Appendix B Argonne National Laboratory SOW.pdf

4/26/2024 10:30:00 AM

A r g o n n e N a t i o n a l L a b o r a t o r y | 9 7 0 0 S . C a s s A v e n u e | L e m o n t , I L 6 0 4 3 9

EXTRACTION CHICANE MAGNETS FOR

FOR THE ATLAS MULTI-USER UPGRADE

(AMUU) PROJECT

April 25, 2024

ANL Point of Contact (POC): Brahim Mustapha Responsible Institution: TBD Responsible Institution POC: TBD Period of Performance: 9 months from Order

Abstract: The ATLAS Multi-User Upgrade (AMUU) project requires a new beam extraction chicane to share beam between two target stations in pulsed mode. The kicker magnet system is already under contract. This RFP covers the rest of the DC magnets, which are part of the extraction chicane. They include a compact quadrupole triplet, a septum and three regular dipole magnets.

Appendix B: Argonne National Laboratory Scope of Work

ANL Physics Division ATLAS MUU Project Upgrade

Request for Proposal for the ATLAS MUU Magnetic Kicker System

April 25, 2024

Table of Contents

1. Introduction

2. Scope

3. Specifications and Requirements

3.1 Specifications for the quadrupole triplet

3.2 Specifications for the septum magnet

3.3 Specifications for the dipole magnets

3.4 Specifications for the magnet materials

4. Preliminary design and simulations required for this RFP

5. Design Review & Approval following Award

5.1 Preliminary Design Review

5.2 Final Design Review

6. Required tests and measurements for the magnets

6.1 Tests prior to magnet assembly

6.1.1 Coil turn-to-turn insulation

6.1.2 Iron core dimensions

6.2 Tests following magnet assembly

6.2.1 Coil resistance test

6.2.2 Water pressure application BEFORE electrical tests

6.2.3 Applied high-voltage tests

6.3 Onsite tests – eventual ANL visit

6.4 Required magnetic measurements

7. Paintings, Surface Protection and Markings

7.1 Painting & Surface Protection

7.2 Marking & Nameplate

8. Packing and Shipping

8.1 Shipment

8.2 Weather protection

8.3 Crating

9. Deliverables

10. Final acceptance tests at ANL

1. Introduction This request for proposal (RFP) covers the magnets of a new chicane required for beam extraction as part of the ATLAS Multi-User Upgrade (AMUU) project.

Combined with a kicker magnet, the new chicane will allow pulsed switching of the beam between two experimental areas as shown in Figure 1 below. The kicker magnet is already under contract.

Figure 1: New magnetic chicane added to switch the beam in pulsed mode between two experimental areas.

2. Scope This RFP scope covers the DC magnets of the new AMUU extraction chicane which include a compact quadrupole triplet, a septum magnet and three regular dipole magnets. These elements are shown schematically in dark blue in Figure 1 above.

Also included are the vacuum chambers for the septum magnet and the 20⁰ dipoles.

Following selection, the Contractor shall perform all work necessary to design, prepare drawings, manufacture, assemble and factory test the magnets included in the contract. Labor and materials are the Contractor’s responsibility. Upon completion, the Contractor shall prepare and load for shipment the components included in the agreement and deliver to Argonne National Laboratory (ANL).

3. Specifications and Requirements

3.1 Specifications for the quadrupole triplet

Although it is not part of the chicane, the quadrupole triplet is essential for matching the beam to the two beam channels after separation. Due to space limitations, the main requirement for the triplet is to be compact while delivering the required beam focusing to both the chicane and the main ATLAS line (existing beamline).

Table 1 lists the specifications for the quadrupole triplet and Figure 2 shows a schematic of a possible design of such a triplet.

Table 1: Specifications for the quadrupole triplet.

Figure 2: Schematics of a possible design for the compact quadrupole triplet.

3.2 Specifications for the septum magnet

The specifications for the septum magnet are listed in Table 2 while a schematic of a possible design is shown in Figure 3.

Magnetic Field & Dimensional Specifications Parameter Value Unit

Number of Quadrupole Lenses 3 - Lens Effective Length (All the same) 25 cm

Lens Effective Separation 7.5 cm Lens Center-to-Center Separation 32.5 cm Aperture Diameter (Pole tip gap) 6.5 cm

Maximum Physical Length (Including coils)

90 cm

Field Strength at Pole tip 0.65 Tesla Field Gradient 20 T/m

Gradient Integral 5.0 Tesla Radius of Good Field Area (GFA) at all excitations

2.8 cm

Gradient Integral Uniformity over GFA at all excitations

< 10-2 10-3 desirable

Power and Cooling Requirements Cooling Type Water -

Inlet Water Temperature 25 C Maximum Temperature Rise 20 C

Available Water Pressure Drop 4 bar Minimum Cooling Channel Diameter 3 mm

Maximum Cooling Water Speed 3 m/s

Table 2: Specifications for the septum magnet which include the vacuum chamber.

Parameter Value Unit

Number of Magnets 1 - Magnet Type Curved Septum

Deflection Angle 10 deg Entrance Edge Angle 0 deg

Exit Edge Angle 10 deg Peak Magnetic Field 1 Tesla

Bend Radius 2.5 m Magnet Gap 4 cm

Septum Thickness 4 cm Maximum Physical Length (Including coils) 60 cm

Effective Field Length 43.63 cm Field Integral at Peak Field 0.44 T.m

Width of Good Field Area (GFA) at All Excitations

8 cm

Height of Good Field Area 3.4 cm Field Integral Uniformity over GFA at All Excitations < 10-2 10-3 desirable Maximum Field seen by non-deflected beam < 5 Gauss

Power and Cooling Requirements Cooling Type Water -

Inlet Water Temperature 25 C Maximum Temperature Rise 20 C

Available Water Pressure Drop 4 bar Minimum Cooling Channel Diameter 3 mm

Maximum Cooling Water Speed 3 m/s Vacuum Chamber Specifications

Vacuum Airgap Height 3.4 cm Vacuum Airgap Width 10 cm

Vacuum Level 10-8 torr Input and Output Flanges, ConFlat type 6 inches

Magnet Yoke Requirement Split Yoke for VC installation/removal

Figure 3: Schematics of a possible septum magnet design, including a field screen.

3.3 Specifications for the dipole magnets

The specifications for the regular 20⁰ dipole magnets are listed in Table 3 while a schematic of a possible design is shown in Figure 4.

Table 3: Specifications for the 20⁰ dipole magnets, including the vacuum chambers.

Parameter Value Unit

Number of Magnets 3 - Magnet Type Sector

Magnet Geometry C-Shaped Deflection Angle 20 Deg

Entrance Edge Angle 10 Deg Exit Edge Angle 0 Deg

Peak Magnetic Field 1.5 Tesla Bend Radius 1.67 m Magnet Gap 4.5 cm

Maximum Physical Length (Including coils)

70 cm

Effective Field Length 58.3 cm Field Integral at Peak Field 0.88 T.m

Width of Good Field Area (GFA) at All Excitations

8 cm

Height of Good Field Area 4 cm Field Integral Uniformity over GFA at All Excitations < 10-2 10-3 desirable Power and Cooling Requirements

Cooling Type Water - Inlet Water Temperature 25 C

Maximum Temperature Rise 20 C Available Water Pressure Drop 4 bar

Minimum Cooling Channel Diameter 3 mm Maximum Cooling Water Speed 3 m/s

Figure 4: Schematics of a possible design for the 20⁰ dipole magnet.

3.4 Specifications for the magnet materials

The magnets shall be constructed from high-quality, low-carbon, high-permeability magnetic steel. The yoke and pole pieces shall be formed from a single billet of steel to ensure uniform magnetic properties.

The coils conductors shall be high-conductivity, oxygen-free copper (OHFC) and shall be in accordance with the latest revision of ASTM B-188 specifications. The conductors shall be hollow to allow for the passage of cooling water.

Thermal switches shall be installed on the outlet of every coil pancake or cooling circuit.

4. Preliminary design and simulations required for this RFP The interested Contractor shall provide preliminary designs for the magnets including relevant cross sections and dimensions. 3D simulations results are recommended to show that the design parameters can be reached.

The Contractor shall demonstrate through simulations that the required field integral at maximum field is achieved within the specified physical dimension, and that the required field integral uniformity is achieved for at least the minimum, mid-range and maximum coil excitations.

The interested Contractor shall also provide the maximum current, voltage and dissipated power for the magnets and demonstrate through calculations that the

Vacuum Chamber Specifications Vacuum Airgap Height 4 cm Vacuum Airgap Width 10 cm

Vacuum Level 10-8 torr Input and Output Flanges, ConFlat type 6 inches Tube extensions & flanges for straight beam from both ends 2 both ends

Magnet Yoke Requirement Split Yoke for VC installation/removal cooling requirements are achieved for the specified pressure drop, inlet temperature and temperature rise.

5. Design Review & Approval following Award

5.1 Preliminary Design Review

The Contractor shall submit within 60 calendar days after award of the contract copies of CAD models, drawings and specifications showing:

1) Overall dimensions and total weight for each magnet.

2) Cross sections of coils and conductor indicating finished dimensions and tolerances.

3) Specifications for magnet steel type and coil design, including conductor type for each magnet.

4) Details of insulation materials to be used.

5) Locations and sizes of coil power connections.

6) Details of power consumption and power supply requirements.

7) Details of water-cooling requirements, including flow rates, pressure drops and maximum temperature rise. Include mechanical details of water manifolds and proposed water fittings.

8) Details of mechanical, magnetic, and electrical test procedures proposed by the Contractor.

9) Details of core and coil supports, eyebolts for lifting, etc.

10) Details of proposed alignment fiducials.

11) Details of vacuum chamber designs for the septum and dipole magnets.

12) Details of alignment pins to ensure proper positioning of poles when magnet is split to install/remove vacuum chamber.

13) Specific Q&A Plan

The Laboratory will review the material and notify the Contractor of preliminary design approval and/or submit comments within 30 days after receipt of the drawings and specifications listed above.

5.2 Final Design Review

Following implementation of eventual changes and recommendations from the preliminary design review, the Contractor shall furnish the updated design and documentation and additional details as needed within 30 days for a final design review. Final approval shall be expected within 30 days.

Approval by the Laboratory of the Contractor's design shall not be held to relieve the Contractor of any part of the Contractor's obligation to meet all of the requirements of these specifications or of the responsibility for the correctness of the Contractor’s drawings.

6. Required tests and measurements for the magnets Prior to delivery of the magnets, the supplier shall provide a Certificate of Conformance stating that as produced, the magnets comply with all contract provisions and specifications and purchase order requirements.

The Contractor shall perform the following tests for each magnet. The results of all tests and/or inspections are to be certified, in writing, by the Contractor. The final test reports, certifying results of specified tests, shall be compiled by the Contractor and forwarded to the Laboratory before shipment of the magnet assemblies. The following items must be available for review by the Laboratory:

1) The results of all dimensional inspections performed on the magnets.

2) Calibration records for all critical measuring and test equipment.

3) The results of all tests required by these specifications.

4) Non-conformance reports if there are any departures from specified dimensions or specified requirements.

5) A record of verification that Argonne National Laboratory has approved any and all changes to the original if applicable.

6) Full DC power characterization of the magnets to use as input for specifications of the power supplies.

6.1 Tests prior to magnet assembly

The following tests shall be performed for each magnet prior to assembly.

6.1.1 Coil turn-to-turn insulation

The Contractor shall perform a test for turn-to-turn shorts on each coil section and find no shorts. The Contractor shall describe the test to be used for the detection of turn-to-turn shorts for approval by the Laboratory. The Contractor shall demonstrate or otherwise prove that a shorted turn can be detected.

Following vacuum impregnation, each finished coil section shall contain NO cracks, voids, soft spots or areas un-impregnated with resin. No epoxy volume with dimensions greater than 3mm without fiberglass shall be present.

DC Hipot coil to vacuum impregnation mold, aluminum foil wrap, water bath, or wire brush. Test voltage shall be appropriate for operating voltage. Measured leakage shall not exceed 5 μA.

6.1.2 Iron core dimensions

The dimensions of the iron core shall be measured and recorded on an assembly drawing to be supplied to the Laboratory.

6.2 Tests following magnet assembly

The following tests shall be performed for each magnet in the following order after the magnet has been assembled, including water hoses to the coils.

6.2.1 Coil resistance test

Before applying any water to the cooling circuits, the DC resistance of each individual coil subassembly and all coils connected in series shall be measured and recorded. The temperature at which these measurements are taken shall also be recorded.

6.2.2 Water pressure application BEFORE electrical tests

After each coil section is flushed and before any further electrical tests are performed, all water circuits shall be subjected to 250 PSIG water pressure. The temperature of the water shall be lower than the ambient temperature. All air shall be removed from the water filled volume. The water circuit shall be pressurized and isolated from the pressure source. The initial pressure reading in the isolated circuit shall be recorded and after a time of no less than one (1) hour, the pressure shall also be recorded. The second reading shall not be less than the first reading for an acceptable coil.

6.2.3 Applied high-voltage tests

A 1000 Volt DC hipot test is to be made between all the coil conductors and the magnet steel. The insulation resistance determined shall be recorded and shall be no less than one (1) megohm or a maximum current leakage below 5 μA for an acceptable coil.

6.3 Onsite tests – eventual ANL visit

The Contractor shall perform the tests and magnetic measurements as specified below to demonstrate that the design parameters were achieved. The Laboratory requires a few weeks’ notice prior to these tests to arrange for an eventual visit by a member of the project team to witness the tests.

6.4 Required magnetic measurements

The following magnetic measurements are required for each dipole magnet:

1) The magnetic field and field integral along the central axis, measured for at least 6 current steps; at 10%, 25%, 50%, 75%, 100% and 110% of the full current.

2) 3D magnetic field maps in the gap (suggested: 5 planes and 9 trajectories in each plane), measured for at least 3 current values up to the maximum current (suggested steps: 25%, 50%, and 100% of full current). The measurements must cover and extend beyond the good field area. This data is required to check the uniformity of the field integral at different currents.

The following magnetic measurements are required for each quadrupole magnet:

1) The magnetic field and field integral along the quad at a radius half the pole tip radius, measured for at least 6 current steps; at 10%, 25%, 50%, 75%, 100% and 110% of the full current.

2) 3D magnetic field maps in the gap (suggested: 6 radii and 12 trajectories at each radius), measured for at least 3 current values up to the maximum current (suggested steps: 25%, 50%, and 100% of full current). The measurements must cover and extend beyond the good field area. This data is required to check the uniformity of the field integral at different currents.

7. Paintings, Surface Protection and Markings

7.1 Painting & Surface Protection

All exterior surfaces of the magnets steel and associated ferrous parts shall be properly cleaned and painted with two coats of primer, followed by one coat of blue machinery enamel. Stainless steel and non-ferrous parts shall not be painted. The pole tips shall be painted or coated with a suitable surface coating to be selected by the Contractor to prevent rusting and shall be approved by the Laboratory.

7.2 Marking & Nameplate

Each magnet shall have a plate affixed to it bearing the following information:

• Maximum magnetic field

• Effective field length, bend angle and radius of curvature for dipoles

• Maximum operating current

• Maximum operating voltage

• Water flow at specified pressure drop

• Weight of the magnet assembly

• Lifting points locations

• Magnet identification number.

The Contractor's nameplate may be attached to the magnet core. The location of the plate must be approved by the Laboratory.

8. Packing and Shipping

8.1 Shipment

The magnets shall be shipped completely assembled, including vacuum chambers for the dipoles. All pipe openings shall be capped or plugged. Particular care shall be exercised to protect machined magnet pole surfaces against rusting, scratches, and nicks during shipment or packing for shipment.

8.2 Weather protection

All cooling water passages shall be drained, blown out and capped or plugged. If shipping or storing during a cold season, appropriate protection against freezing shall be taken. No anti-freeze solution please, instead thoroughly blow the water out of cooling circuits.

8.3 Crating

The system components shall be crated in such a manner as to protect the contents from damage while in transit. The packing crates shall be placed on pallets suitable for movement using fork-lift trucks.

9. Deliverables The Contractor shall deliver the following parts, or components included in the contract, within 9 months after award of the contract:

1) The three quadupole magnets of the compact triplet.

2) The septum magnet and its vacuum chamber.

3) The three 20-deg dipoles and their vacuum chambers.

4) Sets of documentation and manuals for each magnet, which include as-built drawings, parts list, installation, alignment and operating instructions and mechanical, electrical, and magnetic test reports and field measurements including field maps at different excitations.

10. Final acceptance tests at ANL Upon receipt of the magnets, the Laboratory will install and connect them to the necessary power, water, and control leads. The Laboratory will then subject the magnets to the following tests within 60 business days of receipt and determine the operating parameters before they can be accepted.

The magnets will be first inspected, then connected and operated at different power levels up to the full design power and the following parameters will be measured:

1) Magnet dimensions, check nameplate information, cables, hoses.

2) Ground insulation resistance (with and without water in the coils).

3) Water pressure test and flow rate measurement.

4) Water temperature rise for each magnet at the full operating current.

5) Maximum temperature of the magnet coil conductor.

6) Magnetic field measurements at different currents up to the full operating current

7) Vacuum tests to check the integrity of the dipoles vacuum chambers and the required vacuum level.