240 'A' Dipole Final Assembly
TD / Engineering and FabricationSpecification # 5520-TR-318887
April 2, 1997
Rev. K
f / Fermi National Accelerator LaboratoryBatavia, IL 60510
FERMI MAIN INJECTOR DIPOLE
240" 'A' FINAL ASSEMBLY TRAVELER
Reference Drawing(s)
240" 'A' Dipole Magnet Assembly
5520-ME-274896
Budget Code: / Project Code:
Released by: / Date:
Prepared by: T. Skweres, R. Safarik
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
Revision Page
Revision / Revision Description / DateA / Changed resistance specs. in Steps 5.2 & 7.1 and added Final Electrical Test.
TRR No. 0140
Changed position of end keys in Step 3.5, reworded Steps 8.9 & 8.10, changed Coil to Thru Bus Jumper number from SK-318346 to SK-331097, added post-weld survey.
TRR No. 0141
Changed Step 5.1 to include measurements on 6" intervals pre-weld, and 6" intervals as possible, post-weld. TRR No. 0152
Added steps to stamp and verify serial number, added Budget Code & Project Code line to title page. TRR No. 0156
Changed Beam Tube Support part number in Steps 3.8 and 3.9 from MB-274887 to
MC-318673. TRR No. 0190
Incorporated a Pre-Weld Pole Tip to Coil Check. Changed formula in Step 3.3 Total Gap - Coil Block to Coil Block - Total Gap. Changed Beam Tube Support Step to a Pass/Fail. Corrected a typo at Step 3.3 X not required in the left margin. TRR No. 0191 / 9/26/94
B / Added note about cracked tack welds to Step 6.6, Refer to DR MID-0215. TRR No. 0200
Added to note to Step 3.10 about clamp and welding within 6 hours of epoxy application. Changed Herculite stock number to 1740-0100 in Step 1.7. TRR No. 0204
Changed the limit criteria for Pole Tip to Coil Measurement Step 5.3. Incorporated 4 survey locations to Step 11.3, 8" in from each end of the magnet as per John Carson.
TRR No. 0228 / 10/24/94
C / Changed parting plane limit to .006" in Step 5.1. TRR No. 0236
Step 11.3 changed "Inspector" to "Approved Technician". Changed Sicomet in Step 3.8 to Room Cure Epoxy as per ECO 3716. TRR No. 0238
Step 2.2 added note to attach core OK to Proceed Tag to this traveler. Step 9.2 Deleted note saying not to use Thru Bus Jumper Hose (SK-331097). TRR No. 0243 / 11/14/94
D / Modified the block size - gap adjustment in Step 3.3. TRR No. 0258
Replaced the Helium Leak Check in Step 9.1 with the house air & snoop check from Step 9.2. Added a note to Step 12.1 "Do not paint around upper core, lead end concave side lowest hole (1")". Changed .0025" to .006" in the Pre-Weld (Clamped) Parting Plane Verification Step 5.2. TRR No. 0259
Added the installation of the Beam Tube Support Inner and Outer Stops in Step 3.8,
ER 5407. TRR No. 0274 / 12/28/94
E / Incorporated procedure Steps 5.3, 6.1 - 6.12, 8.7 and 11.1 from "B" Dipole Final Assembly. TRR No. 0319 / 2/21/95
F / Incorporated elbow unions to Step 9.2 (install) and 9.3 (remove). Changed Step 8.10 to non-lead end. Grayed out Step 6.9 Parting Plane Measurements not performed.
TRR No. 0253
Changed Step 9.2 to ≥ low flow rate. Changed Step 8.4 to Lead Person. Changed Step 2.2 from "attach core" to "attach the". Decimal point missing from resistance in Step 11.1. Deleted with associated drawings in Step 2.1. TRR No. 0346
Deleted Step 3.3 Coil Support Block Measurement replace with > 2.250" no shim required < 2.205" shim. Incorporated Cross Member Transport Fixture to Steps 4.5 and 6.6. Changed limits as per Nelson Chester Dipole Spec Sheet.
TRR No. 0391 / 6/26/95
Revision Page
Revision / Revision Description / DateG / Added a note to jumper the Thru Bus for the Hipot only and shaded in the serial number for the Thru Bus Hipot. Added a new review criteria to the survey review Step 11.4 as per Nelson Chester's E-Mail dated 7/19/95. Changed Limits for the Electrical Inspections as per Nelson Chester's Dipole Test Specification dated 8/7/95. Changed MA-225104 to
MA-274991 as per ECO-3797. Changed Step 3.4 dimension 116.70 to 116.83 as per
ECO 3775. Removed Step 3.4 table diagram has enough information for support placement. TRR No. 0394 / 8/30/95
H / Moved Step 12.1 painting of the leads to after Step 10.1. Moved Step 10.2 to before Step 12.1. Moved Step 6.11 after 6.1. Incorporated Support Block dimension inspection after Step 3.3. TRR No. 0455 / 2/20/96
I / Changed the Survey Limit in Step 11.3 Flatness .030" and Average Lateral Deviation to .005" as per DR MID-0392. Incorporated Step 8.10 a check of the lead extension to the core dimension after brazing. TRR No. 0505 / 4/8/96
J / Changed Step 8.9 Lead End to Return End. TRR No. 0539 / 7/3/96
K / Deleted Lower Coil Heading in the Flow Test Box Step 9.2. Changed cover page references to TS / MDF to TD / E&F and AD to BD. Deleted Dipole Designer from cover page. TRR No. 0623 / 4/2/97
Ensure appropriate memos and specific instructions are placed with the traveler before issuing the sub traveler binder to production.
1.0General Notes
1.1White (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.
1.2All steps that require a sign-off shall include the Technician/Inspectors first initial and full last name.
1.3No 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.
1.4All 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.
1.6Personnel shall perform all tasks in accordance with current applicable ES&H guidelines and those specified within the step.
1.7Cover the magnet assembly with green Herculite (Fermi stock 1740-0100) when not being serviced or assembled.
1.8To determine the Magnet Lead End, stand on concave side of the magnet, the lead end is located to your right.
1.9All Room Cure Epoxy to be applied at an ambient temperature of 65° F.
2.0Parts Kit List
2.1Attach the completed Parts Kit List for the 240" 'A' Dipole Final Assembly 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.
Process Engineering/DesigneeDate
2.2List all component serial numbers below.
Upper Half Core
Lower Half Core
Upper Coil
Lower Coil
Thru Bus
Note(s):
Attach the "OK to Proceed" tags to this traveler
Assembly/DesigneeDate
3.0Lower Core Pre-Assembly
3.1Using the overhead crane and the Dipole Half Core Lifting Fixture (ME-274106) or the Dipole Full Core Lifting Fixture (ME-318060) position the Lower Coil/Core Assembly on the Assembly Table (ME-318532).
Note(s):
To determine the Magnet Lead End, stand on concave side of the magnet, the lead end is located to your right.
Lead End View
Top View
Technician(s)Date
3.2Assemble the Coil Support Blocks (Qty. 10) by gluing the Support Blocks (MB-274387) (Qty. 2) to each of the Base Blocks (MB-274386) (Qty. 10) using Sicomet Super Glue (MA-274442).
Coil Support Block Assembly
End View
Technician(s)Date
3.3Place the Urethane Spring (MB-274389) and the Top Plate (MB-274388) on the Coil Support Block Assemblies as shown in the diagram below.
Note(s):
Do not affix the Urethane Spring to the Base Block at this time.
Coil Support Block Assembly
End View
Using the Coil Support Block Checking Gage or equivalent ensure that the height of the Coil Support Block Assemblies are over 2.205". If a Coil Support Block Assembly is under 2.205" a G-10 Spring Shim (MB-318693) is required. Glue the G-10 Spring Shim to the Base Block (MB-274386) using Sicomet Super Glue (MA-274442).
If after adding the G-10 Spring Shim (MB-318693) the Coil Support Block Assembly is still under 2.205" an additional G-10 Spring Shim (MB-318693) is required.
Attach the Urethane Spring (MB-274389) on center of the Base Block (MB-274386) or the G-10 Spring Shim (MB-318693), parallel with the Support Blocks (MB-274387), sticky side down.
Coil Support Block Assembly
End View
Technician(s)Date
X3.4Verify that the Coil Support Block Assemblies are over 2.205" as per Step 3.3.
Lead PersonDate
3.5Using Sicomet Super Glue (MA-274442), glue the Coil Support Block Assemblies in the proper location as shown on the diagram below and on the 240" 'A' Dipole Magnet Assembly (ME-274896).
Top View
Technician(s)Date
3.6Install Alignment Keys (MB-318489) (Qty. 6) in the groove of the Lower Core. Each key is 79.75 inches long and each side of magnet will use three keys.
Note(s):
The end keys should be recessed 1/4" from the face of the end pack.
Technician(s)Date
X3.7Verify the Alignment Keys location as per Step 3.6 and the 240" 'A' Dipole Magnet Assembly (ME-274896).
Lead PersonDate
XX3.8Verify that Steps 3.1 through 3.7 have been performed correctly and in accordance with the 240" 'A' Dipole Magnet Assembly (ME-274896).
Lead InspectorDate
Crew ChiefDate
Note(s):
The Upper Coil/Core Assembly should be ready to be placed on the Lower Coil/Core Assembly within 45 minutes of applying the epoxy to the Coil Support Block Assembly.
3.9Install the Beam Tube Support (MC-318673) in the center of the lower core assembly (118.83" ± .06"). Using Room Cure Epoxy with Cab-O-Sil (MA-274695) on the contact areas, glue the support and stops in place as per the 240" 'A' Dipole Magnet Assembly (ME-274896).
Technician(s)Date
X3.10Measure the position of the Beam Tube Support (MC-318673) from the lead end side of the support to the lead end core face as per the 240" 'A' Dipole Magnet Assembly (ME-274896).
Beam Tube Support Location Dimension (118.83" ± .06")Pass Fail
InspectorDate
3.11Place a bead (1/2" dia.) of Room Cure Epoxy Mix with Cabosil (MA-274695) on each of the Coil Support Block Assemblies.
Place the Top Plate (MB-274388) on the Urethane Spring (MB-274389) and epoxy mixture.
Attach 2 mil Adhesive Kapton Tape (MA-274451) on top of the Coil Support Block Assembly as shown in the diagram below.
Note(s):
The Cores must be clamped and welded within 6 Hours after the application of epoxy to the Support Blocks
Coil Support Block Assembly
End View
Technician(s)Date
XX3.12Verify that Steps 3.9, 3.10 and 3.11 are in accordance with the 240" 'A' Dipole Magnet Assembly (ME-274896).
Lead InspectorDate
Crew ChiefDate
4.0Upper Core Pre-Assembly
4.1Vacuum dust from Upper and Lower Coil/Core Assemblies before assembly.
Install the Coil Support Brackets (MC-318080) (Qty. 2) and (MC-318081) (Qty. 2) and the Intermediate Coil Support Fixtures (ME-318100) (Qty. 4) equally spaced on the Upper Coil/Core Assembly.
Place 2 X 4's (Qty. 3) on the Lower Coil/Core Assembly to allow for removal of the Coil Support Fixtures and the Posi-Turner Roll-Over Fixture Slings. Refer to the diagram below.
Note(s):
The 2 X 4's at the ends of the core are to be between the 3rd and 4th side plate holes.
Top View
X4.2Verify that the Brackets and Support Fixtures installed in Step 4.1 are in the proper location for rolling the Upper Coil/Core Assembly. Ensure the placement of the 2 X 4's (Qty. 3) on the Lower Coil/Core Assembly allow for the removal of the Coil Support Fixtures and the Posi- Turner Roll-Over Fixture Slings.
Verify the cleanliness of the Upper and Lower Coil/Core Assemblies before assembly.
Lead PersonDate
4.3Roll over the Upper Coil/Core Assembly using the overhead crane and the Posi-Turner Roll-Over Fixture Model 1-192-25L, refer to 5520-ES-318930 for the operation of the fixture. Place Upper Coil/Core Assembly on the Lower Coil/Core Assembly and remove the Posi-Turner Roll-Over Fixture.
Note(s):
Check the sagitta and the coil lead orientation before removing the Posi-Turner Roll-Over Fixture.
Technician(s)Date
4.4Using the overhead crane and the Dipole Half Core Lifting Fixture (ME-274106) or the Dipole Full Core Lifting Fixture (ME-318060) lift the Upper Coil/Core Assembly. Remove the Coil Support Brackets (MC-318080) and (MC-318081), Intermediate Coil Support Fixtures (ME-318100) (Qty. 4) and the 2 X 4's.
Position top half core over bottom core equidistant longitudinally. Take care when lowering the Upper Coil/Core Assembly onto the Lower Coil/Core Assembly.
Note(s):
If core lengths are not equal, split the difference between cores equally on both ends.
Technician(s)Date
X4.5Using the overhead crane lift and position the Dipole Cross Member Transport Fixture (MD-331174) and place on the magnet on the Assembly Table (ME-318532).
Note(s):
Before installing the nuts to the clamping rods remove the overhead crane from the Dipole Cross Member Transport Fixture (MD-331174).
Install the nuts on the clamping rods. Using the Assembly Table (ME-318532) draw core halves together as per the FMI Dipole Hydraulic Clamping Table Operation Procedure (5525-OP-318982).
Lead PersonDate
XX4.6Inspect the Upper Coil/Core Assembly position as per Step 4.4 and the 240" 'A' Dipole Magnet Assembly (ME-274896).
Note(s):
If core lengths are not equal, release the pressure if any, from the Hydraulic Clamping Table. Then split the difference between cores equally on both ends, then perform Step 4.5 again.
Lead InspectorDate
Crew ChiefDate
5.0Pre-Weld (Clamped) Inspections
X5.1Measure and record the parting plane gap at 6" intervals starting at the lead end on both sides of the magnet.
Inches from the Lead End / Convex Side / Concave Side0
6
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
126
132
138
144
150
156
162
168
174
180
186
192
198
204
210
216
222
228
234
240
Note(s):
The Parting Plane average distance is not to exceed .006" per side and it is not to exceed 0.012" in any one location.
InspectorDate
XXX5.2Using the raw data from Step 5.1 plot the Pre-Weld (Clamped) Parting Plane Gap Measurements.
Note(s):
The Parting Plane average distance is not to exceed .006" per side and it is not to exceed 0.012" in any one location.
Evaluate Parting Plane Gap Plot. O.K. to proceed ?Yes No Attach the plot behind this page.
Process Engineering/DesigneeDate
X5.3Insert and expand the measuring fixture (MD-331115). Measure and record the pole tip to coil clearance of the Upper and Lower Coils at both ends in the center of the Pole Tip using feeler gauges.
Note(s):
Compare these measurements to the initial measurements in the appropriate Half Core Preparation Traveler or refer to the OK to Proceed Tag for the specific core/coil set.
Lower Core 5520-TR-318870, Upper Core 5520-TR-318869.
If the measurement is less than .030" the measurement fails and requires a Discrepancy Report. If the measurement is less than .030", but is the same or greater than the initial measurement from the Coil Preparation Traveler no Discrepancy Report is required.
Dimension / Limit / Initial Measurement from the Core Prep. Traveler or the Tag / Actual Measurement / Difference between the measurements / Pass / FailUpper Coil Lead End / See Note
Lower Coil Lead End / See Note
Upper Coil Return End / See Note
Lower Coil Return End / See Note
InspectorDate
X5.4Perform an electrical check of the Upper and Lower Coil and record results below.
Note(s):
To ensure proper electrical readings during these test separate the coils at points of contact with .060 G-10.
The Thru Bus is to be jumpered to the Coil for the Hipot Test only.
Upper Coil
Electrical Test / Equipment Serial Number / Limit / Actual Measurement / Pass / Fail / Out of ToleranceCoil Resistance / .360 to .380 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 to Ground / 5 KV @ < 5 µA
Lower Coil
Electrical Test / Equipment Serial Number / Limit / Actual Measurement / Pass / Fail / Out of ToleranceCoil Resistance / .320 to .340 mΩ
Thru Bus Resistance / .030 to .050 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 Bus to Ground / 5 KV @ < 5 µA
Hipot
Coil to
Thru Bus / 5 KV @ < 5 µA
InspectorDate
XX5.5Verify that the measurements and readings taken in Step 5.3 and Step 5.4 are acceptable before continuing with this traveler.
Lead InspectorDate
Crew ChiefDate
6.0Welding
6.1Locate magnet serial number printed on the bottom of this traveler. Using 1/2" high steel stamps, stamp the serial number onto each of four corner tie plates.
Technician(s)Date
X6.2Verify stamping of all four corner tie plates with proper serial number
Lead PersonDate
6.3Position the Tie Plates (MB-274079) (Qty. 30) using the Tie Plate Tooling Support Bar (MD-318615) and the Tie Plate Tooling Saddle Support (MD-318616).
Technician(s)Date
6.4Cover the ends of the magnet with the Dipole Welding Cover Assemblies (SK-318345).
Technician(s)Date
X6.5Verify that the tie plates are placed in the proper locations for welding as per the 240" 'B' Dipole Magnet Assembly (ME-274897).
Lead PersonDate
6.6Weld the tie plates from the center of the magnet towards the ends of the magnet according to the 240" 'B' Dipole Magnet Assembly (ME-274897) and Welding Procedure 5520-ES-318552.
Technician(s)Date
WeldorDate
X6.7Release the pressure on the magnet assembly and disassemble the Assembly Table (ME-318532) as per the FMI Dipole Hydraulic Clamping Table Operation Procedure (5525-OP-318982). Remove the Dipole Welding Cover Assemblies (SK-318345) from the ends of the magnet.
Note(s):
Before removing the Dipole Cross Member Transport Fixture (MD-331174) remove the nuts to the clamping rods before attaching the overhead crane.
Remove the Dipole Cross Member Transport Fixture (MD-331174) using the overhead crane.
Lead PersonDate
XX6.8Verify that the tie plates were welded at the proper locations as per the 240" 'B' Dipole Magnet Assembly (ME-274896). Visually inspect tie plate welds for general integrity including porosity (holes in weld), cracks and excessive build-up.
Note(s):
Cracks in the vertical tack welds are acceptable since the tack welds no longer serve any functional purpose.
Lead InspectorDate