TD/MSD

TORUS CMM PRODUCTION: OVERVIEW

G. Velev

Clas12 Torus CCM Production Readiness Review –Dec 4, 2013

TD/MSD

Outline

• Scope of the current FNAL effort• Project Organization Structure, Responsibilities,

Supervision, and Oversight• Technician and Staff Training, Qualification, and

Training Records• Work Environment• Project QA/QC Plan and Manufacturing Plan• Suspect Counterfeit Items Awareness &

Prevention

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TD/MSD

Scope of the FNAL effort

• Develop a manufacturing plan and tooling to wind the torus coils and insert them in the cold cases

Tooling fabricated, travelers written, and practice coil is potted

• Deliver to JLAB One prototype coil Seven production CCM’s (8 total)

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Organization of the CMM production effort

• The project is executed in MSD with the help of QMD• FNAL Team

G. Velev (TORUS coil project lead)

A. Makarov (project engineer)

Luciano Elementi (EE), TJ Gardner (PM), Oliver Kiemschies (Floor lead), Bill Robotham(ME), Jan Szal(QA/QC & travelers),

technicians at el.• Weekly Video Conferences between JLAB and FNAL

½ hour for schedule and cost ~hour to discuss technical details

• Frequently trips of Jlab personnel to FNAL – participation in the major steps of the practice coil fabrication

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FNAL Project Organization

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Technical and stuff training, Qualification and training record

• Training General, Fermilab/DOE required Specific for CLAS12 - local Operational procedures,

connected with CLAS12 tooling or local devices • paper copies provided

• Qualifications Out engineers and technicians have many years

experience in building conventional and SC magnets for different accelerators.

• Training records - paper copies provided

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Training Records –Example

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Work environment

• All manufacturing processes are done in Industrial Building 2 (IB2)

It is a standard TD/FNAL building with fully operational HVAC system

• Most of the materials are stored in the same building

Cable, insulation tape, copper All materials coming to the building are inspected and

cleaned if needed • Planed visit in the IB2 building

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IB2 building

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Competing Projects

• The CLAS12 project is going with higher priority in the MSD Accelerator support (AS) group

• In average 3-4 technicians are working on the project all time

• We have to finish until Oct 2014: in other case we are starting to have a conflict with other incoming projects

• During the CLAS12, AS group should support the magnets for the Fermilab accelerator - mostly repairs and production of small batches.

• No conflict with the working space• In case of manpower problem - technical help

from the other groups is possible

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Work Environment

• IB2 is not connected to backup power generator

To connect it ~ $100k is needed, preliminary estimation Critical production point depending of the power: one day

during the potting The weather is very predictable: we will not start potting if

severe event is expected.• Computer protection

Standard computer protection – DOE regulated All high level computers use a kerberized access +VPN The control computers are behind a firewall or not

connected to the network Some low level devices (PLC) which are used for monitoring

are accessible but not programmable from outside

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Project QA/QC

• In TD, QA/QC is a part of the MSD and Quality and Materials department

Fermilab Engineering manual Process Engineering group of QMD

• Major Tool: Travelers (Jan’s talk) QA/QC is integrated part of the travelers. All QA/QC steps are described in them Traveler is created with direct participation of the

traveler person under the supervision of the production engineer

Before to create a revision “None”, an internal traveler review is performed discussing safety, production steps and QA/QC for these steps

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Traveler example

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Manifacturing Plan

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1. Clean and inspect conductor from soldering manufacturer (AES) while re-winding from AES supplied spool to the production spool.

2. Wind cooling tube on to winding table, apply ground insulation to cooling tube

3. Insulate conductor, backwind 1/2 of conductor

4. Wind first pancake layer, inspect and set dimensions, install ground insulation on coil OD and install layer-to-layer insulation

5. Wind second layer, inspect and set dimensions, install ground insulation on OD

6. Install ground insulation and solder on copper foil over 2nd layer

7. Push into potting mold and flip

8. While in potting mold, install ground insulation and solder on copper foil over 1st layer

9. Close and seal the mold

10. Vacuum Impregnate the coil in the mold using CTD-101K epoxy; cure the epoxy

11. Remove from the mold – full coil electrical test

12. Install coil into coil case, position coil, shim ID with 2mm shims and shim OD as required

13. Vacuum impregnate coil into coil case using CTD-101K epoxy; cure the epoxy.

14. Ship to JLAB

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Counterfeit Items

• All Engineers and Supervisors are trained Fermilab training

• We are ordering from reputable suppliers• Special training for the QC incoming inspection• http://www.fnal.gov/directorate/OQBP/sci_doe_sci_program.html • http://www.fnal.gov/directorate/OQBP/sci_reference_docs.html • http://www.fnal.gov/directorate/OQBP/sci_other_resources.html

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TD/MSD

Summary

• The project organization is in place• Manufacturing plans exist• QA/QC is well under control• We are using Fermilab/DOE regulations and

Fermilab infrastructure for this project • The practice coil is 98% done• We are ready to start the production

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