TD / Engineering and Fabrication Specification # 5520-TR-318868
April 2, 1997
Rev. F
f / Fermi National Accelerator LaboratoryBatavia, IL 60510
FERMI MAIN INJECTOR DIPOLE
160" 'D' FINAL ASSEMBLY TRAVELER
Reference Drawing(s)
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
Revision Page
Revision / Revision Description / DateA / 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 the diagram in Step 3.1 lead end is right not left when standing on the concave side of the lower core. Step 3.4 modified measure core face to the center of the coil support block, and space all blocks center to center 50.00 ± .50" TYP. Removed Step 3.4 table diagram has enough information for support placement. Changed MA-225104 to MA-274991 ECO-3797. Changed Beam Tube Support dimension in Step 3.9 from 118.83" to 80.33".
TRR No. 0397 / 8/30/95
B / Changed Post Weld Parting Plane Check shading in Step 6.9 position 150 cleared and position 156 shaded. TRR No. 0422 / 10/2/95
C / Changed Step 6.2 number repeated changed to 6.3. 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. 0458
Changed 'D' Upper Coil Resistance Limits from .215 - .235 mΩ to 2.25 - 2.45 mΩ as per Dave Harding's E-Mail dated 2/9/96. TRR No. 0473 / 2/20/96
D / 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. 0504 / 4/8/96
E / Changed Step 8.9 Lead End to Return End. TRR No. 0535 / 7/3/96
F / 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. 0625 / 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 magnet assembly with green Herculite (Fermi stock 1740-0100) when not being serviced or assembled.
1.8 To determine the Magnet Lead End, stand on concave side of the magnet, 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" 'D' 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/Designee Date
2.2 List all component serial numbers below.
Upper Half Core
Lower Half Core
Upper Coil
Lower Coil
Thru Bus
Note(s):
Attach the "OK to Proceed" tag to this traveler
Assembly/Designee Date
3.0 Lower Core Pre-Assembly
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 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 left.
Lead End View
Top View
Technician(s) Date
3.2 Assemble the Coil Support Blocks (Qty. 8) by gluing the Support Blocks (MB-274387) (Qty. 2) to each of the Base Blocks (MB-274386) (Qty. 8) using Sicomet Super Glue (MA-274442).
Coil Support Block Assembly
End View
Technician(s) Date
3.3 Place 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
X 3.4 Verify that the Coil Support Block Assemblies are over 2.205" as per Step 3.3.
Lead Person Date
3.5 Using Sicomet Super Glue (MA-274442), glue the Coil Support Block Assemblies in the proper location as shown on the diagram below and on the 160" 'D' Dipole Magnet Assembly
(ME-274896).
Top View
Technician(s) Date
3.6 Install Alignment Keys (MB-318489) (Qty. 4) in the groove of the Lower Core. Each key is 79.75 inches long and each side of magnet will use two keys.
Note(s):
The end keys should be recessed 1/4" from the face of the end pack.
Technician(s) Date
X 3.7 Verify the Alignment Keys location as per Step 3.6 and the 160" 'D' Dipole Magnet Assembly (ME-274910).
Lead Person Date
XX 3.8 Verify that Steps 3.1 through 3.7 have been performed correctly and in accordance with the 160" 'D' Dipole Magnet Assembly (ME-274910).
Lead Inspector Date
Crew Chief Date
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.
3.9 Install the Beam Tube Support (MC-318673) in the center of the lower core assembly
(80.33" ± .06"). Using Room Cure Epoxy with Cab-O-Sil (MA-274695) on the contact areas, glue the support in place as per the 160" 'D' Dipole Magnet Assembly (ME-274910).
Technician(s) Date
X 3.10 Measure the position of the Beam Tube Support (MC-318673) as per the 160" 'D' Dipole Magnet Assembly (ME-274910).
Beam Tube Support Location Dimension (80.33" ± .06") Pass r Fail r
Inspector Date
3.11 Place 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
XX 3.12 Verify that Steps 3.9, 3.10 and 3.11 are in accordance with the 160" 'D' Dipole Magnet Assembly (ME-274910).
Lead Inspector Date
Crew Chief Date
4.0 Upper Core Pre-Assembly
4.1 Vacuum 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
X 4.2 Verify 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 Person Date
4.3 Roll 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
4.4 Using 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
X 4.5 Using 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 Person Date
XX 4.6 Inspect the Upper Coil/Core Assembly position as per Step 4.4 and the 160" 'D' Dipole Magnet Assembly (ME-274910).
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 Inspector Date
Crew Chief Date
5.0 Pre-Weld (Clamped) Inspections
X 5.1 Measure 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
160
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.
Inspector Date
XXX 5.2 Using 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 ?
r Yes r No
Attach the plot behind this page.
Process Engineering/Designee Date
X 5.3 Insert 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-318874, Upper Core 5520-TR-318873.
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 / Fail
Upper Coil Lead End / See Note
Lower Coil Lead End / See Note
Upper Coil Return End / See Note
Lower Coil Return End / See Note
Inspector Date
X 5.4 Perform 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 / .225 to .245 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 Bus to Ground / 5 KV @ < 5 µA
Hipot Coil to Thru Bus / 5 KV @ < 5 µA
Lower Coil
Electrical Test / Equipment Serial Number /Limit
/ Actual Measurement / Pass / Fail / Out of ToleranceCoil Resistance
/ .250 to .270 mΩLS @ 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
Inspector Date