h. Coil inductance

i. Visual inspection after all other testing is completed

5. Subcontractor’s acceptance of all information and results, with signature and date.

Parameter specifications corresponding to the tests listed above are provided in the coil drawings or Table 2-1. Tests/measurements with no tolerances specified for the Table 2-

1 result parameters are informative. LBNL may reject outlier results at their discretion.

Table 2-1 Functional parameter specifications for the dipole coils.

Parameter TBENDJ TBENDK Unit

Minimum Insulation Resistance Testing Voltage (main)

ID # (S09-02-)

017125

018104 V

Minimum Insulation Resistance Testing Voltage (trim)

ID # (S09-02-)

017172

- V

Minimum Insulation Resistance

ID # (S09-02-)

017126, 017173

018105

GΩ

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Parameter TBENDJ TBENDK Unit

Minimum Inter-Turn Insulation Testing Voltage

ID # (S09-02-)

017128, 017177

018132 V/turn

Main Coil Resistance

ID # (S09-02-)

27.1

017103

31.6

018082 mΩ

Trim Coil Resistance

ID # (S09-02-)

476.1

017153

- mΩ

3 YOKE

Each dipole magnet yoke consists of two halves. Both halves are machined to an identical intermediate drawing level and inspected before they are finished into yoke half assemblies, with variations in hole patterns, welded parts, and paint masking for the upper/lower halves (TBENDJ) or left/right halves (TBENDK).

The applicable production drawings are identified in the drawing list (see Section 5), with additional requirements listed in Sections 3.1 – 3.3.

3.1 Material

1. The specified yoke material is solid AISI 1006 low carbon steel.

2. Material certificates, including chemistry reports, must be provided and traceability to individual yoke parts must be maintained.

3.2 Heat treatment

1. To ensure good magnetic properties, the yoke parts must undergo a magnetic anneal after rough machining.

2. All final machining operations, the installation of inserts, etc., must occur after magnetic anneal.

3. The anneal cycle listed in Table 3-1 is specified by LBNL for AISI 1006 steel to achieve acceptable magnetic properties. Note that this heat treatment process must be performed in a dry reducing atmosphere.

4. Heat treatment logs (the standard process traveler) must be provided containing the following information and results:

a. Atmosphere used

b. Heat treatment time-temperature profile used in the furnace (by zone if applicable) ci al ly R el ea se d to th e

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c. Logged temperature vs time (plot preferred), with sensor locations identified

d. Serial numbers of individual yoke parts per heat treatment run

Table 3-1 LBNL specified heat treatment for AISI 1006 steel yoke components.

Activity Time [h]

Place yoke components in an oven which is at any temperature below 50°C n/a

Heat oven at ≤ 220°C/hour up to 660°C 3

Hold at 660°C ±10°C 4

Heat oven from 660⁰C to 770°C at ≤55°C/hour 2

Hold at 770°C ±10°C to reach soak temperature 4

Hold at 770°C ±10°C for one more hour 1

Leave yoke components in oven; cool oven at ≤90°C /hour down to ≤500⁰C 3

Leave yoke components in oven, cool oven at ≤120°C /hour down to a maximum temperature 260⁰C 2

Remove yoke components from oven and air cool down to room temp n/a

3.3 Inspection

1. Inspection after intermediate machining. The Subcontractor must conduct a documented coordinate measurement machine (CMM) inspection once each yoke half is machined to either of the drawings listed below, but before additional work to the next level yoke assembly drawing is done. The CMM inspection reports must be provided as part of the FAT report package for each magnet.

a. AL-1520-2859 YOKE, STRAIGHT, TBENDJ (2x/magnet)

b. AL-1548-5340 YOKE, TBENDK-A, COMMON (2x/magnet)

2. Yoke half assembly inspection. CMM reports containing measured results for indicated inspection dimensions at the yoke assembly drawing level must be provided as part of the FAT report package for each magnet.

4 MAGNET ASSEMBLY

The dipole magnets must be fully assembled according to the drawings in Section 5 and tested/inspected as indicated in Section 4.1.

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4.1 Factory acceptance test reports

A FAT report must be provided for each magnet assembly that contains results of tests performed on the assembled magnet and references to documentation of constituent parts.

The FAT report for each magnet must include:

1. LBNL drawing number, serial number, and subcontract number

2. Yoke half serial numbers together with the corresponding inspection reports (as applicable per Section 3.3), material certificates, and heat treatment logs identified

3. Coil serial numbers for each assembly location with corresponding test reports identified

4. Mechanical dimensions, fully assembled: pole gap1 between opposing pole faces at both sides of the magnet.

5. Insulation resistance, DC 1 minute at specified voltage:

a. Between main coil terminals and yoke

b. Between main coil terminals and each thermal switch circuit

c. Between each thermal switch circuit and yoke

TBENDJ magnets also require:

d. Between the trim circuit and yoke

e. Between main coil terminals and the trim circuit

f. Between the trim circuit and each thermal switch circuit

6. Resistance, corrected to 20°C

a. Between main coil terminals

TBENDJ magnets also require:

b. Between the trim coil circuit terminals

7. Hydrostatic leak test for each cooling circuit

8. Cooling water flow for each cooling circuit

1 Nom. gap 20 mm for TBENDJ and 15 mm for TBENDK, per the yoke machining drawings listed in

Section 3.3.

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9. Power/temperature test: magnet powered with main coils at nominal current, and trim coils at max current for TBENDJ, with nominal cooling water pressure drop for 2 hours, with magnet voltage and water inlet, outlet, coil surface, pole and ambient temperatures logged

10. Visual inspection after all other testing is completed

11. Subcontractor’s acceptance of all information and results, with signature and date

Parameter specifications corresponding to the tests listed above for the assembled magnets are provided in Table 4-1. Tests/measurements with no tolerances specified in

Table 4-1 are informative. LBNL may reject outlier results at their discretion.

Table 4-1 Functional parameter specifications for the dipole magnets.

Parameter TBENDJ TBENDK Unit

Minimum Insulation Resistance Testing Voltage (main)

ID # (S09-02-)

017125

018104 V

Minimum Insulation Resistance Testing Voltage (trim)

ID # (S09-02-)

017172

- V

Min. Insulation Resist. Testing Voltage (thermal switch)

ID # (S09-02-)

017265

018134 V

Minimum Insulation Resistance

ID # (S09-02-)

017126, 017173

018105

GΩ

Main Coil Resistance

ID # (S09-02-)

54.2

017103

63.3

018082 mΩ

Trim Coil Resistance

ID # (S09-02-)

952.1

017153

- mΩ

Cooling Circuit Hydrostatic Leak Test Pressure

ID # (S09-02-)

017210

018133 kPa

Design Cooling Circuit Pressure Drop

ID # (S09-02-)

017203

018110 kPa

Number of Cooling Water Circuits/Magnet

ID # (S09-02-)

017252

018119

Cooling Water Flow/Circuit

ID # (S09-02-)

5.1

017207

3.7

018114 l/min

Main Coil Nominal Current

ID # (S09-02-)

285.2

017100

231.2

018079 A

Main Coils Voltage at Nom. Current

ID # (S09-02-)

15.45

017101

14.63

018080 V

Trim Coil Maximum Current

ID # (S09-02-)

3.7

017175

- A

Trim Coils Voltage at Max. Current

ID # (S09-02-)

3.55

017176

- V

Water temperature rise at nom. current

ID # (S09-02-)

12.5

017206

13.1

018113 °C ci al ly R el ea se d to th e

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5 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document shall be valid to the fullest extent, unless specifically noted within this document. Applicable documents must originate from the LBNL Document Control Center (DCC) and will be made available by

LBNL as needed.

Document Number Title

AL-1700-9211 Statement of Work for the ALS-U ATS STA Transfer Line Magnets

AL-1437-1565 MAGNET ASSY, TBENDJ-A

AL-1437-1567 MAGNET ASSY, TBENDJ-B

AL-1595-2412 MAGNET ASSY, TBENDK-A

AL-1704-0625 Drawing List for the ATS/STA Dipole Magnets

10068 LBNL Engineering Paint Specification ci al ly R el ea se d to th e

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