SPECIFICATIONS for the INJECTION DIPOLES OF THOMX 29 January 2015 1 INTRODUCTION: THE THOMX PROJECT... 4 2 DESCRIPTION OF THE MAGNETS... 4 2.1 DIPOLE MAGNET... 4 3 SUBJECT OF THE SPECIFICATION... 4 3.1 GENERAL AND NUMBER OF DIPOLE... 4 3.2 DEFINITION DRAWINGS... 4 3.3 REFERENCE DESIGN... 5 3.4 VARIANT... 5 4 SCOPE OF SUPPLY... 5 4.1 RESPONSIBILITY OF THE CONTRACTOR... 5 4.2 LIST OF ELEMENTARY PARTS TO BE SUPPLIED... 5 5 MAGNETIC CIRCUIT... 6 5.1 STEEL CHARACTERISTICS... 6 5.1.1 General... 6 5.1.2 Working out mode... 6 5.1.3 The required relative permeability... 6 5.1.4 Coercivity... 7 5.1.5 Chemical characteristics... 7 5.1.6 Mechanical characteristics... 7 5.2 YOKE... 7
5.2.1 General... 7 5.2.2 Complementary pieces... 7 5.3 PROTECTION AND PAINTING... 8 6 COILS... 8 6.1 DESCRIPTION OF THE COIL... 8 6.2 CONDUCTOR... 8 6.3 COIL WINDING... 8 6.4 COIL INSULATION AND IMPREGNATION... 8 6.5 REPAIR... 9 7 MAGNET ASSEMBLY AND AUXILIARY EQUIPMENTS... 9 7.1 MAGNET ASSEMBLY... 9 7.2 ELECTRICAL EQUIPMENT... 9 7.3 SAFETY ELEMENT... 9 8 INSPECTION AND CONTROL... 9 8.1 MAGNETIC YOKE... 9 8.1.1 Magnetic tests... 9 8.1.2 Dimensional controls... 10 8.2 TESTS ON COILS... 10 9 TOOLING AND SPECIAL REQUIREMENTS... 10 10 CONTRACT EXECUTION, SCHEDULE AND PROGRESS REPORT... 11 10.1 REQUEST FOR DEVIATIONS FROM THE SPECIFICATIONS... 11 10.1.1 Schedule... 11 10.1.2 Approbation of drawings... 11 10.1.3 Progress report... 11 10.2 FACTORY ACCESS... 11 11 QUALITY INSURANCE... 11 11.1 QUALITY INSURANCE PROVISION... 11 11.2 NUMBERING... 11 12 DOCUMENTATION... 12 13 PACKING AND TRANSPORTATION... 12 13.1 PACKING... 12 13.1.1 Transportation and Delivery... 12 13.1.2 Storage... 13 14 PARAMETER LIST... 13 14.1 MAGNETIC PARAMETERS... 13 14.2 MECHANICAL PARAMETERS... 13 14.3 ELECTRICAL MAGNET PARAMETERS... 13 14.4 CONDUCTOR: PLAIN ENAMELLED COPPER... 13 14.5 GEOMETRICAL PARAMETERS FOR ONE COIL... 14 14.6 ELECTRICAL PARAMETER FOR ONE WINDING... 14 15 LIST OF DRAWINGS... 14 16 LIST OF SKETCHES... 14 THOMX injection dipole magnets specifications 2/16
THOMX injection dipole magnets specifications 3/16
1 Introduction: the THOMX Project THOMX is a compact light source project in the range of the hard X rays (40 90keV), based on Compton Back Scattering effect. At present there is a strong interest in the scientific community to explore the performances and the experimental applications of such kind of light sources. In this context the THOMX project has provided a collaboration framework for different French institutes. The machine, which is currently under construction on the Orsay University campus, is composed of an injector Linac and a Storage Ring where an electron bunch collides with a laser pulse accumulated in a Fabry-Perot resonator. The final goal is to provide an X-rays average flux of 10 11 10 13 ph/s. The emitted flux will be characterized by a dedicated X-ray line. Different users are partners in the THOMX project, especially in the area of medical science and cultural heritage. The present specification contains the technical specifications of the 2 injection dipole magnets of THOMX accelerator. All dimensions and tolerances of the magnets are defined within these specifications and attached definition drawings. 2 Description of the magnets 2.1 Dipole magnet THOMX dipole is a resistive magnet manufactured in a solid magnet technology. The magnetic field is produced by two coils alimented by a DC current. The variation of the DC current allows for the variation of the magnetic field and the dipolar strength of the dipole. The coils are mounted on two poles which concentrate and define the dipolar magnetic field path. The dipole yoke is manufactured with two half-yokes. A coil is mounted on each pole. The dipole magnets will operate at maximum dipolar strength of 0.2 T with a 40 mm gap necessary to contain the beam vacuum chamber. The magnets will be excited by coils mounted on the dipole. These coils will be wound from emmaled copper conductor of dimension 5.6 mm x 2 mm. Nominal dipolar strength: 0.2117 T Gap dimension : 40.00 mm Mechanical length: 290 mm 3 Subject of the Specification 3.1 General and number of Dipole This document is concerned with the engineering design, manufacturing, testing and delivery of the 2 injection dipole magnets for the THOMX project. 3.2 Definition drawings The specification drawings are part of the specification. These drawings are definition drawings giving all the tolerances and interfaces on all aspects. THOMX injection dipole magnets specifications 4/16
3.3 Reference design THOMX has established the above drawings according to a reference design. These drawings are included in the specification, and necessarily contain certain assumptions concerning parts of the magnets design that will be the responsibility of the manufacturer. Contractor should therefore be aware that certain features shown on the drawings are tentative, and will be subject to adjustment by the manufacturer during the engineering design phase. 3.4 Variant The contractor may propose an alternative scenario to manufacture the magnets. In this case, he will have to prove that it complies with all the requirements. 4 Scope of supply 4.1 Responsibility of the contractor Explicitly included in the supply are: Follow-up schedule with constant updating engineering design and construction drawings Manufacturing of the injection dipole magnets as specified, including all the procurements. Manufacturing of 2 spare coils for the injection dipole magnets. Manufacturing, procurement and mounting of all auxiliary equipment as specified All tests of parts and assemblies required to guarantee the product quality, acceptance test in factory Complete documentation on paper and in data base of manufacture, tests and measurements All relevant drawings on paper and in CD in CATIA Protection, packaging, transportation and delivery on THOMX site including all the formalities as designed in chapter 13. Keeping of all the specific tooling and test equipment during 10 years The magnetic design of the electromagnets is not part of the supply and the responsibility of the magnetic performance remains with THOMX. 4.2 List of elementary parts to be supplied All the supports of electrical connections Mechanical support Thermal interlocks Safety box Coil supports Stainless plates for survey reference system THOMX injection dipole magnets specifications 5/16
5 Magnetic circuit The information concerning the magnetic circuit, in particular the tolerances, are given in the drawings listed in chapter 15 All the tests to be performed will conform to the description in chapter 8.1. 5.1 Steel characteristics 5.1.1 General This section specifies the electrical and magnetic properties, and the pre-production tests required for the steel of the magnets. Steel of such quality is available from a number of suppliers and the manufacturer has full liberty to choose any source of suitable material. THOMX believes that e.g. steel type XC 06 or pure iron ARMCO will comply with the specification. 5.1.2 Working out mode The specification will be met by fully annealed iron rolled or wrought iron (XC06 quality). All pieces of the dipole magnets have to be built from the same casting. 5.1.3 The required relative permeability H-field (A/m) Minimum induction B (T) Mini relative permeability 166 0.58 2755 199 0.68 2720 240 0.79 2622 289 0.89 2465 347 0.99 2273 418 1.08 2062 502 1.16 1845 604 1.24 1631 726 1.30 1428 872 1.36 1240 1049 1.41 1068 1261 1.45 914 1823 1.52 662 2192 1.55 561 3167 1.60 401 4579 1.65 286 6619 1.70 205 9568 1.77 147 11499 1.80 125 THOMX injection dipole magnets specifications 6/16
13831 1.84 106 16624 1.88 90 19990 1.92 77 24032 1.96 65 28893 2.00 55 Table 1 required minimum values of induction at set values of external magnetic field H-field. 5.1.4 Coercivity The coercivity is designed as the field required to produce zero induction in a sample of the steel after repeated excursions to high induction with a field of 30 000 A/m. The maximum allowed coercivity Table 2 : Required coercivity 120 A/m 5.1.5 Chemical characteristics The internal carbon rate should be inferior to 0,06 %. 5.1.6 Mechanical characteristics Elastic limit at 0.2 % 12 dan/mm 2 Breaking Stress b 12 dan/mm 2 5.2 Yoke 5.2.1 General The manufacturer shall design the yoke so as to achieve the required mechanical tolerances in the completed magnets, taking due account of the coil dimensions and of the space required to introduce the coils into the magnet. These methods shall be proposed as part of the engineering design, and subject to THOMX approval. 5.2.2 Complementary pieces They are explicit part of the supply: Rods : in soft iron material, but with the required mechanical properties Pins : they make the assembly of the magnet easier (XC10) Tools for separation and handling the quarters of the magnet Elevating rings : 3 for the dipole Screws : if necessary, in the same steel as the magnetic circuit Girder interface : aluminium alloy Temporary interface for magnet storage, which preserves the girder interface THOMX injection dipole magnets specifications 7/16
5.3 Protection and painting After assembling and measurement, the yokes shall be protected against rust by twocomponent epoxy paint. The paint shall be hard and mechanically resistant. The mating faces and alignment grooves will not be painted and shall be protected by phosphatation or similar surface treatment. The manufacturer shall also ensure that any surface on the pole faces or other faces of the magnet that will be required for mechanical measurements on the assembled magnets will remain unpainted. Such unpainted areas shall be protected by light oil or other rust preventative techniques. The colour of the paint that is to be used shall be chosen with THOMX agreement. The reference will be given according to RAL standard: Red (or rouge oriental ) ref 3031 for the dipole 6 Coils 6.1 Description of the coil The dipole is equipped of two coils. The design considers each coil counting a total of 308 turns. The outside cross-section of the coil is 60 x 60 mm. The coil shall be manufactured using a standard solid copper conductor with. 6.2 Conductor These coils will be wound from plain standard enamelled copper conductor of dimension 2 mm x 5.6 mm (non insulated conductor dimensions) with a thin isolating layer (Grade 1). The copper has a Cu A1 quality according to the NF A51-050. The electrical resistivity shall be less than 17.8 10-9 m at 20 C. 6.3 Coil winding Before the winding of the coil, the conductor shall be cleaned. Inter-turn electrical insulation shall be provided by the copper conductor itself. After completion of winding, outer ground insulation shall be provided with a standard fibreglass tape, half-overlapped to produce a minimum insulation thickness of 0.2 mm. Scrupulous care shall be exercised at all stages of the coil construction in the handling of all the components, which shall be undertaken in a clean environment. All working surfaces shall be cleaned immediately prior to be used, and protective gloves shall be worn by all the staff involved. Quality control of this design will have to guarantee the all conductive occlusion lacks between wires (cutting, dust, ). Moreover, excessive hammering (hardening) of the conductor which could destroy the fibreglass tape shall be avoided. 6.4 Coil insulation and impregnation Each coil shall be vacuum impregnated with radiation resistant epoxy resin (10 7 Gray) which will be polymerised under pressure. The out-gassing of the epoxy resin shall be controlled carefully. The use of a mould is considered to be essential to achieve the coil sizes, therefore the manufacturer has to design it. All the hollowed parts shall be filled up with fibreglass before impregnation in order to avoid pure resin blocs. After THOMX injection dipole magnets specifications 8/16
completion, the resin on the coil shall be fully transparent, with no colouring or additive that would limit observation of the copper turns used. No painting or other external coating will be allowed. 6.5 Repair No coil shall be repaired after its initial impregnation without the written approval of THOMX. 7 Magnet assembly and auxiliary equipments 7.1 Magnet Assembly After completion of controls by the contractor on magnetic circuit and coils, each magnet will be assembled and fully equipped. The contractor will execute the engineering design of the electrical, hydraulic and mechanical equipment and produce the execution drawings in agreement with the location of interfaces and according to the European standards. 7.2 Electrical equipment The supply includes: - Insulating wedges and supports to be built in non magnetic material - Connecting terminations to be brazed on the copper conductor and connecting plates rigidly supported on the magnet (these terminations must be insulated from the ground with a resistance of more than 10 M in presence of a direct tension of more than 5 kv) 7.3 Safety element The supply includes a total of 4 thermoswitches per dipole. Each dipolar coil will be equipped with 2 thermoswitches located on impregnated copper plates. The thermoswitches coming from the upper coils will be in serial connected respectively from the lower coils. The location of the thermoswitch are not specified on the drawings. ThomX leave to the manufacturer to choice of the best place on the coil knowing the space constraints. The manufacturer will ask a written approval to ThomX for the final location. 8 Inspection and Control 8.1 Magnetic yoke 8.1.1 Magnetic tests They will be made on ring samples machined at the same time as the yoke rough forming. Ring sample dimensions will the following: THOMX injection dipole magnets specifications 9/16
I = 76 ( 0.1 0 ) mm 0.1 e = 114 ( 0 ) mm thickness is 15 mm +- 0.1 mm I is the inner diameter and e is the outer diameter of the ring The samples will be indelibly marked with the batch number and the position reference. Relative permeability and coercivity will be systematically measured by the contractor according to the Tables 1 and table 2. These controls are mandatory and THOMX will apply the double control. In exceptional circumstances, where tests on these samples indicate a large variation of magnetic properties, THOMX shall be entitled to call for further samples to be taken. 8.1.2 Dimensional controls Before machining the steel homogeneity shall be proved for instance by ultrasound tests. After machining and assembling, the main geometrical dimensions will be carefully checked according to the tolerances of the relevant drawings. The field quality relies on the strict observance of symmetry, parallelism of the poles and position of the chamfers as mentioned. After assembling of the two half yokes, the functional tolerances will be finally checked including interfaces with supports and survey reference system. 8.2 Tests on coils Leakage measurement The leakage current shall be measured by using voltage until 1 kv during 1 minute. The ground shall be created by aluminium leaf wrapped or another process. Number of turns All the coils shall have the same number of turns. In order to detect a lack of turns, a non-destructive test will required to determine the number of turns of each coil. A coil without the right number of turns will be rejected. Coil resistances The electrical resistance of all coils shall be measured with a DC bridge. The value shall be corrected to 20 C, and must be within 1 % of the mean value for all coils. 9 Tooling and special requirements The manufacturer is fully responsible of the tooling. The specific tooling may be: Winding mandrels Impregnation moulds THOMX injection dipole magnets specifications 10/16
These specific tooling have to be kept by the manufacturer during 15 years. 10 Contract execution, schedule and progress report 10.1 Request for deviations from the specifications During execution of the contract any deviation from this specification asked by the contractor will be submitted to THOMX in writing for approval. 10.1.1 Schedule The contractor shall supply within one month of notification of the order a written programme detailing the manufacturing and testing schedules. The programme will include expected dates for inspection and tests. 10.1.2 Approbation of drawings The drawings established by the contractor will be submitted to THOMX for functional approval. 10.1.3 Progress report A written progress report shall be sent to THOMX every month until final delivery. 10.2 Factory access THOMX and its representatives shall have free access during normal working hours to the manufacturing or assembly sites including any subcontractor's premises during the contract period. The contractor will give 15 day notice for the inspection and tests, THOMX will give 8 day notice before any visit. 11 Quality insurance 11.1 Quality insurance provision The contractor must be able to demonstrate that he has ISO 9001 series certification or an equivalent quality control certification which is appropriate to the subject of the specification. The contractor will provide to THOMX for approval a flowchart of its quality control procedure which would be aligned to ISO 9001. THOMX will give its acceptance or refusal of the procedure in writing within 10 days of receipt. 11.2 Numbering Each individual coil block, yoke, or yoke section and each completed magnet will be identified and numbered. The identification number shall be scentilled onto the component at an agreed position as shown on manufacturer drawings approved by THOMX. A signaletic plate will be fixed on the magnet. THOMX injection dipole magnets specifications 11/16
12 Documentation The following documents will be delivered according to the schedule Schedule Construction drawings of coils and magnetic circuits Travellers of control executed at each step of the manufacturing A manufacturing booklet which will be composed of: - For the coils: Mechanical and electric tests - For the magnetic circuit assembly: Mechanical and electric tests - For the magnet assembly: Mechanical and electric tests - The results of the final receipt - The list of the non-compliances processed All the documents delivered by the contractor shall be drafted in French or in English. The contractor will have to insure the archiving of documents which will not be send to THOMX during the guarantee period. After this delay, those documents will be delivered to THOMX or burnt with its agreement. 13 Packing and transportation 13.1 Packing The contractor will submit to THOMX a solution for the packing. This packing will have to imply the use of the classic handling tools. The devices packed shall be protected against the elements, the projections and the breaks for the transport and the storage. The packing of each magnet shall be dust proof, water proof and will have to protect the steel parts against the oxidation. Moreover, the pieces shall be protected against the strain, impacts and rubbing which can damage their surfaces. A particular protection shall be required for brittle parts (reference surfaces, electrical connections and coils). The coils shall be rinsed, dried and sealed before expedition in order to avoid the freezing. 13.1.1 Transportation and Delivery The contractor will include in his tender the transport from the factory: - to the LAL site LAL Centre Scientifique d Orsay Bât. 205 (9h-12h / 14h-17h) 91405 ORSAY CEDEX FRANCE THOMX injection dipole magnets specifications 12/16
The contractor keeps the responsibility of the goods until the delivery to the site cited above. THOMX will supply the local handling tools. The transfer of risks shall take place when the load is laid down on the ground. 13.1.2 Storage The storage of materials in its original packing can be considered for a period of several months after the construction in the contractor's docks or in the THOMX site. So, the packing must provide the protection of material during this period. 14 Parameter list 14.1 Magnetic parameters Magnet type: dipole with C-Shape yoke. Maximum ampere-turns per coil Maximum dipolar strength Theoretical magnetic length 3600 Aturns.2117 T 198.5 mm 14.2 Mechanical Parameters Gap 40 mm Pole width 69 mm Yoke width 69 mm Cross section width (horizontal) and height 210x 250 mm 2 Mechanical length 150 mm Full longitudinal size with coils 290 mm Weight of steel 40 kg Weight of coils 43 kg 14.3 Electrical magnet parameters Number of coils per magnet 2 Effective number of turns per magnet 616 turns Maximum current per coil 12 A Maximum Power loss per magnet 100 W Electrical resistance 690 m Voltage 8.3 V 14.4 Conductor: plain enamelled copper Maximum resistivity at 20 C 1.78 10-8 m Copper conductor size (non insulated conductor dimensions) 2 x 5.6 mm 2 THOMX injection dipole magnets specifications 13/16
14.5 Geometrical parameters for one coil Number of wire 308 turns Average turn length 738 mm Weight of copper per coil xxx kg Dimensions 60 x 60 mm 2 14.6 Electrical parameter for one winding Maximum current 12 A Electrical resistance 345 m Current density 1.07 A/mm 2 Voltage 4.14 V Power loss 50 W 15 List of drawings Dipole injection 170 mrad Dipole injection 170 mrad Culasses I742E T7100 I740S T7100 16 List of sketches 16.1. THOMX Accelerator complex 16.2. Examples of THOMX magnets arrangement 16.3. 3D view of THOMX injection dipole magnet THOMX injection dipole magnets specifications 14/16
Fig 16.1. THOMX Accelerator complex Fig 16.2. Examples of THOMX accelerator magnets arrangement
Fig 16.3. 3D view of the THOMX injection dipole magnet THOMX injection dipole magnets specifications 16/16