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EUROPEAN ORGANIZATION FOR NUCLEAR RESEARCH 78-16 TECHNICAL SPECIFICATION FOR THE BENDING FOR THE CERN ANTIPROTON TRANSFER LINES Geneva July, 1978

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Page 1: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

EUROPEAN ORGANIZATION FOR NUCLEAR RESEARCH

SPS/E~~/Spec. 78-16

TECHNICAL SPECIFICATION FOR THE BENDING ~GNETS

FOR THE CERN ANTIPROTON TRANSFER LINES

Geneva July, 1978

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Contents

1. Introduction and scope of the tender

2. List of drawings

3 • List of main parameters

4. List of components supplied by CERN

5. Responsibility of the manufacturer

6. Modifications to the specification

7. Modifications to the specification after delivery of the first magnet

8.

9.

10.

11.

Additional short versions of the magnets

Inspection and acceptance tests

The half-cores, description and tests 10.1. General 10.2. Steel sheet supply 10.3. Insulation of the laminations 10.4. Test of insulation resistance 10.5. Punching of the laminations 10.6. Geometrical tolerances concerned with

the laminations 10.7. 10.8. 10.9. 10.10. 10.11 . 10.12.

Inspection of the punched laminations End plates and angular plates Stacking of the laminations Welding of the stack Finishing of the half-cores Tests to be performed on the half-cores 10.12.1. Filling factor 10.12.2. Length of the half-cores 10.12.3. Straightness of the half-cores 10.12.4. Perpendicularity of the end faces 10.12.5. Other dimensions

10.13. End shims

The excitation winding, description and tests 11.1. General 11.2. Conductor material and dimensions 11.3. Conductor brazings 11.4. Winding of the coils 11.5. Insulation

11.5.1. General 11.5.2. Insulation procedure 11.5.3. Radiation resistance of the

thermosetting resin

1

2

2

3

3

3

4

4

4

4 4 5 5 6 6

7 7 8 9 9

10 11 11 11 11 12 12 12

13 13 13 13 15 15 15 15

16

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Contents (contin'd)

11.6. Prototype coil 11.6.1. Tests to be done on the prototype coil

11.7. Provisional acceptance tests on the series coils 11.7.1. Geometrical test 11.7.2. Flow and pressure test 11.7.3. Electrical tests

11.7.3.1. Measurement of insulation resistance

11.7.3.2. Ground insulation test 11.7.3.3. Interturn insulation test 11.7.3.4. Electrical resistance

17 17 17 17 17 18

18 18 18 18

12. The completed magnet, description and tests 19 12.1. General 19 12.2. Assembly 19

12.2.1. General 19 12.2.2. Coil into core 19 12.2.3. Assembly of magnets 20

12.3. Tests on the assembled magnetic circuits 20 12.3.1. Longitudinal offset 20 12.3.2. Control of the mating surface clearances 21 12.3.3. Transversal offset 21 12.3.4. Straightness of the yoke 21

12.4. Finishing of the magnets 21 l2.5. Cooling 22 12.6. Electrical connections 22 12.7. Interlocks 23 12.8. Protective covers 23 12.9. Provisional acceptance tests of the completed magnets 23

12.9.1. Leak test 23 12.9.2. Flow test 23 12.9.3. Resistance of the magnet 24 12.9.4. High voltage test 24 12.9.5. Test run 24 12.9.6. position of target holders and base plates 24

12.10. Tests after delivery at CERN 24

13. Miscellaneous ~5 13.1. Technical information to be communicated by the

manufacturer 25 13.2. List of samples to be furnished by the manufacturer

for approval 25 l3.2.1. Steel stamples 25 l3.2.2. Copper samples 25 13.2.3. Insulation samples 26 13.2.4. Brazing samples 26 l3. 2.5. End connec t ions 26 l3.2.6. Samples of thermal switches mounting 26 13.2.7. Sample card 26

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1. INTRODUCTION AND SCOPE OF THE TENDER

This specification covers the fabrication of the bending nllignets for

the CERN proton-antiproton transfer lines which will be constructed at the

laboratory of the European Organization for Nuclear Research at Prevessin,

France, near Geneva.

There are two different sizes, shown as types B340 and B190, which

have the same cross-section of the core and the coils but different lengths.

As the magnets are matched to different power supplies, the coils of the

two different types of magnets have different numbers of turns and different

conductor dimensions.

The tenderer is invited to make an offer for the manufacture,

testing and delivery at CERN, Prevessin, France, of complete bending

magnets and spare coils in accordance with the present specification which

will form part of the contract.

The magnets shall be delivered completely assembled and ready to

go into service.

The price shall include all mechanical, electrical and hydraulic

measurements and tests as described in this specification, and any special

tooling needed for the magnet manufacture.

The manufacturer must supply all raw materials and ancillary

components except the items stated under section 4.

CERN will not consider tenders for the supply of the magnetic

circuits only or of the coils only. CERN will, however, consider tenders

from main contractors with a second firm as subcontractor for either the

coils or yoke manufacturing, provided the responsibility for final assembly

and testing remains with the main contractor.

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2. LIST OF DRAWINGS

SPS-8033-17.1.0 Lamination

SPS-8033-17.2.0 End plate

SPS-8033-17.3.0 Cross-section

SPS-8033-17.4.2. Angular plate

SPS-803 3-17 . 5 .0 Cores

SPS-8033-l7. 6.0 Coil B190

SPS-8033-l7.7.0 Bl90 View of connections

SPS-8033-17 .8. () Coil ])340

SPS-8033-17.9.0 ])340 View of connections

SPS-8033-17.ll.3, Inspection of lamination

SPS-8033-l7.12.3 End shims

SPS-8033-17.13.3 Jack

3. LIST OF HAIN PARAl1ETERS

])190 B340 Units

Gap height 52 52 mm

Pole width 240 240 mm

Lamination width 894 894 mm

Lamination height 295 295 mm

Core width 920 920 mm

Core height 600 600 mm

Core length 1912 3412 mm Number of coils per magnet 2 2

Number of turns per magnet 192 72

Cooling circuits 12 8

Conductor dimensions 8.0 x13.2 15 .2x20.6 mm

Cooling duct 0 5.1 7.2 mm

Magnet resistance (20oC) 0.20 0.0376 Sl

Nominal current 375 1000 A

Nominal field 1.6 1.6 T

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B190 B340 Units

Water flow per magnet 20 36 ,Q,/min

Pr es su re drop 6 6 atm

Temperature rise of cooling water 22 15 °c

Copper weight '0 700 '0 1360 kg

Steel weight '0 5.7 '0 11.9 ton

4. LIST OF CmlPONENTS SUPPLIED BY CERN

CERN will supply, free of charge, the following components

Insulating water collectors, equiped with water filter and water c.oupling terminals,

Thermal switches for inlets (45 0 C)

and outlets(60oC)

Special insulated wire for the wiring of the thermal switches,

Terminal strips for the wiring.

5. RESPONSIBILITY OF THE NANUFACTURER

Before the fabrication of the magnets can start, the manufacturer

shall send two complete sets of construction drawings of the magnets to CERN

for approval. However, approval from CERN does not relieve the liability of

the manufacturer who must accept full responsibility for the adopted design

and fabrication and assembly methods as well as for the components and the

completed magnets to conform to the tolerances, tests and requirements specified

herein. The manufacturer is free to propose alternatives which are better

adapted to his particular production facilities. Such alternatives must be

approved by CERN.

6. MODIFICATIONS TO THE SPECIFICATION

CERN reserves the right to make minor modifications at the time

the contract is negotiated. In particular, the details of the pole width,

the angles, the round-off of the corners, the height and width of the pole

shims, the location and diameter of the hole for both the laminations and end

plate, and the details of the end shims may not be definitive and may be

slightly modified at the time of notification of the contract.

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7. MODIFICATIONS TO THE SPECIFICATION AFTER DELIVERY OF THE FIRST MAGNET

After magnetic measurements of the first delivered magnet CERN

will define the final pole profile (taper, height and width of pole

shim, location and diameter of pole hole) for the laminations and end plates

and the final shape of the end shims. The dimensions likely to be modified

are marked with an asterix on the drawings of the lamination and end plate.

Those modifications will be transmitted to the manufacturer by CERN within

4 weeks after delivery of the first magnet.

8. ADDITIONAL SHORT VERSIONS OF THE ~~GNETS

CERN reserves the right to order optionally magnets of different

lengths called B220 & B100. Those magnets will have the same cross-section

as the B190 type (same laminations, end plates, angular plates, same conductor

and number of turns, same cooling circuits, etc), but the iron length and

coil length ",ill be different. The iron length will be 2212 mm for the

B220 type and 1012 mm for the B100 type.

9. INSPECTION AND ACCEPTANCE TESTS

All tests described in this specification must be witnessed by

a CERN inspector. Therefore CERN must be notified at a suitable time before

the tests and the inspector must have free access to the relevant p,arts of

the factory. Reasonable office accomodations and a telephone line must be

provided for. In addition CERN must have free access at any normal time to

the production premises of the main contractor and of his subcontractor.

10. THE HALF-CORES, DESCRIPTION AND TESTS

10.1. GENERAL

Each magnet yoke consists of two identical half-cores. The half­

cores are assembled from precision-punched, insulated steel laminations,

stacked between thick end-plates and held together by angular plates welded

on the outside of the stack.

To meet the magnetic field requirements, tight geometrical tole­

rances are imposed on the magnetic circuit, especially on the pole profile,

the reference surfaces and the mating surfaces. The magnetic circuit must

be mechanically stable with time. Normal handling, transport, etc., shall

not affect the specified dimensions and tolerances.

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10.2. THE STEEL SHEET SUPPLY

The steel sheet to be used for the laminations shall have a nominal

thickness of 1.5 n@ and is subject to the same magnetic, geometrical and

mechanical specifications as contained in the document "Specification of

the steel sheet for the 300 GeV magnet sys tern, Ref. No. WB/I-3960 Lab. II",

and Appendix Ia to the latter document. Copies of these are attached

to the present specification.

The geometrical and mechanical properties of the steel sheet must

be tested by the magnet manufacturer while the magnetic properties will be

tested by CERN, following the procedure laid down in the above-mentioned

document.

The magnetic measurements will be performed on ring samples, prepared

by the manufacturer, each sample consisting of a pile of 10 rings of inner

J:2;\leter 76±0.1 mm and outer diameter 114±0.1 mm. In total 20 samples will be

measured, distributed over the delivery according to size of melts, number

of coils, etc.

The specification of the geometrical and mechanical properties

of the sheets, as agreed between the magnet manufacturer and his steel

supplier must have prior approval of CERN.

The external dimensions of the steel sheet must be chosen by

the magnet manufacturer and must allow a sufficient margin for accurate

punching of the contour and for the removal of undesirable parts of

the sheets, should they exhibit crowning effects.

10.3. INSULATION OF THE LAMINATIONS

The lamination shall be insulated with a continuous thin layer

of heat and radiation-resistant material, or by a suitable surface treatment.

In proposing the type of the insulation and the insulation proce­

dure, the following considerations are relevant :

a) Prior to being insulated, the plates must be adequately cleaned

and degreased. The laminations may be insulated before or after

punching, but no permanent deformation must be produced in the

insulating process.

b) The process must not affect the magnetic properties of the lamina­

tions, for example, by causing excessive heating. CERN will also

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perform magnetic measurements on insulated rIng samples as in

section 5.2. If the magnetic properties do not comply with the

specifications, the insulation will not be accepted.

c) With the exception of small regions within a few millimetres of

the welds, the insulation layer must not be altered when the

angular plates are welded along the external contour of the stack

of punched laminations. In turn, the quality of the welds must

not be altered by the insulation.

d) Short circuits are not permitted other than at the welds, in

order to avoid conducting loops linked with the magnetic flux.

Therefore, the insulation must be continuous, well adherent and

mechanically strong.

e) In order to achieve a high packing factor, the insulation must

be as thin as possible, consistent with the above requirements.

The insulation used must have CERN's approval.

10.4. TEST OF INSULATION RESISTANCE

The insulation resistance must exceed 6 Q per cm2 and per 10 cm of stack

The insulation of the laminations must be measured on stacks of compressed

punched laminations which are assembled prior to the final stacking under a

pressure of 10 kg/cm2 This check must be done once for every 5 half-cores

on one stack of about 20 cm length.

10.5. PUNCHING OF THE LAMINATIONS

The punching procedure needed to obtain the specified geometrical

accuracy, burr and run-off requirements is entirely the responsibility of

the manufacturer but it is suggested that a compound tool be used (die with

a counter plate). The burr must not exceed 0.06 mm and the run-off must be

smaller than 30 microns.

The die must also punch a witness mark. After each sharpening

of the die, the position of the witness mark must be changed.

The dimensions and tolerances of the laminations are shown in

drawing No. SPS-8033-17.l.0. The precision surfaces are the pole profile

and hole, the mating surfaces and the reference surfaces.

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10.6. GEOMETRICAL TOLERANCES CONCERNED WITH THE LAHINATIONS

Strict tolerances must be kept along the pole profile and hole,

the mating and reference surfaces.

The coordinate system for the geometrical measurements of the

laminations is given by the axes xx' (straight line determined by the

points P and Q and yy' (straight line perpendicular to xx' and equidistant

from the reference faces C and D).

In addition to those shown in the drawings, the following important

tolerances must be adhered to :

The mating faces HH' and NN' must be parallel to xx' to within

± 0.02 mm/m.

The straight parts of the pole profile must be parallel to xx'

to within ± 0.02 mm/m.

The distance from the xx' axis to the central straight part of

the pole profile must be measured at several points. All

values must fall within 26 ± 0.02 mm. (This in addition to the

tolerance on parallelism which is more stringent).

The centre of the pole hole must be on the yy' axis with a

tolerance of ± 0.02 mm.

The distance between the reference surfaces C and D must be

20 j: 0.02 mm.

The distance from the axis xx' to the straight parts of the

pole shims shall be respected ,,,ith a tolerance of ± 0.02 mm.

The distance between the pole shims shall be respected with a

tolerance of ± 0.05 mm.

The reference face E must be at the nominal distance from the

central straight part of the pole profile with a tolerance of

+ 0 and - 0.05 mm.

10.7. INSPECTION OF 'TIlE PUNCHED LAHINATIONS

Before the series punching of the laminations can start, at least

3 laminations must be measured by the manufacturer in the presence of a CERN

representative and subsequently sent to CERN for checking. Only when the

results of these verifications show that the dimensions are correct and the

tolerances are kept, can the series punching start.

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Every 2000th lamination must be separated, marked with an identi­

fication number and inspected by the manufacturer for burr and linear dimensions

(on a jig). The last punched lamination before a sharpening of the die

and the first after sharpening of the die must be completely measured (dimen­

sions and tolerances) and the run-off verified by the manufacturer. These

laminations must be sent to CERN together with the results. CERN will cross­

check these laminations. If these laminations do not satisfy the specified

dimensions and tolerances, all the laminations punched after the last accepted

lamination will be rejected by CERN. The verification of the dimensions and 2 tolerances must be done whilst a pressure of 100 kg/m is applied to the

lamination.

10.B. END PLATES AND ANGULAR PLATES

The stack of punched laminations must be terminated by end plates,

with a thickness of 60 rom.

The contour of the end plates must stay within the nominal contour

of the laminations with a tolerance of 0.1 rom on the pole faces and 1 rom

on the rest of the contour.

The end plates shall be made of low carbon steel having the

following characteristics :

a) The value of the coercive force shall be less than 1.6 A cm

and the spread less than 20%.

-1

b) When subjected to a magnetizing field of 300 A cm- l the induction

shall exceed 2.0 T.

These properties will be measured by CERN on machined rings

(outer diameter: 114 ± .1 rom, inner diameter: 76 ± .1 rom, thickness

The manufacturer must cut out 1 ring for every 50 end plates.

Each end plate has a recess for the location of end shims and drilled and tapped holes for the fixation of these end shims.

The half-cores are assembled by means of angular plates welded

along the outside contour. The angular plates have a number of tapped

15 ± .1 rom) .

and drilled holes and machined plates are welded onto them for lifting and

supporting purposes. The magnetic properties for the material of the

angular plates are not subject to a specification. The choice of the steel

and the mechanical properties is left to the manufacturer.

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The angular plates shall be properly bent and adjusted and the

contact faces machined to ensure that they can be placed in good contact

with the laminations all along the stack.

10.9. STACKING OF THE LAMINATIONS

The laminations must be stacked in a rigid frame which confines

them against suitable reference surfaces. In choosing the stacking references

it must be borne in mind that the pole and mating surfaces should be as

straight and smooth as possible.

The required quality of stacking is determined by the need to

meet the tolerances on the assembled circuit.

In order to achieve a high degree of symmetry in the stack, the

laminations shall be placed in the stack such that successive groups of

30 laminations have their witness mark in alternate positions with respect

to the axis of symmetry.

Because of the inevitable thickness variation over the surface

of the laminations, the stack must be shimmed, by means of thin steel sheets

not thicker than 0.5 mm and of different size. Previous experience shows

that good results are obtained by preparing stacks of 20-50 em and shimming

them in advance. At regular intervals during the stacking operation and 2

at its end, the stack shall be compressed with a pressure of at least 10 kg/em.

Care must be taken that the pressure is applied uniformly over

the cross-section of the stack.

Each time the stack is compressed it must be inspected to make

sure that all laminations are 1n intimate contact with the reference surfaces

of the stacking fixture.

The total length of the stack with end plates must be measured

while the stack is kept under pressure and adjusted by compensating laminations.

10.10. WELDING OF THE STACK

Before welding the angular plates to the laminations and end

plates the pressure must be applied and removed several times to the stack

and the stack must then be left to settle under maximum pressure for

several hours.

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During welding, the angular plates must be kept in contact with

the laminations all along the stack by means of suitable pressure fixtures.

The welding procedure must be carefully established and executed

in order to avoid distortion of the core due to thermal stresses.

The welding shall take place while the stack is kept under

adequate pressure. After welding,the angular plates must provide a suffi­

cient compression on the stack to guarantee the mechanical stability of

the core.

It will be necessary to weld at several places simultaneously

and to establish a suitable sequence of welding. This is however, the

responsibility of the manufacturer.

The straightness of the reference surfaces on top of the lamina­

tions and the straightness and parallelism of the mating surfaces and of

the pole face must be measured before, during and after welding by suitabl~

placed micrometers or electronic feeler gauges.

In order to achieve the specified tolerances of the finished cores

it may be necessary to correct the deformations introduced by welding.

The tenderer is invited to state the procedures he proposes to use for

correcting any such deformations.

The quality of the welds must be such that the magnets can be

handled and transported safely and that normal handling of the magnets

does not affect their dimensions.

10.11. FINISHING OF THE HALF-CORES

The half-core must be degreased and any scale and oxide removed.

After the mechanical measurements on the half-cores as specified

in section 10.12, they shall be painted with at leaot 1 coat of primer and

2 finishing coats of an epoxy paint of colour and quality to be selected in

agreement with CERN. The coil window must be coated only with a primer.

The mating and reference surfaces must not be painted but be

protected by a removable tape. Each half-core must be marked with a serial

number.

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10.12. TESTS TO BE PERFOlU1ED ON THE HALF-CORES

The half-cores will be submitted to the tests as described below

1n the presence of a CERN representative. The results of the measurements

must be recorded together with the serial number of the half-core. The

test reports will be the basis for provisional acceptance or rejection of

the half-core. CERN will reject any core not satisfying the following tests.

10.12.1. Filling factor

The filling factor is here defined as the ratio of the weight

of the finished half-core to the weight of a massive half~core having the

same volume and made of a material having the same density as the laminations.

The nominal filling factor will be measured on the first half-core and

must be larger than 96%. The filling factor of the following half-cores

must be equal to the nominal filling factor to within ± 0.5%.

10.12.2. Length of the half-cores

When the half-core is resting with its mating surfaces on a flat

horizontal surface, the length between the machined surfaces of the end

plates must be measured at the symmetry line of the pole and at the shims.

The average value of the 3 measurements must be equal to the specified

value ± 1 mm, but the maximum difference between the 3 values must be

smaller than 0.5 mm.

10.12.3. Straightness of the half-core

When the half-core is resting with the mating surfaces on a flat

horizontal surface, the deviation of the vertical reference surfaces C and

D (on top of the half-core) from an ideal straight surface must be smaller

than ± 0.15 mm for the B340 and ± 0.1 mm for the B190.

Whi thout any pressure applied to the half-core the maximum clearance

between mating surfaces and the horizontal flat surface must everywhere be

smaller than 1 mm. (To obtain this the deformations introduced by welding

may have to be corrected as discussed in section 10.10). The maximum gap

appearing between mating surfaces and the flat surface when applying

mechanical clamping must be smaller than 0.05 mm.

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10.12.4. Perpendicularity of the end faces

The perpendicularity of the machined surface of the end plates

with respect to the horizontal flat surface must be better than 2 mm/m.

10.12.5. Other dimensions

The other dimensions, especially the position of the holes for

lifting and supporting devices must be checked.

10.13. END SHIMS

Each magnet has two types of end shims :

Thin shims of 1.5 mm and 0.5 mm thickness to adjust the magnetic

length,

Thick shims shaped such as to correct the end field.

The first magnet of each type must be delivered with end shims as

indicated on the drawing attached to the specification.

After magnetic measurements of the first magnet of each type

have been performed, the final shape of the 'thick end shim for each type

will be communicated to the manufacturer.

The magnets of the series production must be delivered with

4 thin shims of 1.5 mm and 1 thick shim mounted on each end of each half-core.

The 1.5 mm shims must be made from the same material as the lamina­

tions and the 0.5 mm shims from dynamo steel sheets.

The thick shims must be made from annealed, hot rolled, low carbon

steel plates having the following magnet characteristics :

At a field of 300 A cm-l , the induction must exceed 2 T,

The coercive force must be smaller than 1.6 A cm-l •

The dowel pin to position the shim fits into the hole in the end

plate and must be made from stainless steel.

In addition, the manufacturer must deliver with each magnet

16 shims of 1.5 mm and 8 shims of 0.5 mm.

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11. THE EXCITATION WINDING, DESCRIPTION AND TESTS

11.1. GENERAL

The excitation winding is composed of 2 identical coils, connect­

ed electrically in series.

The short coils have each 6 layers of 16 turns and the long coils

4 layers of 9 turns.

The coils are made of hollow copper conductor, insulated exclusi­

vely with glass-mica and all glass tape and a thermo-setting, radiation

resistant epoxy resin.

Each short coil has 6 parallel cooling circuits and each long

coil has 4 parallel cooling circuits.

11 .2. CONDUCTOR IIATERIAL AND DIHENS IONS

The conductor must be made from electrolytic copper with a maximum

free oxygen content of 10 parts per million and a resistivity at 200 C

not higher than 1.724 x 10-8 ~m.

The conductor cross-section has the following dimensions.

For B190 For B340

Conductor height 13.2 ± 0.1 mm 20.6 ± 0.1 mm

Conduetor width 8.0 ± 0.1 mm 15.2 ± 0.1 mm

Corner radius 1 mm 1.5 mm

Cooling duct 0 5.1 ± 0.1 mm 7.2 ± 0.1 mm

The copper bars must be of appropriate length to permit windings

with a minimum number of joints. All conductor joints must be in the

long straight part of the coil.

Before winding it must be verified on each copper bar that the

cooling water hole is not obstructed by blowing through a ball.

11.3. CONDUCTOR BRAZINGS

All joints in the conductor shall be silver-brazed without flux

according to an approved method.

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The brazings must be executed under close control to guarantee a

perfect reproducibility. They must be absolutely water-tight and must not

increase the electrical and hydraulic resistance.

CERN demands that the joints be made by means of a machined

sleeve in the water passage.

Before permission can be given to start the production of the

coils, a number of brazing samples must be made and tested to demonstrate

that the brazing technique is entirely satisfactory. The samples will be

submitted to the following tests :

a) The joint shall be cleaned and machined to the nominal dimensions

of the conductor and visually inspected.

b) The joint shall then be stressed with a force corresponding to 2 a tensile stress of at least 4 kg/mm in the copper cross-section

of the conductor. No fissure or surface deterioration shall

appear during this test.

c) Water at SOoC will be passed through the conductor which will

be externally sprayed with cold water on the joint for 3 minutes.

This cycle will be repeated 25 times and test b) repeated after

the las t cycle.

d) The joint shall then be leak tested with gas under pressure

(60 atm. during one hour), the joint being in a water bath.

e) The joint shall then be cut open to inspect the brazing quality

(bad flow of brazing material, porosities) and to check that

the cooling hole is not obstructed.

If the brazing samples show bad flow of brazing material or

porosities and air bubbles in the joints or if they show any deterioration

during the tests, the manufacturer must improve the technique at his own

expense until a set of satisfactory samples has been obtained.

During production, periodic test samples (5 samples per month)

must be prepared by the manufacturer. Those samples will be leak tested

as under d) and then cut open and inspected for porosities, insufficient

flow, etc.

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11.4. WINDING OF THE COILS

It is expected that the conductor be insulated before winding.

In that case, the inner conductors must be filed off if needed where

keys toning will occur.

11.5. INSULATION

11.5.1. General

As the coils will have to operate under severe working conditions

(thermal stresses due to water cooling, magnetic and mechanical forces

and a radiation environment), the manufacturer must assume complete respon­

sibility that the coils will satisfy all the tests described hereafter

which are designed to ensure a reliable and safe operation over years.

Since the inlet temperature of the cooling water may be below the

dew-point of the surrounding atmosphere, the coils may be exposed to conden­

sation. It is therefore important that the insulation be guaranteed water

tight to avoid short-circuits under these circumstances.

The coils will have to operate in the presence of ionizing radia­

tion so that the thermo-setting resin must have an adequate radiation

resistance (see section 11.5.3.).

11.5.2. Insulation proce~ure

Tae manufacturer is entirely responsible for the insulation

procedure; however, the following conditions must be satisfied:

a) Prior to winding the insulating tapes, the conductor surface must

be cleaned and degreased by sand-blasting. Copper oxide

and burrs must be removed.

b) The conductor insulation and ground insulation must be built up

exclusively with glass-mica tapes and all-glass tapes. The tapes

used and the composition of the insulation must have CERN's

approval.

c) The thickness of the conductor insulation must be about 0.65 mm

resulting in 1.3 mm spacing between adjacent turns.

d) Insulating sheets of 0.4 mm thickness must be inserted between layers.

e) For the ground insulation, a thickness of not less than 2.5 mm is

required such as to ensure about 3.15 mm between conductor and ground.

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f) Before winding the ground insulation any empty space shall be

filled with glass fibre since no apprecialbe volume of unfilled

resin in the coil is permitted. This also implies that the

mould must be made in such a way that the external layer of resin

not filled with tape is less than 0.5 mm thick.

g) The completed coil has to be placed in a mould which confines it

to its final dimensions. The coil is then dried and impregnated

under vacuum with a thermo-"setting resin and polymerised.

h) The manufacturer must have CERN's agreement for the composition of

the thermo-setting epoxy resin he intends to use for the impregnation

(see also section 11.5.3.).

i) During polymerisation, thermal gradients shall be minimized and

the temperature difference between the ends and the mid-points

of the coils kept as small as possible.

j) The finished coils shall be free of cracks, voids and dry spots.

The coil surface shall not be machined or mechanically processed

after moulding, except for the removal of flash.

11.5.3. Radiation resistance of the thermo-setting resin

The coil insulation should withstand the absorption of a radiation 9 dose of 2 x 10 rads (1 rad = 100 ergs/gram) and the manufacturer must supply

evidence of the radiation resistance of the proposed resin.

CERN considers the flexural strength behaviour as a criterion for

the radiation resistance of the resin. The flexural strength of the resin after

it has absorbed 2 x 109 rads shall not be inferior to 50% of its original

value.

The tenderer shall specify in his offer the type of resin he

intends to use and its chemical composition as the latter is important for

jUdging the behaviour of the material exposed to radiation. CERN reserves

the right to ask for samples for testing the radiation resistance.

CERN also reserves the right, during production, to ask for

additional resin samples for radiation tests to check that the co:nposition

and curing cycle are still satisfactory.

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11 .6. PROTOTYPE COIL

As soon as possible after the notification of the contract, the

manufacturer must construct a prototype B340 coil. This coil will undergo

a number of tests to verify that the adopted method of coil construction is

satisfactory. The prototype shall not be mounted on a magnet afterwards.

The coil will be considered satisfactory if it withstands the

prescribed tests without degradation. In case of failure(s), the manufactu­

rer must improve his design and construct (a) new coil(s) at his own

expense until a satisfactory solution is found. Only then will CERN give

approval for the series production of the coils to be started.

11.6.1. Tests to be done on the prototype coil

The coil shall be energized and the water flow adjusted to obtain

a SOoC temperature difference between inlet and outlet water, the cooling

circuits being connected in parallel. Once the temperature rise has

reached SOOC, the water flow shall be reversed until the same temperature

difference is reached again. The reversal of the water flow shall be repeated

1000 times. After every 200 reversals and at the end of the cycling, the tests·

11.7.3. must be repeated (measurement of insulation resistance, ground

insulation test, interturn insulation test).

11.7. PROVISIONAL ACCEPTANCE TESTS ON THE SERIES COILS

The series coils must be submitted at the factory to the following

tests in the presence of a CERN representative. The test results must be

recorded together with the coil series number and transmitted to CERN.

11.7.1. Geometrical test

The dimensions and tolerances as indicated on the drawings

will be checked.

11.7.2. Flow and Pressure test

The flow in each parallel circuit must be measured for a pressure

drop of 6 atm. It must exceed 1.6 £/min for the short coils and 4.4 £/min

for the long coils.

The coil must be pressurized during 1 hour at 60 atm. No evidence

of any leal, mus t appear.

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11.7.3. Electrical tests

11.7.3.1. t!~§:~~~~IE~~.!:_2i_~~§.~l~!.=.~£~_~~~~§.!~~£~ The insulation resistance with respect to ground must be measured

with t.he coil immersed in \vater LIt ambient temperature. The coil connec-

dons must be lifted out just as far as needed and wrapped with wet cloths.

The insulation resistance must. be measured at least 2 kV de and must exceed

100 }to.

Before and after each of the following tests 11.7.3.2 and 11.7.3.3.,

this test must be repeated. The value of the insulation resistance must not

be smaller after the test than before (10% tolerance). If it appears to

have dropped by more than 10%, successive tests of half duration shall be

performed and the insulation resistance measured until it stabilizes at a

value exceeding 100 Mll.

1l.7.3.2. Ground insulation test ----------------------This test is to be performed after 12 hours of complete inunersion

111 water at ambient temperature, the coil connection side being above tv-ater

level and wrapped with wet cloths used as artificial ground. A test

voltage of 10 kV r.m.S. at 50 Hz must be applied between copper and ground

for 1 minute.

11.7.3.3. !~~~E~~E~_~~~~l~~~~~_~~~~

Immediately after the above tests, a voltage of 50 V r.m.S.

per turn must be induced for 1. minute in the coil, the coil being used as

the secondary winding of a transformer at a frequency between 50 and 1000 Hz.

The primary current and the induced voltage must not vary during the whole

test period.

CERN vJ:i,ll reject any c.oil showing electricLd or mechanieal

degradation or failures appearing dllriog these tests or not satisfying

the dimensional tolerances.

11.7.3.4. ~~~~£E~~~l_E~~~~£~~~~

The electrical resistance at 20De of each coil must be measlJred

and must not exceed 0.105 !,i for the 13190 and 0.0197 " for the Jl340 types.

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12. THE COMPLETED HAGNET, DESCRIPTION AND TESTS

12.1. GENERAL

After inspection of the half-cores and coils, these components must

be assembled. The cooling circuit must be completed and the ancillary

components mounted so that the magnets are ready for operation. A number

of tests must be performed before the magnets can be delivered at CERN.

12.2. ASSEHllLY

12.2.1. General

The assembly technique must be carefully studied and chosen in

order to satisfy the following requirements :

The coils must be clamped firmly by means of resin-filled tubes

and hard and soft spacers and by means of supporting jacks so

that their position is stable in time and that mechanical forces

caused by magnetic fields and normal handling and transport

cannot harm them.

The geometrical tolerances as indicated on the drawings must be

met and the tests described in section 12.3. must be passed

successfully.

The following is a possible assembly technique, but the manufac­

turer is free to propose alternatives. CERN will give careful consideration

to any alternative proposal.

12.2.2. Coil into Core

It is suggested to assemble first the two half-cores and their

respective coils separately. For that purpose, spacers of glass-fibre

reinforced epoxy resin and ethylene-propylene rubber must be used. The

spacers are placed at the bottom of the coil window at intervals such as to

coincide with the position of the clamping jacks and must be adjusted to

the measured coil dimensions. The spacers touching the pole surface and the

vertical part of the return yoke must be continuous over the entire length,

of the magnet. The thickness of these must be adjusted by adding thinner

spacers wherever required by the coil tolerances. The empty tube for final

clamping must be glued to the coil at a few points for stable positioning.

After checking the coil position, this glass-fibre sleeve must be filled and

pressurized by an epoxy resin. The composition of the resin must be chosen

so as to obtain suitable viscosity and hardening time and minimum shrinkage.

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12.2.3. Assembly of magnets

Since the final magnet has a better stiffness and stability

than the half-cores, an assembly table must be used to correct the

geometry of the half-cores during the final

be equiped with 10 (6 for the short magnets)

assembly. This table must

adjustable jacks, precisely

positioned in an horizontal plane and with a nuber of references positioned

in a vertical plane. In front of each of these horizontal and vertical

reference points a mechanical or hydrau1ica1 device must be present in

order to produce a sufficient pressure to straighten the half-cores before

we1ding.The lower half-core will be put on this table (the jacks fit into

the holes in the angular plates) and the coil supporting jacks put in place

(these are located at the same position as the assembly table jacks).

The upper half-core must now be turned over and placed on the

lower half-core. Consequently the coil supporting jacks are compressed.

During turning over the coil of the upper half-core must be kept in

position by adequate external clamping.

A kapton foil with a thickness of 0.05 rom must be inserted

between the mating faces of the half-cores.

The relative position of the two half-cores shall be adjusted to

obtain the precision indicated in section 12.3. Hechanica1 clamping must be

applied (by jacks fitting in the holes in the angular plates of the upper

half-cores) and magnetic clamping to close the mating surfaces to a clearance

less than 0.1 rom including the kapton foil. Hagnetic pressure can be

obtained by placing a few windings around the lower half-core and exciting

them by a suitable current (turns x current = 6000 At.). The tie plates

are then welded to connect the two half-cores while the magnetic field

is on.

12.3. TESTS ON THE ASSEMBLED HAGNETIC CIRCUITS

The following tests must be performed in the presence of a CERN

representative. The results must be recorded with the 2 serial numbers

of the half-cores and transmitted to CERN.

12.3.1. Longitudinal offset

The longitudinal offset of the 2 machined surfaces of the end

plates of upper and lower half-core measured on the poles must be smaller

than 0.5 mm on each end.

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12.3.2. Control of the mating surface clearances

The clearance between the mating surfaces shall be smaller than

0.1 mm, including the kapton foil.

This check must be done with feeler gauges at all spaces

inbetween the tie plates.

In addition, the magnet gap height must be checked as far as

possible at both ends of the magnets.

12.3.3. Transversal offset

The transversal offset of the vertical reference surfaces of the

two half-cores must be smaller than 0.3 mm for the long magnets and 0.2 mm

for the short magnets.

12.3.4. Straightness of the yoke

The deviation of the vertical reference faces from an ideal

vertical plane shall be measured over the entire magnet length and shall

not exceed ± 0.15 mm for the long and ± 0.1 mm for the short magnets.

The same tolerances apply for the horizontal reference faces.

The twist shall be measured over the entire magnet length and

shall be smaller than 0.75 mrad for the long and 0.5 mrad for the short

magnets.

For this test, the magnet must be supported at the points

foreseen for this purpose (1 jack at 1 end, 2 jacks at the opposite end).

12.4. FINISHING OF THE MAGNET

After assembly, the cooling circuit must be completed, the

electrical connections and interlocks mounted and the covers added.

The "l,qtes which support the target hoiders and the magnet support­

ing plates must be welded to the magnet after assembly.

The serial number must be stamped on the magnet together with

the serial numbers of the half-cores and coils.

In a suitable position, a marking plate must be mounted with

the following indications :

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- 22 -

1. nominal voltage

2. nominal current

3. time constant

4. flux density

5. equivalent length

6. water flow

7 • pressure drop ~p

8. weight

9. serial number and year of construction

The values for items 1 - 7 will be connunicated to the manufac-

turer by CERN.

l2.5. COOLING

The maximum pressure of the cooling water may be as high as

25 atm. The cooling system must be suitable for continuous operation under

these circumstances.

Since demineralized water will be used, all metallic parts of

the cooling system must be made of copper, zinc-free bronze and stainless

steel.

The hydraulic connections between the coil inlets and outlets

and the inlet and outlet manifolds are made of copper pipes.

Some of the connections between copper conductors and copper

pipes are brazed, others bolted,with mineral joints for tightness. The

brazings must be carried out with great care. The manufacturer must

prepare samples of the brazings and perform tests as in section 11 :3. The connections between copper pipes and manifolds are not

brazed but made with standard tube fittings.

The entire cooling system must be insulated from the yoke and

adequately fixed.

The cooling water tubes must be insulated by 2 superimposed layers

of heat shrinkage sleeves.

To insulate the pipes from the clamping pads, 6 layers of kapton

with a thickness of 0.05 mm must be added around the tubes.

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12.6. ELECTRICAL CONNECTIONS

The tHO coils of the magnet are electrically connected in series.

The interconnection has to be insulated aften . .;rards. To conform to CERN's

existing cables, the terminals must be made as indicated on the draHings.

12.7. INTERLOCKS

Near each water inlet small temperature sensitive switches

must be mounted and insulated. The contacts must be connected to a terminal

strip on the front side of the magnet.

The outlets must also be protected by means of small thermal

s,,,itches. These sHitches are mounted at the non-connection end of the

magnet and fixed on the ground insulation, the thio.kness of Hhich must be

controlled. The switches must be wired and connected to a termina~ strip on

the front side of the mngn,ct. The Slditches on the non connection end must

be protected by a removable cover.

12.8. PROTECTIVE COVERS

On the connection side of the magnet a removable protective cover

must be mounted, covering the coil heads, the cooling system and the

electrical connections. The cover must have openings for the vacuum tube,

and the electrical and hydraulid connections. The cover shall be adequately

subdivided enabling e"sy mounting and demounting in the later"l direction.

T:1e covers must be made of an insulating material, e.g. fibre

polyester of "bout 4 mm thickness.

12.9. PROVISIONAL ACCEPTANCE TESTS OF THE COMPLETED MAGNETS

The completed magnets Hill be submitted to the following tests at

the factory. They c"n only be shipped to CERN once they have passed these

tests.

12.9.1. Leak tests

The entire cooling system of the magnet shall be tested with water

at 60 "tm. for 1 hour. It must be absolutely water-tight.

12.9.2. Flow test

The total water flow of the magnet must be measured CIt a pressure

drop of 6 atm. between tllC hydraulic terminals.

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The flow shall exceed 19.6 litres/min for the B190 and 35 litres/min

for the B340 magnets.

12.9.3. Resistance of the magnet

The total electrical resistance of the magnet must be measured

between the electrical terminals. It must not exceed 0.21 Ohm for the

B190 and 0.0396 Ohm for the B340 magnets at 200 C.

12.9.4. High voltage test

5 kV r.m.s. at 50 Hz shall be applied between the coil and the

yoke for 1 minute. After the test, the insulation resistance must

be measured with a voltage of at least 2 kV de and must exceed 100 1m.

12.9.5. Test run

The cooling performance shall be checked during a test run of

a few hours at nominal current. The correct functioning of the thermal

switches must be checked.

12.9.6. The position of the target holders and base plates

The position of the target holders and of the supporting plates

must be verified.

All tests results shall be recorded together with the serial

number of the magnet, the half-cores and the coils.

12.10. TESTS AFTER DELIVERY AT CERN

Each magnet will be excited to full field and magnetic tests

will be carried out at CERN prior to acceptance of each magnet. As a result

of these tests CERN may decide to repeat any of the tests described in

this specification.

CERN reserves the right to return to the manufacturer any magnet

which fails to pass any of these tests.

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13. MISCELLANEOUS

13.1. TECHNICAL INFOR}~TION TO BE COMMUNICATED BY THE ~~UFACTURER

It is requested that CERN be informed about all technical details

of the construction.

The following information shall be provided by the manufacturer

a) Data on the construction materials

copper conductors

steel for laminations, end plates, angular plates, end shims

insulating material, resin, tapes.

b) Data on manufacturing processes

curing cycle for the resin

welding and brazing processes

assembly methods.

c) Drawings before production has started (for approval).

d) Time schedule of manufacture followed by regular progress

reports.

e) Any technical modifications with respect to the present

specification (for approval) .

f) Three complete sets of final drawings (for internal use at CERN).

g) Two copies of all test certificates.

13.2. LIST OF SAMPLES TO BE FURNISHED BY THE MANUFACTURER FOR APPROVAL

13.2.1. Steel samples

- A number of rings cut out of the steel sheets as indicated

in section 5.2.

- Ring samples of the steel for the end plates as indicated

in section 5.B.

A number of punched laminations as stated in section 5.7.

13.2.2. Copper samples

Three samples (2 m length) of insulated copper conductor used

for the coils.

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- 26 -

13.2.3. Insulation samples

Samples of the tapes used for conductor and ground insulation.

Samples of the resin for radiation resistance tests (pure resin).

13.2.4. Brazing samples

Five samples of each particular sort of brazing connection.

13.2.5. End connections

Five samples of water outlets of the coil conductor to copper

tube connection.

13.2.6. Samples of thermal switch mounting

Five samples of the mounting of thermal switches on the inlet

conductors, insulated and wired.

13.2.7. Sample card

Sample card for the selection of the colour for the iron yoke

and the protective covers.

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SPS/EMA/Spec. 78-16

TECHNICAL SPECIFICATION FOR THE BENDING MAGNETS

FOR THE CERN ANTIPROTON TRANSFER LINES

TECHNICAL QUESTIONNAIRE

The answer to the following questions will be taken into account

by CERN for the evaluation of the proposals made. Tenderers are requested

to answer clearly and completely all questions put forward.

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- i -

1. Who will be the proposed steel supplier?

2. What are the magnetic properties of the steel?

3. What type of insulation do you propose for the laminations and indicate

the qualities : thickness, surface resistivity, breakdown voltage,

heat resistance, radiation resistance, mechanical properties.

4. Will the sheets be insulated before or after punching?

5. Give a description of the punching procedure: number of operations,

part of the contour punched in each operation, punching force, tolerances

on punching die, expected frequency of sharpening operations of the die.

6. How do you intend to control dimensions and tolerances of the punched

laminations ?

7. Chemical composition and magnetic qualities of the steel for the

end plates.

8. Information on the steel for angular plates.

9. Give a description of the stacking process: number and location of

references, tolerances on stacking references, stacking pressure,

intervals of applying the stacking pressure, method for controlling

contact between laminations and stacking references, shimming method,

expected precision after stacking.

10. Describe the welding process: welding scheme, welding method and

eventually procedure to correct deformations.

11. Indicate the methods you propose for mechanical controlling of the

core and pole gap tolerances.

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- ii -

12. Information about the copper conductor you intend to use

content, conductivity, tolerances on profile, length.

13. Indicate the brazing technique you intend to use.

14. Description of the winding technique.

oxygen

15. Composition of the conductor and ground insulation

and number of layers of the tapes.

type, thickness

16. Detailed composition of the resin.

17. Description of impregnation and curing cycle and preliminary indications

on the mould you intend to use.

18. Information on the radiation resistance of the proposed resin.

19. Describe the procedure for the final assembly you will propose if

different from section 12 of the specification.

Page 33: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

EUROPEAN ORGANIZATION FOR NUCLEAR RESEARCH

300-HA/lnt-71-3

WE/I - 3960/Lab. II

SPECIFICATIONS OF TIlE STEEL SHEET' Fon TIm 300 GeV

HAGNET SYSTE}!

Original issue

Amendment A

Amendment B

9 August 1971

4 January 1972

27 July 1972

Geneva - 9th August, 1971

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B

- 1 -

1. Introduction

The European Organization for Nuclear Research (CERN) in Heyrin

(Geneva) has established a second laboratory adjacent to the existing

one. This laboratory is to be the site of the world's largest proton

synchrotron. One of the main components of this machine is the system

of approximately 1000 magnets weighing in total 15,000 T, which are

spaced around the 7 km circumference. The iron cores of these magnets

will be fabricated from precision punched laminations of 1.5 rom thick

cold-rolled, insulated, low-carbon steel.

1.1 Dimension of ~,e steel sheet and quantity required

The nomina'l thickness of the steel sheet shall be 1.5 rom. This

figure represents a compromise between minimizing stacking costs and

obtaining the required punching accuracy. In the present design there

are three types of magnets in the system. One type is the quadrupole

focusing magnet, 1.0 m long, the other two types are bending magnets both

.qhou t ~ 2& mlong but with different apertures . . ,

The external diluension of the steel sheet must be such as to

allow a sufficien'/; margin for accurate punching of the contour and for

the removal of undesirable wedge-shaped regions at the edges. Hargins

of 30 rum on the sides parallel to the rolling direction and of 15 rom

on the others have been found adequate.

The total amount of steel required is approximately 8,000 T in

stage A Rnd up to a further 8,000 T in stage B. The steel will be

supplied in sheets suitable for punching one or more of the

laminations'

1.2 Scheme of the steel delivery

It is proposed that CERN will place overall contracts with one

or more coremakers, who will be responsible for the placing of a sub­

contract for the supply of the stml sheet. 1'he coremaker will be

responsible for all mechanical aspects of the strol supply, while CERN

will define and carry out the acceptance tests concerning the magnetic

properties of the steel sheet.

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S-L(~el prodllction te~"ts ~.;1l.al1 lJC sLarted illlmedjately after tlle

steel order is placed anfl t"\\fO l)atellcs oJ' =50 tons produc(~d separately

B shall be sullmitt(>d; the first ,ifi-iJJ:in 30 d .. 1V(; and the second ,,,ithin

B 60 d s of the Ord(~T <18 eVlc1eJ)cP of thC' ach.ievemell-L of II sai;:isfactory

II

quality in tIle process l}ro]}osctl for llirge-Hcaic prodllci;ioIl. After

in.'3pection and testing~ this '-rill be 1HH~d by the corf:maicers for the

construcLion of magn('t core..').

Hr::,r;,u"lar steel del ivery !;11nll_ start:

rate of 1)000 tOll!~/mo\lth~ or a.':> determ"i.nc:d hy the rC',qui.rement!; of tlH~ cor(~l1lakC'L

1.3 Transpor'ta'j;ion nnd stOl'[lcrC

rnle steel shall l)(~ oilQd iJ-nU packaged in sl]ch a way a~--l to be

protected agninst surface detcriorntioll Illld dU1Dage during transport­

ation and storage.

2. }fa.r.~n(~'t;ic propc!l't-i (~S of tll(,~ :~te(>l s]lec~t

2.1 GCllcrnl.i'ties

IJ1he :500 GeV magnet , .... il1 operate ll11dc:r plliseti GnJldit,ions over

a range of liOO _ JB,OO{) G dl1)'ing tlle n.cc(~ler;ltjon cyelt'. Due to the

101>/' v'alue oJ tJIC' illitial f:i (lId it iH illl}'lOl'tan-i, t.llat tllP ;:-;tc~(>l 1)n;-.) as

J..owa eoereivit .. y a:-:-; POL1Hil)lc, lind :it is parT,icularly Jmpori"tllt i;]lat

tIle ''\7nrint:ion ill coereivity tJll'Ollgllout L]l(~ 8teel prodllc'i:.i.O),l he kept

\rery smull.

very importan-L f,O that tolerances must he impoHed. boCh on the \l111\1e8

and t.he sprf~ad of tIle vnluen of COPl'civity and perlll(li\·!Jilit.y,

}i'rom prcviol1B eX])(,1'iencQ~ tll(; n('Qd 1'01' hig}l slltllrati()ll indllction

requireLi the une of 11 lO'\v-cHl'"bon Hteel; vl'ith a, 10""1'1"" content of impul'itieH.

Page 36: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

- 3 -

Experience obtained in the construction of the CmlN Proton Synchrotron

and more recently "ith Lhe ISn indicates that a substantial improvement

of the low-field permeability and of the coercivity can be obtained by

a combination of suitable annealing treatments and cold reductions,

which further reduce the carbon content and increase the grain size.

'rhe magnetic characteristics indicated in these specifications have

actually been achieved on this type of cold-rolled, very low-carbon

steel sheet.

2.3 Coereivitv

The eoercivity value II hereafter specified is the value of the c lw\gnctizing field which reduces the induction in the steel to zero

from the value existing after complete saturation (II > 60 oersted). max

The vdlues of the coercivity through the whole delivery (measured on

samples as indicated in 2.7) must stay within an interval of :!:. 0.15

oersted with respect to a nominal value proposed by the steelmaker.

This nominal vnlue must be as low as possible, and in any case lower

than 1 oersted.

2.~ Pcrmeabi.litv

'rhe required values of permeability, i.e. the ratios of the

magnetic inductions n (in Gauss) to the applied fields II (in oersted)

measured at points along the normal magnetization curve, and their

permissible spread are usually specified, for the purpose of magnet

design, as n function of the induction B.

In order to facilitate measurements, the following equivalent

specification of the induction n as a function of the field II is

gi von:

n) At a field of 0.5 oersted, all measured values of induction

must be higher than 1,00 G.

b) At Il field of 15 oersted, all lIwasured values of induction

must he higher than 15,()()O G, lind their spread, Le. the

difference beb,een the highest. and lowest, must be less

tl",n 600 G.

c) At a field of 300 oersted, all measured values of induction

must be higher than 20,000 G.

Page 37: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

B

- 4 -

2.5 Ageing

In principle, the steel supply should be entirely stable with

respect to time in both coercivity and permeability. Since the

opcrating temperature of the magnet cores is expected not to exceed

25° C, stability of the magnetic properties refers to several years

of operation at this temperature.

As a practical criterion, it is proposed that the ageing

properties of the steel sheet are evaluated by remeasuring the

coercivity after 100 hours accelerated ageing at 150 0 C on the samples

submitted by the steelmaker. The measured values on the aged samples

should not exceed the limits specified in section 2.3 by more than

0.1 oersted.

After the order, similar measurements "ill be repeated on samples

from full scale production tests. The results of these measurements

should meet the same condition. It is not proposed to perform

systematic ageing tests throughout the delivery, but it is expected

that the constancy of the ageing properties will be ensured by the

constancy of the chemical composition and by the reproducibility of

the production process. Therefore, the results of the chemical

analysis carried out by the steelmaker onea~h batch of steel and

the records of the processing shall be made available to CERN. The

relevant tolerances should be proposed by the steelmaker and agreed

by CERN.

2.6 ,Surface resistance

The surface resistance of the laminations will be tested during

fabrication of the half-cores as described in the specification for the

manufacture of half-cores.

Page 38: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

- 5 -

2.7 Procedure for Dlntrnctic m('asnr(~m(>nt~

The magnetic pl'operties of the steel will be tested by CERN by

systematic measurements on samples taken throughout the delivery.

The steelmaker shall offer CEJU'! satisfactory facilities for the

inspection of the delivery and the taking of the samples. Samples

shall be taken from each batch of steel in its final condition previous

to delivery and the batcl. will not be permitted to enter the stores

for core-making until the samples have been tested.

A representative of CEJU'! will be present during the preparation

of samples by the steelmaker.

TI.e detailed sampling arrangements for the performance of the

magnetic tests and the insulation test will depend upon the form of

the steel provided and will be decided by agreement between the steel­

maker and' CEJU'!. In any event the maximum amount of steel from the

production used in this way will not exceed 0.2%.

It is proposed that the results of the measurements by CEJU'! shall

be submitted to the steelmaker. Unless an objection is made within

fourteen days after receipt of the data, it will be assumed that the

steelmaker is in agreement with the results. Subsequently, these

figures will be used for the purpose of acceptance and rejection.

In the event of an irresolvable dispute about the results of the

measurements, a neutral institution will be requested to arbitrate.

2.8 Tolerances on magnetic characteristics measured on samples

In principle it is desirable that from any steel batch no sample

should show magnetic characteristics outside the limits stated in

scction 2.3 and 2.4.

CEJ1N must reServe the right to refuse acceptance of a batch of

steel which exhibits unsatisfactory magnetic characteristics.

3~ Geometrical and 1U(~cllil,nical pl'opert:ir?s oJ th(~ steel

TIle final geometrical and mechanical specifications of the steel

will be the entire responsibility of the coremllker and the steelmaker

Page 39: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

- 6 -

and will have to be subject of the contract between those two parties

for the steel supply, but the agreement of CEIL'! to these precise

B specifications will have to be obtained prior to the signature

of the conctracts. In order to maintain constant magnetic character_

istics, no mechanical processing of the steel sheets except shearing,

punching and deburring can be permitted after the sampling for magnetic

measurements.

As a general statement, it is required that the steel in its

final condition be suitable for precision punching, and for assemblin.,

in straight stacks with a large pocking factor.

It will be the responsibility of the coremaker to undertake

adequate geometrical and mechanical testing on the steel supply during

delivery and to define, in agreement with the steelmaker, the precise

methods of inspection. The wastage of steel through sampling for

geometrical and mechanical tests should not exceed 0.1% of the supply.

CF.JlN sholl be informed of the agreed methods of inspection and the

results of the inspection shall be made available to CEIL'!.

Page 40: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

- 7 -

~~~)J.:i~~2-f~_OJtl('tricn1. :JnrI Ewehan.-i c'~U~:.2~:rtj os

yJ' ___ U!...::_~~:t.e (' ~ Sll ce ts

The sheets shoull!' l)c as flut as possible and free of in·Lernal

!3C:L"QS:)(~S, ill ortlcr to avoid mo\"c]!)(!nts of the' gap profile nft'ir punch­

ing nrH1 lo(;al pcrtul'bat,ions of the magnetic properties in staclring

U]}acr pressure. ThlaCV~].Op~ll)lc 1111fl.utncs8 is cHpccially harmful.

o encler a prC~,~~llrc! o·r 100 l:'g/m"··, all POjllts of [t f311cct shouJd

be c(lllfj)lQ{: bct'w(~en t1'10 IFl)';,)llel plal1C'B, di~)tnnt i'l'om caeh other

1)), d + 5 m!l1, ,·,'hQre d i::,; the thietncss of the sheet in millimeters.

Norccl"I'cl'} tJI(~ HHlJJlitude of any local \-I<1\'e sllould not exceed. 0.5 per­

CCllL of the '\,:_n/clcnt~th.

As a erit(~rion for the UhsC'f!ce of int(,Tnal stresses, it is

pJ'Clposecl tll[tt, iJ a shpct is cut and the two halves nrc hrought back

to contr •. ct, the JlJa:dr.1'Ul1l clcaranee appearing oC'bvoen t.he edges should

not exceed 0.3 Gml.

IJ' ·[.he S!l(~(~ t. i::; :fillully ttllnl~aled.·, ill coils, the light sl\:illlJaSB

oj' the coil, (l'ctlucti()ll oj' less than U.3 pCl'eent) may be pcrfol'mcd

to flatten the sheet previous to fly-cuttinc;, Although this operation

Jlny 1", not too harmful :frolll the point of vie" of the alllount of' stress

hHi.lt into the Silcct, it~-i in:fluQnec on the coercivity is not negligible

and must be tali:{~n iuto [)'(;COUllt ill the preparation of samples for the

t(:ndcr.

no] "i.eJ' :flnttf'ning 01' skin Jlas~;ing of tJl<~ indiyidunl 811('0-(-..''; aft,cr

:f'lY~CHt.tjll:~ is not PC]'?:!j ssilJle, llcc:nnse it ".'Ollld ntlver~-iely affect. the

longitudjlwJ dj;-d:.l'.illut)Ull oJ tlJielclless.

'! ,- .

sllc'et.

Page 41: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

- 8 -

Tn order to obLain a sa-tisfnct.()~{·y s':~ael:, it is ef:l}(~cially :ii."ljJcrklllL

to reuuco us lUuch as possible the systematic uifferences in thicl,ncss

uct,\.,r-ecn ':nrious Tegions of the sheets, '\Ihich give ris.c to the lHlild.-1!p

of voitls in the f-;tnc:1c Therefore, -(:·lle conv(~xi t.y o:f the IlJ'ofilc oJ' the

sheet crOSH section perpendicular to the rolling direction ~IOI1Id be

reduced to a minimulU an(1 e:fforts should be wade to maintain the 1)1'ofile

close to two straight parallel lines over the widest possible region.

Statistical C01iJI)(~nf3ation 101' the convexity 01' tlH~ profile coult! of course

be olrtainecl lJY the presonco of a CUl'l'cspol1uil!g amount of sheets ,.,ith

conC[lve profile, if the prtHluction of such sh(,ets ,.,ould he at all co)~­

patiblc '.,ith sou·nd manu:facturing processes.

In order to illustrnte the naturc of the requirelllent, the follo\·.'-

illg (>x[!.mplc oJ a possilJlc critorioTJ for thie!(ncss l)nifol'l"JiLy is giY(!]1,

A ntllicl~ness sprcacl index" is cnlcnl{~ted for a sample sheet from tho

,,{eights of 'f groups of djscs of 80 E 1n diameter, punched from tho sheet

along }-! lines parallel to the rolling directj on, tvo ncnr the edges

and t;\~·o nenr the mitldlc. rrhc "thiclrness spread index" is eXIH'cssc£1

by the f01'mul,,:

p max

q = ---p

- p . mlll

avc

where Panel P. are th" "eights of the heaviest and of' the lightest max mln

of tI10 ~ groups, respectively, and p .. ' . is tho nVC:CF\.f.rC of the It vci[(hts . avo L> '-'

The "thickness spread index" should 1)0 lover than n given value. li"'l'OlU

our experience this limit value might be 10l:er than 1.5 percent. Other

criteria, based on a statistical co}~)inntion of crOBS sectional profile

measurements could, of course, be cf}"tlD.lly ncccFtn.1)lc.

No operation vhich vould t(mo. to C:l'Cilte ft syst."","t.ici.t.y ill t.he

lor:.~it1'!.dinnl pattern oJ th:i..el::ncsB in the ~;heets, BllCh as, for il):',:d:nncc,

flattenillg 01' sld.lI-pussillg of. tIle illdividual sheets, if.) pcrnis:-·dblc.

'1111c deviation of t.he absolute value 01." t.ho [lveJ'age th:i.ck~1r!S8 of

each sheet from the nomin<ll value ifJ Hot so import.ant as the thickl1(~SS

un:iJormity in the l})(J.iviunal shf~etn .. As a prnetical staHdal'd, it is

su[!:gested to n<lopt a toll~rancl! of .~ 0.11 Hun,

Page 42: EUROPEAN ORGANIZATION FOR NUCLEAR …...the CERN proton-antiproton transfer lines which will be constructed at the laboratory of the European Organization for Nuclear Research at Prevessin,

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be changed after measurements of the prototype

"OU OJ'"~

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(,I1"'-f)'V

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NlI V (rv Flame cut finish)

2 Hex.sock. ~~ew 3 ~.'---~~!".~. . P.2_~g_I __ pi~l _ 1 Stainless steel

__ );_I1_(:L_p_lgJ~_ . I. _L~~.Gi~~i-:-"-S-ee";;: ecificotions

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