160 'C/D' Dipole Lower Core Preparation

TD / Engineering and Fabrication Specification # 5520-TR-318874 April 2, 1997 Rev. E

Fermi National Accelerator Laboratory f Batavia, IL 60510

FERMI MAIN INJECTOR DIPOLE 160" 'C/D' LOWER HALF CORE PREPARATION TRAVELER

Reference Drawing(s) 160" 'C' Dipole Magnet Assembly 5520-ME-274909 160" 'D' Dipole Magnet Assembly 5520-ME-274910

Budget Code: Project Code: Released by: Date: Prepared by: N. W. Bartlett, R. Safarik, T. Skweres Title Signature Date TD / E&F Process Engineering TD / E&F Assembly TD / E&F Tooling TD / E&F Fabrication Manager TD / E&F Device Design TD / E&F Group Leader TD / QA/QC Manager TD / Main Injector Magnet Project Manager BD / Main Injector Magnet Liaison Project Physicist

FMI 160" 'C/D' Dipole Lower Half Core Preparation Core Serial No.

of 22 TD / Engineering and Fabrication Specification # 5520-TR-318874 April 2, 1997 Rev. E

Revision Page

Revision Revision Description Date

A Incorporated Thru Bus note (Jumper), shaded Thru Bus Hipot Serial Number, Hipot voltage 8/29/95 changed to 5 KV and Thru Bus resistance check to Electrical Inspection Step 5.4. Deleted reference to Coil Support Pads in Step 4.6. Incorporated new Electrical Limits to Step 5.4 from Nelson Chester. Incorporated Epoxy mixing quantities from Dean Sorensen to Step 6.1. TRR No. 0401

B Changed 'C' Lower Coil Resistance Limits from .215 - .235 mΩ to 2.20 - 2.40 m Ω as per 2/23/96 Dave Harding's E-Mail dated 2/20/96. TRR No. 0475 Incorporated after Step 4.6 to check the Pole Tip to Coil Gap and sand/apply epoxy as necessary. TRR No. 0481

C Deleted Step 5.1 Outside Coil to Core Dimension as per Nelson Chester. TRR No. 0524 6/4/96

D Deleted Dipole Designer from the cover page as per Bob Jensen. Incorporated Lead Person 12/2/96 Check for Step 4.2. TRR No. 0596

E Changed cover page references to TS / MDF to TD / E&F and AD to BD. TRR No. 0635 4/2/97

Ensure appropriate memos and specific instructions are placed with the traveler before issuing the sub traveler binder to production.

1.0 General Notes

1.1 White (Lint Free) Gloves (Fermi stock 2250-1800) or Surgical Latex Gloves (Fermi stock 2250-2494) shall be worn by all personnel when handling all product parts after the parts have been prepared/cleaned.

1.2 All steps that require a sign-off shall include the Technician/Inspectors first initial and full last name.

1.3 No erasures or white out will be permitted to any documentation. All incorrectly entered data shall be corrected by placing a single line through the error, initial and date the error before adding the correct data.

1.4 All Discrepancy Reports issued shall be recorded in the left margin next to the applicable step.

1.5 All personnel performing steps in this traveler must have documented training for this traveler and associated operating procedures.

1.6 Personnel shall perform all tasks in accordance with current applicable ES&H guidelines and those specified within the step.

1.7 Cover the half core assembly with green Herculite (Fermi stock 1740-0100) when not being serviced or assembled.

1.8 To determine the 160" 'C' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your right. To determine the 160" 'D' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your left.

1.9 All Room Cure Epoxy to be applied at an ambient temperature of 65° F.

2.0 Parts Kit List

2.1 Attach the completed Parts Kit List for the 160" 'C/D' Dipole Lower Half Core Preparation to this traveler. Ensure that the serial number on the Parts Kit List matches the serial number of this traveler. Verify that the Parts Kit received is complete.

Ensure that all the documentation or tags that were completed during the assembly process are in the Process Engineering Office.

Process Engineering/Designee Date

2.2 Lower Half Core (ME-318056)

Perform a visual inspection of the Lower Half Core. This inspection shall include but not be restricted to the following; rust, damage to pole tip/face, etc.

Verify and record the Lower Core Serial Number

Attach the Incoming Inspection Tag and the FMI Dipole Half Core Off-line Painting Form FM-318894 to this traveler.

Assembly/Designee Date

3.0 Lower Core Preparation

3.1 Using the overhead crane and the Dipole Half Core Lifting Fixture (ME-274106) or the Dipole Full Core Lifting Fixture (ME-318060) position the Lower Half Core (ME-318056) in the Dipole Half Core Rollover Fixture (ME-318741).

3.2 Clean the core of all loose dust/debris using vacuum cleaner.

Technician(s) Date

3.3 Mix and apply the Room Cure Epoxy Mix (MA-274696) to the entire bottom (coil area) of the core to the predominant break line of the pole tip. Apply the Room Cure Epoxy Mix to the trimmed lamination area as shown in the diagram below and the 160" 'C' Dipole Magnet Assembly (ME-274909) or 160" 'D' Dipole Magnet Assembly (ME-274910).

Note(s): Do not apply epoxy to the pole face of the core assembly or the center 36.00" ± .25" of the bottom (coil area) of the core.

R o o m C u r e E p o x y M i x B o t t o m ( C o i l A r e a ) 3 6 . 0 0 " ± . 2 5 " M A - 2 7 4 6 9 6

E n d P a c k T r i m m e d P o l e F a c e L a m i n a t i o n P o l e T i p A r e a Lower Core Top View

P o l e F a c e R o o m C u r e E p o x y M i x M A - 2 7 4 6 9 6

End View (Typical)

Technician(s) Date

3.4 Install the G-10 Insulators (MA-318359) (Qty. 4) along the bottom of the core. The G-10 is to be centered laterally in the core cavity and the G-10 is to extend 1" past the core face.

Note(s): Do not cover the middle 36.00" ± .25" of core with G-10.

Using a squeegee or a roller smooth out the G-10 to remove any trapped air.

Install the G-10 Triangular Pieces (SK-318359) (Qty. 4), onto each of the non-covered areas at each end of the core. Refer to the diagram below.

Install the Center G-10 Coil Supports (MA-318626) to the center of the core using Henkel-77 Sicomet Adhesive (MA-274442) as per the 160" 'C' Dipole Magnet Assembly (ME-274909) or 160" 'D' Dipole Magnet Assembly (ME-274910).

Note(s): Ensure that the G-10 is installed into the epoxy while it is still wet.

G - 1 0 I n s u l a t o r s 3 6 . 0 0 " ± . 2 5 " M A - 3 1 8 3 5 9

G - 1 0 C o i l S u p p o r t M A - 3 1 8 6 2 6 Lower Core Top View

G - 1 0 I n s u l a t o r M B - 2 7 4 6 6 5

End View (Typical)

G - 1 0 I n s u l a t o r M A - 3 1 8 3 5 9

1 " G - 1 0 T r i a n g u l a r P i e c e S K - 3 1 8 3 5 9

Technician(s) Date

3.5 Install Beam Tube Support Inner Stop (MA-318763) and Outer Stop (MA-318764) with Sicomet Adhesive. Refer to the 160" 'C' Dipole Magnet Assembly (ME-274909) or the 160" 'D' Dipole Magnet Assembly (ME-274910).

Technician(s) Date

X 3.6 Verify G-10 placement, refer to the 160" 'C' Dipole Magnet Assembly (ME-274909) or the 160" 'D' Dipole Magnet Assembly (ME-274910).

Note(s): Do not proceed to the next step until the epoxy is cured (approximately 4 to 5 hours).

Lead Person Date

4.0 Coil Installation

4.1 Mix 500 to 600 grams of Room Cure Epoxy Mix with Cabosil (MA-274695). Mix thoroughly until paste-like. Apply the epoxy mixture to the bottom inside of the core 18" from the center on both sides.

Record the Coil Serial Number ______

Attach the "OK to Proceed" Tag to this traveler.

Note(s):

If the coil serial number recorded above has a prefix of IDCL refer to the 160" 'C' Dipole Magnet Assembly (ME-274909) and the diagrams labeled 160" 'C' Dipole.

If the coil serial number recorded above has a prefix of IDDL refer to the 160" 'D' Dipole Magnet Assembly (ME-274910) and the diagrams labeled 160" 'D' Dipole.

The coil should be ready to be placed into the core within 45 minutes of applying the epoxy to the core. This applies to all subsequent steps to allow time for adjustments.

Parting Plane Gap and Pole Tip Clearance readings MUST be taken before the epoxy cures. (Step 5.3)

S i d e V i e w C o r e

R o o m C u r e E p o x y M i x G - 1 0 C o i l S u p p o r t G - 1 0 I n s u l a t o r s w i t h C a b o s i l M A - 3 1 8 6 2 6 M A - 3 1 8 3 5 9 M A - 2 7 4 6 9 5

T o p V i e w

3 6 . 0 0 " ± . 2 5 "

Technician(s) Date

4.2 Apply silicone caulk (MA-274682) in a 1/4 inch bead next to the bottom G-10 Insulators opposite the pole tip.

G - 1 0 I n s u l a t o r M A - 3 1 8 3 5 9

S i l i c o n M A - 2 7 4 6 8 2

Silicone Placement (Typical)

Technician(s) Date

X 4.2.1 Verify that the silicone caulk is placed in the proper location to cause sealing when the coil is placed in the core.

Lead Person Date

4.3 Using the overhead crane and the Caldwell Model 20S3-72 Lifting Fixture (Capacity 6000 Lbs.) and Lift All (Type ENI-801T) 6' long slings position the prepared Lower Coil (ME-274912) 'C' Dipole Coil or (ME-274914) 'D' Dipole Coil into the prepared core assembly. The lead end of the coil should be lowered into the core first, followed by the return end, centering accordingly.

Note(s): Step 4.3 through 4.5 must be completed before the epoxy cures, to allow for repositioning if necessary.

To determine the 160" 'C' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your right.

To determine the 160" 'D' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your left.

Ensure that no damage occurs to the coil at the inner radii closest the end pack corners. The coil should be centered longitudinally and laterally in the core. However, the maximum dimension of 5.00" from the return end core face to the end of the coil takes precedence. Shift the coil longitudinally, if necessary, to conform. Refer to the diagrams on the following page.

L o w e r C o i l

Lead End View

5 . 0 0 " M a x . C o n v e x S i d e L e a d E n d

R e t u r n E n d C o n c a v e S i d e

160" 'C' Dipole Top View

L e a d E n d C o n v e x S i d e 5 . 0 0 " M a x .

C o n c a v e S i d e R e t u r n E n d

160" 'D' Dipole Top View

Technician(s) Date

X 4.4 Use the Half Core/Coil Assembly Positioning Fixture (ME-331113) to set the coil to core position. Verify that the coil is placed in the core properly, refer to the 160" 'C' Dipole Magnet Assembly (ME-274909) or the 160" 'D' Dipole Magnet Assembly (ME-274910). Refer to the diagrams on the previous page.

Note(s): Ensure that the inside walls of the coil are 10 5/16" apart at the center.

Ensure that no damage occurs to the coil at the inner radii closest the end pack corners. The coil should be centered longitudinally and laterally in the core within 1/16". However, the maximum dimension of 5.00" from the return end core face to the end of the coil takes precedence. Shift the coil longitudinally, if necessary, to conform.

If the coil serial number has a prefix of IDCL refer to the 160" 'C' Dipole Magnet Assembly (ME-274909). To determine the 160" 'C' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your right.

If the coil serial number has a prefix of IDDL refer to the 160" 'D' Dipole Magnet Assembly (ME-274910). To determine the 160" 'D' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your left.

Lead Person Date

XX 4.5 Verify that the coil is placed in the core properly, refer to the 160" 'C' Dipole Magnet Assembly (ME-274909) or the 160" 'D' Dipole Magnet Assembly (ME-274910). Refer to the diagrams on the previous page.

Note(s): Ensure that the inside walls of the coil are 10 5/16" apart at the center.

Ensure that no damage occurred to the coil at the inner radii closest the end pack corners. The coil should be centered longitudinally and laterally in the core within 1/16". However, the maximum dimension of 5.00" from the return end core face to the end of the coil takes precedence. Shift the coil longitudinally, if necessary, to conform.

If the coil serial number has a prefix of IDCL refer to the 160" 'C' Dipole Magnet Assembly (ME-274909). To determine the 160" 'C' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your right.

Crew Chief Date

Lead Inspector Date

4.6 Restrain the coil in place with G-10 Wedges (SK-331073) and Carver 24" Medium Duty Clamps. Dam up ends with O-Ring Material (Fermi stock 1045-6850 or equivalent) and G.E. RTV-112, white (Fermi stock 1940-0800 or equivalent) as required to prevent leaking of the epoxy during filling.

G - 1 0 W e d g e s O - R i n g M a t e r i a l a n d G . E . R T V - 1 1 2

Lead End View

R e t u r n E n d

L e a d E n d C l a m p T y p . Top View

Technician(s) Date

4.7 Check the pole tip to coil clearance at both ends in the center of the of the core using a Starrett 12" Steel Rule CME 600 (Fermi stock 1252-2100 or equivalent) and Thickness Gage/Feeler Stock (Starrett Part No. 667 or equivalent). If the gap is less than .030" sand the area and apply a coat of Room Cure Epoxy Mix (MA-274696).

Note(s): Ensure that the sanding doesn't penetrate the glass tape.

Technician(s) Date

5.0 Inspection

X 5.1 Measure and record the coil lead positions. Refer to the diagrams on the following page.

Note(s): If the coil serial number has a prefix of IDCL refer to the 160" 'C' Dipole Magnet Assembly (ME-274909).

If the coil serial number has a prefix of IDDL refer to the 160" 'D' Dipole Magnet Assembly (ME-274910). The 160" 'D' Lower Coil does not have a Thru Bus.

Place N/A in the appropriate unused blocks.

'C' Dipole

Dimension Limit Actual Pass Fail Out of Tolerance Measurement Lead End Core Face to the Thru Bus Reference Test Only Lead (Do Not Include the Plug) "Z" Not Subject to Limit Values Parting Plane to the top of the Lead End Reference Test Only Thru Bus Lead "Y" Not Subject to Limit Values

Dimension Limit Actual Pass Fail Out of Tolerance Measurement Return End Core Face to the Return End Reference Test Only Coil Lead (Do Not Include the Plug) "Z" Not Subject to Limit Values Parting Plane to the top of the Return Reference Test Only End Coil Lead "Y" Not Subject to Limit Values

Dimension Limit Actual Pass Fail Out of Tolerance Measurement Return End Core Face to the Thru Bus Reference Test Only Lead (Do Not Include the Plug) "Z" Not Subject to Limit Values Parting Plane to the top of the Return Reference Test Only End Thru Bus Lead "Y" Not Subject to Limit Values

'D' Dipole

Dimension Limit Actual Pass Fail Out of Tolerance Measurement Lead End Core Face to the Lead End Reference Test Only Coil Lead (Do Not Include the Plug) "Z" Not Subject to Limit Values Parting Plane to the top of the Lead End Reference Test Only Coil Lead "Y" Not Subject to Limit Values

of 22 TD / Engineering and Fabrication Specification # 5520-TR-318874 April 2, 1997 Rev. E " Y " L o w e r C o i l P a r t i n g P l a n e M E - 2 7 4 9 1 2

C o i l L e a d

L e a d E n d V i e w P a r t i n g P l a n e

C o i l L e a d

C o r e F a c e

S i d e V i e w

Inspector Date

X 5.2 Measure and record the pole tip to coil clearance at both ends in the center of the of the core using a Starrett 12" Steel Rule CME 600 (Fermi stock 1252-2100 or equivalent) and Thickness Gage/Feeler Stock (Starrett Part No. 667 or equivalent). Refer to the diagrams below.

L o w e r C o i l P o l e T i p

L e a d E n d V i e w S t e e l R u l e

G r e a t e r t h a n o r E q u a l t o . 0 3 0 "

C o i l

C o r e C r o s s S e c t i o n

Dimension Limit Actual Pass Fail Out of Tolerance Measurement Lead End ≥ .030"

Return End ≥ .030"

Inspector Date

X 5.3 Perform an electrical check of the Lower Coil and record the results below.

Note(s): If the coil serial number has a prefix of IDCL refer to the 160" 'C' Dipole Magnet Assembly (ME-274909). To determine the 160" 'C' Lower Half Core Lead End, stand on concave side while the core sits with its parting plane up, the lead end is located to your right.

The Thru Bus is to be jumpered to the Coil for the Hipot Test only.

If the Coil does not have a Thru Bus, place N/A in the appropriate blocks.

Electrical Test Equipment Serial Limit Actual Measurement Pass Fail Out of Number Tolerance Coil Resistance 'C' - .220 to .240 mΩ 'D' - .250 to .270 mΩ Thru Bus Resistance .020 to .040 mΩ

LS @ 1 KHz Reference Test Only Not Subject to Limit Values Q @ 1 KHz Reference Test Only Not Subject to Limit Values LS @ 100 Hz Reference Test Only Not Subject to Limit Values Q @ 100 Hz Reference Test Only Not Subject to Limit Values 100 Volt Ring

Hipot Coil and Thru 5 KV @ < 5 µA Bus to Ground Hipot Coil to Thru 5 KV @ < 5 µA Bus

Inspector Date

XX 5.4 Verify the previously performed steps to ensure that they were performed correctly (Steps 5.1 through 5.3) and that the measurements and readings taken are acceptable before continuing with this traveler.

Lead Inspector Date

Crew Chief Date

of 22 TD / Engineering and Fabrication Specification # 5520-TR-318874 April 2, 1997 Rev. E 6.0 Epoxy - Final Pour

6.1 Mix a batch of Room Cure Epoxy Mix (MA-274696) (2.5 kg of DER-828, 2.0 kg of EM-308). Pour the epoxy into the gap between the coil and the core. Allow the epoxy to cure at least 12 hours. R o o m C u r e E p o x y M i x M A - 2 7 4 6 9 6

S e e D e t a i l

Lead End View R u b b e r C e m e n t

K a p t o n T a p e . 0 0 2 " C o r e

R o o m C u r e E p o x y M i x M A - 2 7 4 6 9 6

C o i l

S i l i c o n e

G - 1 0 I n s u l a t o r Detail

Cure Start Time

Cure Completion Time (Not to be less than 12 Hours)

Technician(s) Date

6.2 Remove the clamps, boards, RTV and O-Ring Material. Peel the Kapton Tape along the sides of the coil and trim the Kapton Tape even with G-10 Liners.

Technician(s) Date

6.3 Using the overhead crane and the Dipole Half Core Lifting Fixture (ME-274106) or the Dipole Full Core Lifting Fixture (ME-318060) transport the Lower Coil/Core Assembly to the staging area.

Note(s): Cover the Lower Coil/Core Assembly with green Herculite (Fermi stock 1740-0100).

Technician(s) Date

7.0 Production Complete

XXX 7.1 Process Engineering verify that the FMI 160" 'C/D' Dipole Lower Half Core Preparation Traveler (5520-TR-318874) is accurate and complete. This shall include a review of all steps to ensure that all operations have been completed and signed off. Ensure that all Discrepancy Reports, Nonconformance Reports, Repair/Rework Forms, Deviation Index and dispositions have been reviewed by the Responsible Authority for conformance before being approved.

Comments:

XXX 7.2 Assembly verify that the FMI 160" 'C/D' Dipole Lower Half Core Preparation Traveler (5520-TR-318874) is accurate and complete. This shall include a review of all steps to ensure that all operations have been completed and signed off. Ensure that all Discrepancy Reports, Nonconformance Reports, Repair/Rework Forms, Deviation Index and dispositions have been reviewed by the Responsible Authority for conformance before being approved.

Comments:

Assembly/Designee Date

7.3 Attach the Process Engineering "OK to Proceed" Tag on the coil/core assembly.

7.4 Proceed to the next major assembly operation - 160" 'C' Dipole Final Assembly Traveler (5520-TR-318901)or the 160" 'D' Dipole Final Assembly Traveler (5520-TR-318868)