Abstract

1. Abstract Magnet Incoming Inspection & Testing Tom Dilgen, NSLS-II Project My presentation described the testing done to every magnet received from the many manufacturers contracted to build magnets for The NSLS-II Project. It described many of the problems that were encountered while doing this testing and how they were resolved. How we use our DR system to record each magnet's discrepancies, if any, and the travelers used to record the all the significant aspects of each magnets testing history was touched on briefly as well. Pictures were shown to illustrate the more common magnet problems that were seen during testing. The repairs that were done to abate most of the magnet issues were also described. Being most of these problematic issues were fixed by the manufacturers after receiving our feedback, I felt the need to thank the contractors for their effort in this soon to be successful collaboration at the close of this presentation. *Work performed under auspices of the United States Department of Energy, under contract DE-AC02-98CH10886

2. SR Magnet Incoming Inspection and Testing Thomas Dilgen Magnet Workshop April 11 – 12, 2012

3. Magnet testing & Inspection • Inspect for shipping damage • Visual inspection (de-lamination of iron, rust, hardware markings, paint, clearance over base plate hole gage inspection..…) • Check base plate bolt torques • Vacuum chamber gage inspection • Flow rate test through magnet coils (@60 psi) • Pressure test (165 psi, hold 15 minutes) • Electrical testing (hipot coils & resistance checks of coils and temperature sensors) • Survey with arm to characterize magnets and check vital dimensions • Vibration tests (done on early magnets) • Magnetic measurement testing

4. Shipping Issues • Crates of inadequate strength, crate size/ pallet design not compatible with shelving or pallet jacks, not sealed well enough for trip to BNL (rusted unpainted surfaces) Residual water found in magnet water lines, freezing temperatures during shipment, poor handling of crates causing damage to crates and in a few cases damage to magnet. • Resolution: In most cases these issues were resolved with feedback to the manufacturers. Some crates/ pallets are still not compatible with shelving. Too late now for resolution, so we have made adjustments.

9. Safety Cover issues Many safety covers were deemed inadequate initially. Many covers took several iterations by the manufacturers to correct. • Lesson learned : We should’ve made it clear to the manufacturers from the start what BNL’s criteria for a safe cover should be. (no bare conductors can be touched with fingers through gaps in cover) • Resolution: All the safety covers were fixed to meet our expectations with feedback and the cooperation of the manufacturers .

10. Safety Cover issues Many safety covers were deemed inadequate initially. Many covers took several iterations by manufacturers to correct. • Lesson learned : We should’ve made it clear to the manufacturers from the start what BNL’s criteria for a safe cover should be. (no bare conductors can be touched with fingers through gaps in cover) • All covers were fixed at manufacturers to meet our expectations

11. Magnet Base Plates • Base plate to magnet iron bolting allows the skewing of base plate relative to pole position. The bottom of base plates not painted. Bolts found loose between magnet iron and base plates causing failed vibration tests. • Resolution: Incoming inspection and testing of the magnets allowed us to figure out solutions to these issues and correct them with feedback to the manufacturers . In some cases simple extra checks performed during incoming inspection resolved the problems

12. Magnet Base Plates • Base plate to magnet iron bolting allows the skewing of base plate relative to pole position. The bottom of base plates not painted. Bolts found loose between magnet iron and base plates causing failed vibration tests. • Lesson Learned: Incoming inspection and testing of the magnets allowed us to figure out solutions to these issues and correct them with feedback to the manufacturers . In some cases simple extra checks performed during incoming inspection resolved the problems

13. Corrector Magnet Straps • Failure of straps that held coils in place on corrector magnets proved the straps to be inadequate for the forces seen during shipping. The straps were replaced with stronger straps by the manufacturer here at BNL. • Lesson Learned: Good feedback to the vendor allowed a fast resolution to this problem. Vendor came to BNL and replaced the smaller straps with stronger ones and there’s been no problems since then.

14. Plumbing Problems • Supply and return lines reversed. Temperature sensors on wrong (inlet) side of coils. Welded elbows on supply and return lines. Poorly soldered joints between coils were found to leak (only two cases to date). Initial design allowed water connections to protrude beneath magnet the base plates of some magnets. No bulkhead fittings at supply and return water connections. Ferrules in backwards or missing.

15. Plumbing Problems ... • Tube to fitting swaging done poorly. Manifold block to fitting leaks. Straight pipe threads in manifolds with no sealing washer was used vs. tapered pipe threads. Thread sealant compatibility with manifold block (no Teflon tape), Manifold block material issues . Copper tube to stainless steel fitting compatibility may be an issue later on with cycles of assembly and disassembly.

16. Plumbing Problems … • Resolution: Some of these problems were due to inadequate testing during manufacturing. Perhaps a traveler system at the manufacturers factory may have helped? Some of these problems should have been caught earlier in the design reviews by BNL. “You get what you ask for” More comprehensive design review of the smaller details would’ve helped.

17. Plumbing Problems … • Lessons learned: Some of these problems were due to poor workmanship or inadequate testing during manufacturing. Perhaps a traveler system at the manufacturers factory may have helped? Some of these problems should have been caught earlier in the design reviews by us. “You get what you ask for” More comprehensive design review of the smaller details would’ve helped.

18. Plumbing Problems … • Lessons learned: Some of these problems were due to poor workmanship or inadequate testing during manufacturing. Perhaps a traveler system at the manufacturers factory may have helped? Some of these problems should have been caught earlier in the design reviews by us. “You get what you ask for” More comprehensive design review of the smaller details would’ve helped.

19. Plumbing Problems … • Lessons learned: Some of these problems were due to poor workmanship or inadequate testing during manufacturing. Perhaps a traveler system at the manufacturers factory may have helped? Some of these problems should have been caught earlier in the design reviews by us. “You get what you ask for” More comprehensive design review of the smaller details would’ve helped.

20. Plumbing Problems … • Lessons learned: Some of these problems were due to poor workmanship or inadequate testing during manufacturing. Perhaps a traveler system at the manufacturers factory may have helped? Some of these problems should have been caught earlier in the design reviews by us. “You get what you ask for” More comprehensive design review of the smaller details would’ve helped.

21. Plumbing Problems … • Lessons learned: Some of these problems were due to poor workmanship or inadequate testing during manufacturing. Perhaps a traveler system at the manufacturers factory may have helped? Some of these problems should have been caught earlier in the design reviews by us. “You get what you ask for” More comprehensive design review of the smaller details would’ve helped.

22. Girder Hardware Interference • “No Fly Zone” violations. Magnet iron and some of the buss connections between coils interfered with hardware or wrenches used to fasten, adjust, and torque the magnets to the girders. • Resolution: Feedback to the manufacturers in all these cases led to good resolutions of these issues. This could’ve been a chronic issue that was handled well with collaboration between the manufacturers and BNL.

23. Fiducial Issues • Poor placement of machined survey fiducials on the magnet iron wouldn’t allow them to be used. Missing fiducials. Fiducial holes not reamed deep enough in some cases. • Lessons learned: Involving a Survey Group member at the design reviews would have helped to make manufacturers aware of the issues associated with the survey of the magnets, such as placement of fiducials on magnet iron.

24. Fiducial Issues • Poor placement of machined survey fiducials on the magnet iron wouldn’t allow them to be used. Missing fiducials. Fiducial holes not reamed deep enough in some cases. • Lessons learned: Involving Survey Group member at the design reviews would have helped to make manufacturers aware of the issues associated with the survey of the magnets, such as placement of fiducials on magnet iron.

25. Certified Hardware • Non- certified lifting eye bolts. Unmarked bolts used in some magnet assemblies. • Resolution: The safety of our workers requires the need to make sure any lifting hardware supplied with the magnets is certified and has the documentation to prove it. We need to ensure suspect hardware isn’t used in magnet assemblies as well.

26. Certified Hardware • Non- certified lifting eye bolts. Unmarked bolts used in some magnet assemblies. • Lessons leaned: In our present environment we need to make sure any lifting hardware are certified and have documentation from the vendor to prove it. Ensure suspect hardware isn’t used in magnet assemblies.

27. Vacuum Chamber Clearance • Vacuum gage interference with coils. Still an ongoing issue with some manufacturers. Poor coil restraint design may have caused movement of coils during shipment or handling. Improper coil mold size. • Lesson learned: This should’ve been addressed much earlier in the whole process for such a basic but important issue. Testing should’ve been done at the manufacturer with proper vacuum chamber gages to confirm there was clearance between the coils. The coil restraint design should have been more carefully studied at the design review to ensure no movement of coils was possible during shipment or handling.

28. Vacuum Chamber Clearance • Vacuum gage interference with coils. Still an ongoing issue with some manufacturers. Poor coil restraints may cause movement of coils during shipment or handling. Improper coil molding. • Lesson learned: This should’ve been addressed much earlier in the whole process for such a basic but important issue. Testing should’ve been done at the manufacturer with proper gages to confirm that the coil mold size was correct. The coil restraint design should have been more carefully studied at the design review to ensure no movement of coils was possible during shipment or handling.

29. Electrical Problems • Hipot failures to ground. Coils were shorted to ground through coil restraint tabs. Coils shorted to ground through contaminated manifold blocks. Some un-insulated areas of coils or buss protruded outside of safety covers. No standard wiring schematic caused temperature sensors to be wired poorly for serviceability. Some early magnets required the temperature sensor wires to be cut and re-soldered for the disassembly operation.

30. Electrical Problems … • Resolution: Mostly all of these issues were resolved with feedback to the manufacturers. • Almost all of the repairs were dealt with here to move production along. • One magnet was returned to the manufacturer when larger problems such as shorted coils to ground through the coil restraint tabs was found.

31. Reproducibility Testing • Magnet design hindered the easy separation of top half of magnet from lower half. Many of these issues were handled with feedback to the manufacturer causing a design change or were handled by changes to the disassembly procedures, and in some cases they were handled by improvised tooling.

32. Reproducibility Testing… • Loose or over-tightened bolts found during this testing. • Each magnet type has its own sequence for tightening its bolts to the proper torque. Plastic charts were made to bring to the magnet/girder assembly to enable the technicians to torque each magnet type to the manufacturer’s specifications.

33. Reproducibility Testing… • Bolted C-clamps at poles were found to be an issue for reproducibility, ease of disassembly, and ease of re-assembly. These clamps were later removed from all the magnet assemblies. • Rust on mating surfaces. • Unexpected shims on mating surfaces. • Lessons learned: The required magnetic field reproducibility is very dependant on bolt torque and magnet iron mating surfaces.

34. Reproducibility Testing… • C-clamps at poles were found to be an issue for reproducibility, ease of disassembly, and ease of re-assembly. These clamps were later removed from all the magnet assemblies. • Rust on mating surfaces. • Unexpected shims on mating surfaces. • Lessons learned: Magnetic field reproducibility is very dependant on bolt torque and magnet iron mating surfaces.

35. Reproducibility Testing… • C-clamps at poles were found to be an issue for reproducibility, ease of disassembly, and ease of re-assembly. These clamps were later removed from all the magnet assemblies. • Rust on mating surfaces. • Unexpected shims on mating surfaces. • Lessons learned: Magnetic field reproducibility is very dependant on bolt torque and magnet iron mating surfaces.

36. Discrepancy Reporting • Any test failure or magnet defect is recorded by a Discrepancy Report. This report is sent to QA and the Cognizant Engineer. • The magnet can’t be used on a girder until the problem/s is resolved. • The resolution of all issues are provided by the Engineering Staff or Scientists. A disposition of these issues on the DR follows to direct the technician’s efforts in fixing the problems correctly. • Retesting of the magnet is then done if required to ensure the magnet is able to be used on a girder assembly.

37. Travelers • These documents are attached to each magnet when it’s received in order to record the results of each of the incoming inspection tests. • Discrepancies are recorded on the traveler as well. • The traveler stays with the magnet until the magnet is accepted for use in production. • After acceptance the travelers are collected and are on file for future reference if needed.

38. Final Thoughts • More comprehensive design reviews might have prevented many of the basic discrepancies. (water line reversed, klixons on wrong side of coils, unusable fiducials…..) • “Build to print” may be an alternative we’d like to try for magnet sub-assemblies in the future. More work for us up front, but may lead to less problems in the long run.

39. More Final Thoughts • Get first articles to us faster so that the issues can be worked out before production at the manufacturer starts. Changes made to design during production slowed us down and drove up labor costs. • Late magnets changed and continue to change girder production plans. We need to figure out a way to get them here on schedule??

40. More Final Thoughts • Get first articles to us faster so that the issues can be worked out before production at the manufacturer starts. Changes made to design during production slowed us down and drove up labor costs. • Late magnets changed and continue to change girder production plans. We need to figure out a way to get them here on schedule??

41. Conclusion • In an effort such as this the cooperation of both parties is very important!! Feedback of the issues to the manufacturers has worked very well for us in getting valid resolutions. By repairing the magnets already here we’ve gained valuable knowledge and insight as well. It has also saved both parties valuable time and money. I believe the end result of this collaboration will be extremely beneficial to everyone involved.