4. AL-1704-5148B Technical Specification for the ALS-U ATS_STA Quadrupole 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

Quadrupole Magnets

M. Johansson, P. Wehle

Release Date: Apr 8 2024 1:08:29 PM PDT

Document Number: AL-1704-5148 Revision: B

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 and mechanical fiducialization

4 Magnet Assembly

4.1 Factory acceptance test reports

5 Applicable Documents

REVISION HISTORY

Rev. CM Number Description of Change

A Initial Release

B 000529-CN-Magnet Updated Table 4-2 values for TQFK/TQDL.

APPROVALS

Approver Project Role

Ken Chow ALS-U Accelerator Mechanical Systems Lead

Sol Omolayo ALS-U Accelerator Mechanical Systems Technical 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

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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 σ Standard deviation

SMR Sphere-mounted Retroreflector

STA Storage Ring To Accumulator Ring (transfer line)

TQDJ Quadrupole, Horizontally Defocusing, Configuration “J”

TQDK Quadrupole, Horizontally Defocusing, Configuration “K”

TQDL Quadrupole, Horizontally Defocusing, Configuration “L”

TQDM Quadrupole, Horizontally Defocusing, Configuration “M”

TQFJ Quadrupole, Horizontally Focusing, Configuration “J”

TQFK Quadrupole, Horizontally Focusing, Configuration “K” 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) transfer line quadrupole magnets under a build-to-print subcontract.

There are 6 quadrupole magnet types of 10 different variants, corresponding to different magnetic field requirements and constraints for different install locations in the STA and

ATS transfer lines. The base variants (-A) of each quadrupole type are shown in Figures

1-1 through 1-6. Key design parameters for the magnet types are listed for reference in

Table 1-1. Due to having different field polarity and field strength, TQFJ and TQDK are designated as separate types, but they share the same yoke and coil design.1 This is also the case for types TQFK and TQDL.2

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

1 With the AL-1473-8121 subassembly – containing the yoke, coils, bus routing and safety covers – being identical for all five TQFJ/TQDK variants listed in Section 5.

2 With the AL-1472-4910 subassembly – containing the yoke, coils, bus routing and safety covers – being identical for all three TQFK/TQDL variants listed in Section 5.

Figure 1-1 Magnet type TQDJ, variant A (TQDJ-A quadrupole)

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

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Figure 1-3 Magnet type TQDL, variant A (TQDL-A quadrupole)

Figure 1-4 Magnet type TQDM, variant A (TQDM-A quadrupole)

Figure 1-5 Magnet type TQFJ, variant A (TQFJ-A quadrupole)

Figure 1-6 Magnet type TQFK, variant A (TQFK-A quadrupole) ci al ly R el ea se d to th e

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Table 1-1 Design parameters for the 6 ATS/STA quadrupole magnet types.

Parameter TQDJ TQFJ TQDK TQFK TQDL TQDM Unit

Effective Magnetic Length

ID # (S09-02-)

0.312

019001

0.120

020002

0.217

021002

0.217

0022001 m

Max. Quadrupole Gradient

ID # (S09-02-)

6.05

019011

-41.43

020013

39.42

020014

-70.62

021016

70.80

021017

20.63

022011 T/m

By Corrector Field

ID # (S09-02-)

±0.0171

019192

- ±0.0444

020240

±0.0246

021186

±0.0246

022192 T

Bx Corrector Field

ID # (S09-02-)

±0.0171

019193

- ±0.0444

020241

±0.0246

021187

±0.0246

022193 T

2 COILS

The quadrupole magnet main coils are layer-wound hollow conductor coils of rectangular shape with different exit lead routings for each coil location. Each coil assembly includes two 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. Results and information must be provided for both main and trim windings, as applicable. All results must be for tests performed on the finished coils.

The FAT report for coils must include the following information and test results:

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. Insulation resistance between windings, 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 and summarized in Table 2-1 and Table 2-2. Tests/measurements with no tolerances specified for the Table 2-1 and Table 2-2 result parameters are informative.

LBNL may reject outlier results at their discretion.

Table 2-1 Common functional parameter specifications for all quadrupole coils.

ID # (S09-02-) Parameter Value Unit

0191203 Minimum insulation resistance testing voltage (main) 1200 V

019141, 019162 Minimum insulation resistance testing voltage (By and Bx) 200 V

019121, 019142, 019163 Minimum insulation resistance 2 GΩ

019194, 019195, 019196 Minimum inter-turn insulation testing voltage 10 V/turn

3 The LBNL internal parameter specification ID numbers listed are for magnet type TQDJ. The other magnet types have the same specified parameter values.

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Table 2-2 Unique functional parameter specifications for the different quadrupole coil types.

Parameter TQDJ TQFJ/TQDK TQFK/TQDL TQDM Unit

Main Coil Resistance

ID # (S09-02-)

10.0

019098

11.2

020142

9.1

021131

7.8

022098 mΩ

By Coil Resistance

ID # (S09-02-)

44.4

019126

47.4

020170

67.4

021135

33.6

022126 mΩ

Bx Coil Resistance

ID # (S09-02-)

44.4

019147

47.4

020191

67.4

021156

33.6

022147 mΩ

3 YOKE

Each quadrupole magnet yoke consists of four quadrants, which are assembled into a

“yoke pre-assembly,” where the final pole profiles are precision-machined in situ. 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 material for the yoke quadrants for all quadrupole types is solid AISI

1006 low carbon steel.

2. Material certificates, including chemistry reports, must be provided and traceability to individual yoke quadrants 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 ≤500 ⁰C 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 and mechanical fiducialization

1. Yoke pre-assemblies. Coordinate measurement machine (CMM) inspection reports of each yoke pre-assembly must be provided as part of the FAT report package for each magnet.

a. CMM reports must contain measured results for dimensions noted as “to be measured and recorded” in the LBNL drawings, plus measured locations of the sphere-mounted retroreflector (SMR) nests4 that are part of the yoke pre-assembly within a coordinate system that is best fit to the pole profiles

(mechanical fiducialization).

b. Repeatability of dis-assembly/re-assembly and CMM re-inspection for the yoke pre-assemblies must be demonstrated for the first of each yoke pre-assembly type. Results must remain within tolerances, with fiducial position spread <10 µm σ in the X, Y and Z-directions.

4 Utilizing 1.5” tooling balls.

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2. Yoke quadrants. CMM inspection reports of yoke quadrant dimensions noted as “to be measured and recorded” in the LBNL drawings must be provided as part of the FAT report package for the first of each yoke pre-assembly type.

4 MAGNET ASSEMBLY

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

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 pre-assembly serial number together with the corresponding inspection report, part serial numbers, part 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:

a. Pole flat gaps between closest points on pole profiles5

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

a. Between each coil circuit and yoke

b. Between the different coil circuits

c. Between each coil circuit and the thermal switch circuit

d. Between the thermal switch circuit and yoke

6. Resistance, corrected to 20°C:

a. For each coil circuit

7. Cooling circuit hydrostatic leak test

8. Cooling water flow

5 Dimensions are specified in yoke pre-assembly drawings (see the drawing list in Section 5).

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9. Power/temperature test: magnet powered with main and trim coils at maximum current with a nominal cooling water pressure drop for 2 hours, with magnet main coil and trim coil voltages, water inlets, water outlets, coil surfaces, 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 and Table 4-2. Tests/measurements with no tolerances specified in Table 4-1 and Table 4-2 are informative. LBNL may reject outlier results at their discretion.

Table 4-1 Common functional parameter specifications for all quadrupole magnets.

ID # (S09-02-) Parameter Value Unit

019120 Minimum insulation resistance testing voltage (main) 1200 V

019141, 019162 Minimum insulation resistance testing voltage (By and Bx) 200 V

019198 Minimum insulation resistance testing voltage (thermal switch) 300 V

019121, 019142, 019163

Minimum Insulation resistance 2 GΩ

019175 # of cooling circuits/magnet 1 -

019197 Cooling circuit hydrostatic leak test pressure 1900 kPa

019168 Design cooling circuit pressure drop 448 kPa

Table 4-2 Unique functional parameter specifications for each of the 6 quadrupole magnet types.

Main Coil Circuit Resistance

ID # (S09-02-)

40.0

019098

44.6

020142

36.6

021131

31.2 022098 mΩ

By Coil Circuit Resistance

ID # (S09-02-)

177.6

019126

189.4

020170

269.6

021135

134.3

022126 mΩ

Bx Coil Circuit Resistance

ID # (S09-02-)

177.6

019147

189.4

020191

269.6

021156

134.3

022147 mΩ

Cooling Water Flow

ID # (S09-02-)

0.48

019172

0.75

020216

0.84

021164

0.55

022172 l/min

Main Coil Max. Current (I)

ID # (S09-02-)

35.0

019099

93.3

020143

147.0

021132

67.1

022099 A

Main Coils Voltage at Max. I

ID # (S09-02-)

1.40

019100

4.17

020144

5.38

021133

2.09

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By Coil Max. Current (I)

ID # (S09-02-)

16.4

019127

18.67

020171

10.1

021136

17.7

022127 A

By Coils Voltage at Max. I

ID # (S09-02-)

2.91

019128

3.54

020172

2.73

021137

2.38

022128 V

Bx Coil Max. Current (I)

ID # (S09-02-)

16.4

019148

18.67

020192

10.1

021157

17.7

022148 A

Bx Coils Voltage at Max. I

ID # (S09-02-)

2.91

019149

3.54

020193

2.73

021158

2.38

022149 V

Water Temp. Rise at Max. I

ID # (S09-02-)

1.5

019171

7.5

020215

13.6

021163

3.7

022171 °C

5 APPLICABLE DOCUMENTS

The released version of the documents listed in this section are integral to this specification, and all information contained therein is to be taken as valid to the fullest extent unless specifically noted within this specification. 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-1437-1569 MAGNET ASSY, TQDJ-A

AL-1437-1571 MAGNET ASSY, TQDK-A

AL-1437-1573 MAGNET ASSY, TQDK-B

AL-1437-1574 MAGNET ASSY, TQDL-A

AL-1437-1576 MAGNET ASSY, TQDL-B

AL-1437-1577 MAGNET ASSY, TQDM-A

AL-1437-1572 MAGNET ASSY, TQFJ-A

AL-1583-7952 MAGNET ASSY, TQFJ-B

AL-1584-0842 MAGNET ASSY, TQFJ-C

AL-1437-1575 MAGNET ASSY, TQFK-A

AL-1704-0849 Drawing List for the ATS/STA Quadrupole Magnets

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