Status of the SR Lattice Magnets for the NSLS II

1. Status of the SR Lattice Magnets for the NSLS II John Skaritka Magnet Coordinator Report to the Accelerator Systems Advisory Committee March 26-27, 2009 ASAC Review of NSLS-II Project March 26-27, 2009 1

2. Magnet Systems Team Acknowledgements M. Anerella, J. Bengtsson ,J. Cintorino, G.Danby, T. Dilgen, L. Doom, J. Escallier. R. Faussete, S. Cianci G. Ganetis, W. Guo, R. Gupta, P. He, A. Jain, J. Jackson, P. Joshi, P. Kovach, S. Kramer, S. Krinsky, M. Loftus, Marone S. Plate, M. Rehak, A. Sauerwald, S. Sharma, C. Spataro, D. Sullivan, F. Willeke, G. Woods And many others at BNL, collaborating institutions and industry that have contributed to the success of the magnet systems. Critical Design and Production Readiness Review BNL, February,23-25, 2009 ASAC Review of NSLS-II Project March 26-27, 2009 2

3. Magnet Status Talk Outline • Requirements of the prototype magnet program. • Progress since the Last ASAC Review • Results of the Magnet Critical Design Review • Prototype Magnet Measurements Results and Magnet Optimization • Production activities to date • Summary ASAC Review of NSLS-II Project March 26-27, 2009 3

4. Progress made since the Last ASAC Review • Following earlier ASAC recommendations, The project approved the production of all pertinent prototype magnet types needed for NSLS II with in the budget constraints. • The Magnet Program was presented at 3 major Reviews: • Comprehensive Review • Doe Review • CD-3 Lehman Review • The Contractors proceeded to complete the design, manufacture, and deliver all of the prototype magnets that were assigned. • The Critical Design and Production Readiness Reviews were accomplished on Schedule. • Magnet Production process has begun with the preparation of a Final Production Strategy, Magnet Requisitions, a Statement of Work and Refined Specifications for each magnet Type. ASAC Review of NSLS-II Project March 26-27, 2009 4

5. Prototype Magnet Production and Testing Status • Storage Ring Magnet Prototype Production Contracts were a placed with 3 vendors in the Spring of 08. • USA One 90mm Dipole, two 66mm Quadrupoles, one 68mm Sextupole • China One 90mm Quad, One 76mm Sextupole • New Zealand One 35mm Dipole,90mm Quad,76mm Sextupole,66mm Quad • Manufacturing Began in Late Summer 08 • China completed all magnet fabrication, measurements and delivered in January 09 • NZ vendor completed all magnet fabrication and delivered 2 magnets in January and 2 magnets in February. They Mapped the Dipole magnet. • US vendor completed a Dipole and two Quads in February 09 and shipped the final Sextupole to BNL in early March. • Measurements have been made on all Magnets and testing shall continue into April. ASAC Review of NSLS-II Project March 26-27, 2009 5

6. Magnet Types in a Typical Cell Wide Quadrupoles & Sextupoles to accommodate X-ray transport. Correctors Regular Quadrupoles &Sextupoles Dipoles ASAC Review of NSLS-II Project March 26-27, 2009 6

7. Review the Goals of the Prototype Program • To demonstrate that magnets with acceptable Field Quality can be affordable produced by industry with in programmatic constraints, then using experimental results to establish a refined and conservative set of specifications for the production magnets. • Evaluate advanced manufacturing methods in industry that maintain required parameters while reducing technical and schedule risk and improving reliability • To Prototype all the basic magnet types to uncover design and manufacturing problems early in the program so to reduce the risk of problems occurring in full production. • To establish multiple competent NSLS II magnet producers to reduce the risk of cost increases and schedule delays. • To demonstrate a test methods and independently verify vendor measurements at BNL • To do all this by the time of the CDR/PDR scheduled for February 09 ASAC Review of NSLS-II Project March 26-27, 2009 7

8. CDR/PRR Findings Reviewers: Chair Jack Tanabe (SLAC Ret.), Montse Pont (ALBA), Fabrice Marteau (SOLEIL), Satoshi Ozaki (BNL), Jon Sandberg (BNL), Steven Hoey (BNL) • CDR - Critical Design Review • All technical goals of the NSLS II Prototype Magnet program to a level that the Magnet production process may commence. • PRR - Production Readiness Review • Procurement strategies, acquisition plans, proposal evaluation criteria are adequate and the cost and schedule risks of magnet production have been reduced to manageable levels. • The plans for magnet testing, girder integration and alignment have matured and BNL should be ready when the production magnets arrive. • The Technical documents such as the Statement of Work and Specifications can be improved. • Over all, the Magnet Program Can Proceed to the next Level and Production Magnet Procurement efforts should now commence. ASAC Review of NSLS-II Project March 26-27, 2009 8

9. The NSLS II Dipole Magnet Reference Design • NSLS II will require 54 each, 35mm aperture dipoles, and 6 each, 90mm aperture dipoles used toservice the IR user community. • All Dipole magnets are wired in series, 2.62 M long with a field strength of 0.4 Tesla . A 3% trim is added for dipole matching and future implementation of Decker distortion. • A special magnet end feature called a “Nose piece” has been added to extend the magnet gap past the end of the coil. This saves significant of space in the lattice and provides a means to match the fields of the two aperture magnets. 90mm Dipole 90mm Dipole Space Saving Nose Piece on the end of the 35mm Dipole. ASAC Review of NSLS-II Project March 26-27, 2009 9 35mm Dipole

10. Dipole Assemblies in the SR 35mm dipole magnet integrated to it’s girder, vacuum system and a 3Pole Wiggler 90mm dipole with vacuum system and IR extraction system. ASAC Review of NSLS-II Project March 26-27, 2009 10

11. 35mm Dipole Results 35mm Dipole being measured at Buckley Hall probe mapping show acceptable 2-D homogeneity of <1.5 units ASAC Review of NSLS-II Project March 26-27, 2009 11

12. 90mm Dipole Results Initial Results show excellent 2-D and integrated field quality, Studies continue. ASAC Review of NSLS-II Project March 26-27, 2009 12

13. 35 and 90 mm Dipole Optimization and Field Matching. • Nose Length will be adjusted to match Magnetic lengths. • Adjusting the end chamfer on the 35mm dipole nose will improve integrated field quality. ASAC Review of NSLS-II Project March 26-27, 2009 13

14. Integrated Field no chamfer Field Quality 10-4 Dipole Nose chamfer Integrated Field “upper bound chamfer” Field at Z=0 X Transverse Pole, mm Integrated Field “lower bound chamfer” ASAC Review of NSLS-II Project March 26-27, 2009 14

15. Dynamic Aperture and Relaxing Multipole Field Quality • Studies by Weiming Guo show that relaxing some harmonic content tolerances have negligible effects on dynamic aperture and can be adopted. • Machine Performance is primarily sensitive to higher order terms in the Large Aperture magnets. • The studies show that even for the large aperture magnets, relaxing some lower order harmonic terms is tolerable and this was done. • Prototypes conservatively meet all the higher order term requirements and instruments are available to confirm this during production. ASAC Review of NSLS-II Project March 26-27, 2009 15

16. The NSLS II Quadrupole Magnet Reference Design • For a two piece yoke, the higher field quads require double coils, but 60 will require a single inner coil reducing cost. • This technique implemented at Spear-3, Shanghai and IHEP has been successfully implemented into NSLS II prototypes • The yoke design allowing assemble around the vacuum chamber with negligible effects on field quality has been demonstrated. • All Metal bussing terminate into a APS style electrical isolation blocksresulting in a hose/maintenance free assembly has been demonstrated. Wide Quadrupole Standard Quadrupole • The Quad designs have been optimized to match lattice tuning range requirements yielding significant cost savings. • Systematic field errors of <3x10-4 @ R=25mm are achievable for all Quads and terms of <1x10-4 are easily obtainable by chamfering. ASAC Review of NSLS-II Project March 26-27, 2009 16

17. ASAC Review of NSLS-II Project March 26-27, 2009 17

18. 66mm Quadrupole Results ASAC Review of NSLS-II Project March 26-27, 2009 18

19. The NSLS II Sextupole Prototypes • The NSLS II sextupole splits about the mid-plane with a removable center pole has been demonstrated. • This allows simple assembly around the vacuum chamber. • The design of the sextupole is highly constrained by the vacuum chamber resulting in a unique narrow pole design. • Extensive studies show the NSLSII sextupole should not have integrated steering of skew quad trim windings. Standard Sextupole Wide Sextupole Inner pole stabilizer ring locates the removable pole and stiffens the assembly. ASAC Review of NSLS-II Project March 26-27, 2009 19

20. ASAC Review of NSLS-II Project March 26-27, 2009 20

21. Mechanical Tolerances vs. Field Quality • Mechanical Measurements of the 90 and 66mm Quadrupoles are underway to compare actual as built Mechanical Tolerances to their effects on field quality. • These resulting relationships will be used to help the contractors establish minimum acceptable mechanical tolerances. ASAC Review of NSLS-II Project March 26-27, 2009 21

22. 68mm Sextupole Results This magnet showed mechanical assembly problems that were revealed through mechanical inspection and magnetic measurements is being sent back for repair. ASAC Review of NSLS-II Project March 26-27, 2009 22

23. Prototype Magnets Advanced manufacturing methods produced accurate pole profiles Magnets on Girder used in field interaction study. Measurements were reviewed at the contractor by Animesh Jain and BNL Measurements of these multipoles occurred in January and agree well with vendor measurements. View of the surface finish on the machined pole faces of the 66mm gap, 40cm long Quadrupole ASAC Review of NSLS-II Project March 26-27, 2009 23

24. Advanced Measurements Capability • State of the Art NSLS II production measurements coil Designed by Animesh Jain is complete and now being used to measure prototype multipole magnets. • Primarily for use with the large aperture magnets, It can be used with standard aperture magnets as well as any combination of multipoles to study interactions. • The 25+ year old measurements and analytical software system has been completely updated and revised to take full advantage of the new advanced coil design. Testing, debugging and refinement are underway. High order multipoles like b21 and higher can now be evaluated with unprecedented precision. ASAC Review of NSLS-II Project March 26-27, 2009 24

25. Interaction Studies with the 90mm Quadrupole • The 90mm Quad has skew field error terms with it’s steel base plate due to saturation in the top and bottom back legs but excellent field quality if a non magnetic base plate is used. • Interaction studies were performed to determine if the magnet design is effected by stray fields to a level that would necessitate a design change. • Sensitivity to most sources of error were found to have negligible effects on the field. • It was decided to develop an alternative conservative and improved design for the production magnets. ASAC Review of NSLS-II Project March 26-27, 2009 25

26. 90 mm Quadrupole open Design Issue With out the steel base plate the large aperture Quadrupole has good field quality but the steel base plate of introduces an asymmetry that introduced large “a” terms. Note the saturated area in the top back leg. This is resolvable by adding steel to the top of the magnet and has been demonstrated experimentally. ASAC Review of NSLS-II Project March 26-27, 2009 26

27. Additional complexity for the 90mm Quad The X-Ray extraction chamber has been increasing in size. Here the vacuum chamber is interfering with previous the 90mm Quadrupole. ASAC Review of NSLS-II Project March 26-27, 2009 27

28. 90mm Quadrupole Optimized Model Margareta Rehak has developed a viable redesign of the 90mm Quadrupole. Note that the asymmetry saturation in the magnet’s cross section is eliminated and field quality is improved to meet all field quality requirements to sub unit accuracy. This design provides a solution that has no conflicts with the design of the girder or Vacuum system and we are confident that this is achievable in production. ASAC Review of NSLS-II Project March 26-27, 2009 28

29. Progress on Magnet Alignment • The Precision Alignment Environmental Room has been completed. • Temperature control of +/- 0.05C has been demonstrated. • The Vibration Alignment system is operational and system components are under test. • The Girder equipped with ALBA magnets and precision magnet movers have been installed. • Survey and Installation studies to simulate the tunnel environment are underway. ASAC Review of NSLS-II Project March 26-27, 2009 29

30. NSLS II Storage Ring Lattice Magnet Schedule 2008 2009 2010 2011 2012 2013 2014 CD-2 Last Pentant BOD CD-3 1st Pentant BOD Magnet R&D prototype Fab+Test Reference Design PDR Alignment R&D Preparation of 902 Prototyping RFP Reference Design IDR Prototyping magnet Fab. + Test Production Readiness Review Production RFP and Award Magnet Production Contracts First Article. Magnet Batch test Magnet Production Complete Girder Integration and Alignment Completed magnet girder backlog. Magnet Girders tunnel install We Are Here ASAC Review of NSLS-II Project March 26-27, 2009 30

31. Requisitions for all the production magnets are in the approval process. A Statement of Work common to all the Major lattice magnet contracts has been developed and approved. Interface Control Drawings for the Standard Quads are complete and approved. All other interface Drawings will be complete in about 2 week. All lattice magnet specifications are in the final review process prior to production release. Standard Quadrupole Production Requisition documents for the 240 each, 66mm aperture Quads (>$5M) is under review by the Local DOE office. All Magnet Contract Solicitations will be ready to go out to bid in April 09 Preparations of Magnet to Girder assembly and production are underway with all BNL and all infrastructure scheduled to be complete by the end of the 09 calendar year. Production Procurement Activities are Underway ASAC Review of NSLS-II Project March 26-27, 2009 31

32. Summary of Magnet Status • As of today the Goals of the Prototype Magnet program have been Achieved. • Field quality requirements can be acceptably achieved for all the Magnets • Prototypes using advanced manufacturing methods have been successfully built. • Multiple viable cost effective NSLS II magnet manufactures have been established. • All but one prototype magnet has given acceptable results and where there were problems we found them all to be easily resolvable manufacturing issues that will be resolved prior to the start of production. • Production specifications are being optimized to match prototype performance reducing production cost and schedule risks. • Advanced magnetic measurement and precision alignment systems have been developed, and has been commissioned with excellent results. • Aggressive efforts are underway to begin the procurement of production magnet. • The prototype program has been highly successful and we are ready to begin Production! ASAC Review of NSLS-II Project March 26-27, 2009 32