Production Readiness Review for Series Coil Production Coil

Production Readiness Review for Series Coil Production Coil QA Plan Interface from 302. 07 Magnet Structures Katherine Ray, LBNL AUP QA Manager Dan Cheng, Deputy Structures L 3 1

Outline § § § Project organization Interface control documents Electrical QA Plan Mechanical QA Plan ES&H Summary 4/29/2020 PRR for Series Coil Production, Structures QA 2

Organization US HL-LHC Accelerator Upgrade Project: 302. 2 MQXFA Magnets Fabrication 302. 2 L 2: G. Ambrosio (M. Baldini) Control Account Magnet Design, Integration and Coordination 302. 2. 01 L 3/CAM: G. Ambrosio (M. Baldini) Strand Procurement and Testing 302. 2. 02 L 3: L. Cooley (V. Lombardo) CAM: V. Lombardo Cable Fabrication 302. 2. 03 L 3/CAM: I. Pong (C. Sanabria) US-Hi. Lumi Document 104 Coil Parts, Materials, and Tooling Procurement 302. 2. 04 L 3/CAM: M. Yu (A. Nobrega) Coil Fabrication at FNAL 302. 2. 05 L 3/CAM: A. Nobrega (M. Yu) Coil Fabrication at BNL 302. 2. 06 L 3/CAM: J. Schmalzle (M. Anerella) Structure Fabrication and Magnets Assembly 302. 2. 07 L 3/CAM: S. Prestemon (D. Cheng) Heng Pan: Engineering analysis, QC Paolo Ferracin: Engineering and Coils analysis Katherine Ray: QC & QA Manager Mike Solis: Procurements, QC Brian Zatkow: Subcontract Administrator Technical Support T. Lipton: Supervisor Ahmet Pekedis (Lead tech) Joshua Herrera Matt Reynolds Juan Rodriguez Bob Memmo (electrical QA) 4/29/2020 PRR for Series Coil Production, Structures QA 3

WBS 302. 07 Deliverable Cooling holes: 77 mm ID (R 12) Assembly alignment cut-outs Interfaces with the FNAL and BNL Coil Fabrication Activities Shell slot for backing strip Shell cut-out for alignment Mid-plane yoke cutout for assembly alignment 4/29/2020 PRR for Series Coil Production, Structures QA 4

C 1 Interface Control Documents With Coil Fabrication Coils from FNAL 302. 2. 05 Coils from BNL 302. 2. 06 US-Hi. Lumi-doc-252 US-Hi. Lumi-doc-309 4/29/2020 PRR for Series Coil Production, Structures QA 5

C 3, 4 Electrical QC § Electrical QC tests are performed according to US-Hi-Lumi. Doc-956 (LBNL DCC #SU-1010 -1903) § Includes use of Hypot. Ultra hipotting system (10 V/sec ramp) § Updated with definition of impulse test acceptance criteria § LBNL Coil Acceptance data is captured in the same format as the FNAL spreadsheet, based on US-Hi-Lumi-Doc-521 § New technician has been hired to perform EQC operations § Once QEW training is complete we expect to have timely feedback with coil electrical tests § OJT will continue for the next several pre-series coils 4/29/2020 PRR for Series Coil Production, Structures QA 6

C 3, 4 Mechanical QC (CMM) § Starting with MQXFA 05 coils the usual Zeiss Accura system (Calypso) measurements have been compared to the new Leica system (LBNL DCC #SU-10124076, US-Hi. Lumi Doc. DB #3079) § We will measure the rest of the pre-series magnets’ coils (MQXFA 06 and MQXFA 07) with both systems to build more statistics § We will transition to using only the Leica system for the series coils (“Record of Decision LBNL Leica Laser Tracker”, USHi. Lumi Doc. DB #3088) 4/29/2020 PRR for Series Coil Production, Structures QA 7

Mechanical QC (Leica vs. Zeiss) § Comparisons between the Leica and Zeiss include visual comparisons of the profile and graphs of radius, midplane and keyway data § Data will be generated for each coil and will be reported to the Coil Fabrication L 3 s for disposition by uploading to Coil Interface Vector travelers § To facilitate faster feedback to coil tasks an initial measurement will be reported § The 2 nd set of measurements and comparative processing can take place shortly after 4/29/2020 PRR for Series Coil Production, Structures QA 8

Mechanical QC at LBNL § Mechanical CMM of Series Coils will be performed with the Leica system according to LBNL DCC #SU-1012 -3958 (in draft) 4/29/2020 PRR for Series Coil Production, Structures QA 9

Mechanical QC at LBNL (cont. ) § Measurements will be taken and processed on § OD, ID § Midplanes § Arc Length excess § Keyway slot § Disposition will be reported based on specifications in US-Hilumi-doc-3043 “Impregnated Coil Dimensional QC Plan at LBNL” 4/29/2020 PRR for Series Coil Production, Structures QA 10

ES&H § Hazards for Coil QA Work § Laser Tracker (WPC #EG-0126) (Class 2 Laser) § Trained personnel § Electrical Testing (WPC #EG-0087) § Tasks may only be performed by a QEW (qualified electrical worker) § Area roped off with signage and lights during hipot 4/29/2020 PRR for Series Coil Production, Structures QA 11

Summary § Series Coil fabrication interfaces are clearly defined § The use of Zeiss and Leica Systems will continue through coils used in the pre-series magnets (up to MQXFA-07) § The Coil Acceptance criteria (Electrical, Mechanical) are defined § Coil measurements and data will be reported back to respective Coil Fabrication L 3 s via Vector traveler system for disposition and coil approval § ES&H considerations are controlled 4/29/2020 PRR for Series Coil Production, Structures QA 12