bilfinger noell gmbh, magnet technology...information security management system iso 27001: 2005...

Bilfinger Noell GmbH, Magnet Technology

Bilfinger Noell GmbH



Contactus!

CompanyOverview

Projects&

Products

NOELL

Technologies

Contact NOELL Magnet Technology

• Division Magnet Technology

• Head of Sales Department

• Phone: +49 (0) 931-903-6031

• E-Mail: [email protected]

Michael Gehring


Company Overview

Customers &Productsworldwide

Site &Location

Software -Capabilities

CertifiedQuality &Safety

DistinguishedQuality

Member ofBilfinger SE

We are MagnetTechnology

CompanyOverview


Bilfinger Noell: Member of Bilfinger SE

Nuclear Services Nuclear TechnologiesMagnet Technologies

Business Segment Engineering & Technologies (E&T)


Bilfinger SE


We are Magnet Technology

• Physicists, Engineers andTechnicians work hand-in-hand

• More than 30 years magnettechnology experience

• Cooperation with researchinstitutions and industry

WEMAKE

RESEARCHWORK!


Site and Location

Office

2. Workshop: 1.000m²Components

1. Workshop: 2.100m²Prototyping

3. Workshop: 1.100m²Production


Customers and Products Worldwide


Software - Capabilities

CAD CAE Yourdesign

AutoCAD Mechanical ©

CATIA V5 ©

PDMS AVEVA ©

Autodesk Inventor ©

Microstation ©

ANSYS ©

Vector fields Opera ©

Mathematica ©

FEMM ©

LabVIEW


Environmental Management System ISO 14001: 2004Information Security Management System ISO 27001: 2005Specialised company according to German Water Resources Act(WHG)

Quality Management ISO 9001: 2008Occupational Health and Safety Management SystemBS OHSAS 18001: 2007Safety Checklist Contractor (SCC)

Certified Quality, Safety, Environment and IT-Security


Distinguished Quality

Golden Hadron Award(LHC)

AREVA OL3 Safety Award(HSE)

Best result for suppliers:„Top AREVA Supplier“


“This award is granted to suppliers who have not only met ourstringent requirements, but have also exceeded them – in termsof technical performance and cost efficiency – by exploring andimplementing improvements above their contractual obligations”Lyndon R. Evans,CERN, LHC Project Leader

Projects & Products: Overview

Components

FunctionalSystems

SmallSeries

Prototypes &SpecialDesigns

Studies Large ScaleProjects

Projects&

Products


Large Scale Projects: Overview

HERA1986 FAIR

2012

W7-X1998

LHC1999

WEMAKE

PROJECTSWORK!


QDM2018

Large Scale Projects:SIS 100 Dipoles for the FAIR Project

Fast rampingà 4 T/s

111 fast ramped magnets with a superferricdesign

Conductor

Length

Magnetic Field

NbTi

~ 3 m

1.9 T


Large Scale Projects:Non-Planar Coils for Wendelstein 7-X

50 non-planar superconducting coils

Superconductor NbTi-CICC,Extruded conduit, 17.6 kA

Dimension of a coil

Total weight of a coil

Magnetic field

3 m x 2.5 m x 1 m

6 t

6 T


Large Scale Projects:Dipoles for Large Hadron Collider

Up to 4 magnets per week - Delivery 7 months ahead of schedule

416 twin aperture dipolesRutherford Cable

Overall length

Total weight

Magnetic field

Operating current

15 m

30 t

8.33 T

11.8 kA @ 1.9 K


Large Scale Projects:Quadrupoles for HERA

Assembly of 120 quadrupoles - 233 decapole correction coils

Quadrupoles

Length of a magnet

Total weight of a magnet

Field gradient

Operating current

2.6 m to 5.1 m

2 t

91 T/m

7 kA @ 4 K


Large Scale Projects:SIS100 QDM and MDP for FAIR project

Integration of Quadrupole Doublet Modules (QDM) and Manufacturing ofMissing Dipoles (MDP)

83 superconducting QDM

Length of a module

Total weight of a module

Conductor

2 special QDM with

4.9 m to 6.1 m

5.0 t to 6.1 t

NbTi

16 t


12 missing Dipoles

Length of a dipole

Total weight of a module

4.0 m

1.9 t

Components: Overview

Components COLD-DIAG

PotentialBreaks

EDIPO

BusbarsJET

CoilSystem

TJ


CNRS

RFX

Components: COLDDIAG

Universal design à Installation in different synchotron light sources

Cold vacuum chamber for diagnosticsMeasuring of the beam heat load to a cold bore

Retarding field analysers

Temperature sensors

Pressure gauges & mass spectrometers


Components: Potential Breaks

Electrical separation of high pressure coolingchannels for LHeUHV-capability, outstanding pressure tightness forHe even after numerous thermal cycles

Operating temperature

Operating pressure

Maximum pressure

Cool down rate

4.2 K

2 – 5 bar

200 bar

30 K/h

FAIR, ITER, ITER-TFMC, Nb3Sn- Dipole, W7-X

10-9 mbar l / s at RT Helium leakage rate - 15 kV operating voltage


Components:Nb3Sn-Dipole Magnet for ITER Conductor Tests

Nb3Sn, SS-CICC - 12 T Magnetic field

Superconducting race track coilBackground field for conductor tests

Length of cold mass

Total weight

Operating current

~ 3 m

21 t

17.6 kA @ 4 K

Courtesy EPFL-CRPP


Components: Torus and support structure for RFX

Complex geometry – Tolerances ± 1 mm

Toroidal SS-vessel and copper shield

Outer diameter

Sheet thickness of copper

Sheet thickness of stainless steel

5.2 m

3 mm

47 mm


Components: Central Coil System for Stellarator TJ-II

Combination of solenoid and helical coils

Fast ramped resistive coil

Conductor

Large Coil Diameter

Operating current

Hollow copper

3 m

11.7 kA (CC)10.8 kA (HX)


Components: Water-cooled busbars for the JET divertor

Manufacturing and installation on JET site

Glass-mica insulation system

Test voltage

Test pressure

Copper cross section

Total length

40 kV DC

50 bar

35 mm x 82 mm

400 m


Components:Pancakes for 43T Hybrid Magnet

Outsert for High Field Magnet


Large Bore Superconducting Solenoid

Magnetic Field:

Superconductor cross section:

Current:

Total weight:

8.5 T

18 mm x 13 mm

7100 A

20 Tons

Functional Systems: Overview

Idea ConceptualDesign

EngineeringDesign Prototyping Your

Product

SC Undulators SC Undulator/Wiggler

VATESTA Spin-EchoSpectrometers PERC

WEMAKE

PRODUCTSWORK!


Functional Systems:PERC

Complex solenoid systems with 11 single solenoids

PERC, a source of neutron decay products

Conductor

Length

Magnetic Field

Operating current

NbTi-filaments in Cu-matrix

12 m

6 T

ca. 1 kA


Functional Systems:NSE-Spectrometer

2 Superconducting, highly symmetrical solenoid systems

NSE = Neutron-Spin-Echo-Spectrometer

Number of coils in one cryostat

Conductor

Length

Magnetic Field

Operating current

10 (in total: 20)

NbTi

~ 2450 mm

1.5 T

± 220 A


Functional Systems:Solenoids for Spin-Echo Spectrometer

Active shielding, cryogen-free system –Coil position measurement accurate to 2 µm

2 SC solenoid systems for the Spin-EchoSpectrometer, Spallation Neutron Source, USA

Conductor

Magnetic field


Operating current

NbTi, Ø 0.5 mm²

1.4 T

4 K

250 A


Functional Systems:VATESTA

LHe bath cooled solenoid

Diameter warm bore 800 mm

Conductor

Central magnetic field

Field homogenity

Operating currentOperating temperature

NbTi

5 T

5% in a cylindricalvolume of200 mm length100 mm diameteron the central axis400 A

4.5 K

Supported by


Functional Systems:Superconducting Undulator SCU15

In cooperation withIn cooperation with

End field correction, local shimming

Conductor (insulated)

Period length

Active length

Dimensions of gap

Magnetic field

Design beam heat load

Numbers of cryocoolers


NbTi, 0.34 x 0.54 mm

15 mm

1.5 m

7 mm

0.7 T on axis with7 mm gap

4 W

4

4.2 K

Cryogen free magnet


Functional Systems:Superconducting Undulator SCU20

Cryogen free magnet

End field correction, high precision

Conductor

Period length

Active length

Dimensions of gap

Magnetic field




NbTi

20 mm

1.5 m

5 mm to 7 mm

1.63 T on axis with5 mm gap

4 W

4

4.2 K

In cooperation with


Functional Systems:Superconducting Undulator SCU15-2

Cryogen free magnet

End field correction, integral field compensation,low phase error

Conductor

Period length

Active length

Dimensions of gap

Magnetic field




NbTi

15 mm

1.5 m

7 mm

0.7 T on axis

4 W

4

4.2 K

In cooperation with


Functional Systems:Superconducting Undulator SCUW

End field correction, integral field compensation

Conductor

Period length

Active length

Dimensions of gap

Magnetic field




NbTi

18 mm – 54 mm

2 m

8 mm

1.09 T – 3.20 T on axis

4 W

4

4.2 K

Switchable undulator / wiggler – Cryogen free magnet

In cooperation with


Small Series: Overview

Trim Coils forW7-X 2004

In-vessel Saddle Coilsfor ASDEX Upgrade2008

Undulators,FLASH II

PM-UndulatorsPETRA III, FLASH2008

WEMAKE

YOUR SERIESWORK!


Small Series:In-vessel saddle coils for ASDEX Upgrade

3D shaped coils

Casing for UHV application

Conductor

Dimension

Operating current

Mode of operation

Magnetic field

Hollow copper

1,300 mm x 450 mm

1 kA

AC, DC

3.9 T


Small Series:Trim Coils for the W7-X-project

10 non-planar coils

Coils inside a high vacuum tight steel casing

Conductor

Dimension

Input Voltage

Peak current

Mode of operation

Hollow copper

2,035 mm x 356 mm

- 30 V to + 30 V

- 3.125 kA to + 3.125 kA

AC, DC


Small Series:Permanent Magnetic Undulators for PETRA III and FLASH

11 undulators within 11 months

Aluminium girder

Length

Variaton of the gap

2 m

10 mm to 200 mm,Precision and reproducibility of1 µm


Small Series:Undulators for FLASH II

Precision and reproducibility of 1 µm

Build-to-print contract

Total number

Length

Variaton of the gap

12

2 m

10 mm to 200 mm


Prototypes & Special Designs: Overview

TFMC

HTS Undulator

SIS 100 DEMO Coil W7-X

Dipole andComponents for LHC

PM Undulators

Current Leads LHC

SC UndulatorsPENeLOPE

FTC

WEMAKE

PROTOTYPESWORK!


TF Test Chamber

PENeLOPE - a Precision Experiment on the NeutronLifetime Operating with Proton Extraction

Complex solenoid systems multiple solenoids

PENeLOPE – measurement of neutron lifetime

Conductor

Magnet height

Magnetic Field

Cooling method

NbTi-filaments in Cu-matrix

2.5 m

up to 2 T

bath cooled


Copyright: TUM

Prototypes & Special Designs:Cold-Test Facility and Development of Coil-Bedding

Multi-functional cold-test facility for ITER TF

Designed for cold tests at 80 Klevin

Size

Pressure

Leak tests

Paschen test

Electrical tests

16 m x 10 m

10-4 mbar @ RT

10-8 mbar•l/s @ RT

@ RT

Low current @ 80 K


Prototypes & Special Designs:Final Acceptance Test Chamber

Final Test Chamber (FTC) for General Atomics

Final Test Cryostat for the Central Solenoid Modules for ITER

Components

Total HeightTotal weight

• Vacuum vessel, consisting of lower dishedhead and vessel hood

• Coil Support Stand• Active and Passive thermal shield• Vessel hood lifting system• Vacuum- and Paschen testsystem• Walkway around the lower vaccuum vessel• Connecting bridge to loading dock~ 13 m~ 60 t


Prototypes & Special Designs:SIS 100 Fast Ramping Superferric Dipole

Fast rampingà 4 T/s

Manufacturing of the SC cableQualification for the industrial series production

Conductor

Yoke length

Max. magnetic field

NbTi

2.7 m

2 T


Prototypes & Special Designs:SC Undulators

SCU15 Prototype

Effect of wire reaction ontolerancesPeriodsHeat treatment

10 (14 mm)650° C

SCU15 Mock-up

RT impregnation

PeriodsMax. ramp rate

10 (14 mm)240 A/min

SCUW Mock-upSCU Nb3Sn Demo

Undulator-Wiggler modeTest of the switching processPeriods undulatorPeriods wiggler

4.5 (15 mm)1.5 (45 mm)

Local shimmingQuench Protection

PeriodMax. field in conductor

16.5 (15 mm)2.7 T


Prototypes & Special Designs:HTS Undulator

66 mm long voke out of one single block4 µm flatness5 µm overal winding groove precision

Design optimizationReduction of the joints resistanceOptimization of the splicing process

Conductor

Length

Magnetic field on axis

Max. operating current


YBCO

68 mm

1.45 T

550 A

4 K


Prototypes & Special Designs:TFMC Toroidal Field Model Coil

Size: 3.5 m x 2.5 m x 1.2 m

European consortiumQualification for the ITER TF-Coils

Conductor

Magnetic field at the conductor

Operating current

Nb3Sn-CICC

6.7 m

24 kA


Prototypes & Special Designs:DEMO coil for the W7-X project

Non-planar coil

Qualification of the production process for the W7-Xproject

Conductor

Dimension

Magnetic field at the conductor

Operating current

NbTi-CICC

3.5 m x 2.5 m x 1.2 m

6.7 T

16 kA


Prototypes & Special Designs:Dipole and Components for the LHC

1.9 K operating temperature of the dipoles – Cooled by suprafluid helium

Qualification, test and optimization for the industrialseries productionCrystats with radiation shielding and super insulation

Dipoles:ConductorMagnetic flux densityOperating current

NbTi, Rutherford Cable8.33 T11.8 kA

Cryostats:DiameterTotal lengthVacuum

~ 1 m18 m< 10-6 bar


Prototypes & Special Designs:Permanent Magnetic Undulators for XFEL

250 mm variation of the gap height with a precision of 1 µm

Prototype and Study on their industrial production

Weight

Length

Period Length

~ 8 t

5 m

29 mm


Prototypes & Special Designs:600 A HTS Current Leads for the LHC

YBCO Bulk – 4 K to 50 K

Reduction of the heat load by means of ceramic high-temperature superconducting current feedthroughsIn cooperation with ATZ GmbH

Material normal conducting part

Material mechanical structure

Cu with RRRapprox. 30GRP


Picture: ATZ

Studies: Overview

FeasibilityStudies

IndustrializationStudies

Cost & ScheduleStudies


Studies: Feasibility

„Study for a superconducting Solenoid-Pair for aSpin-Echo Spectrometer“

„Transportation of Cryomodules“ for XFEL

„Feasibility study of a magnetic system for heliumpurification“ (PBMR, 2007)


Studies: Industrialization

„Study on series production of AcceleratorCroymodules for XFEL“

„Study on the assembly of the cryomodules of theInternational Linear Collider (ILC)“

„Study on series production of superconductingDipoles and Quadrupoles for SIS 100“


Studies: Costs & Schedule

„ITER Central Solenoid coil cost estimate“

„Toroidal Field coils for JT60-SA – technologies,Time Planning, Cost Structure“


Technologies: Overview

Technologies

WindingGeometry

Highprecision

fabrication

DifferentConductors

Insulation

Cryotechnology

WeldingSoldering/Brazing

Tests andMeasurement

Calculation &Design

WEMAKE

TECHNOLOGYWORK!


Technologies: Calculation & Design

Ø Dynamic

Ø Electromagnetic

Ø Multiphysics

Ø Structural

Ø Thermal

Ø 2 D

Ø 3 D

Calculation Design


Technologies: Winding Geometry

Portal Winding Machine (LHC)

Solenoid-Winding (NSE)

CICC with stainless steel mantlewinding (EDIPO)

3D-Winding (W7-X)


Technologies: Different Conductors


Cu

NbTi

Nb3Sn

HighTemperature

SC (HTS)

LowTemperature

SC (LTS)

PermanentMagnets

Copper

Conductorprofiles HTS

Technologies: Insulation

Vacuum-Pressure-Impregnation (VPI)

Paschen test for failurediagnostic Prepreg-Insulation


Technologies: Cryotechnology

Production according to the Pressure Vessel Regulation 97/23/EG

Cryogen cooled

Bathcooled Forced Flow

LHC CICC:W7-X

Nuclotron-Cable: SIS100

Cryogen-free cooled

Undulator NSE


Technologies: High Precision Manufacturing

SC Undulator production



More than 150 different magnet components have to be woundLength deviations between the yokes: 20 µmYoke flatness along 1.5 m: 50 µm

Tolerances of the nominal diameter 4 m ± 1.0 mmTolerances of the inner diameter 1.06 m + 0.5 mm/- 0.0 mmTolerances of the cross-section 0.2 m ± 0.5 mm

Form tolerances < 0.05 mmPosition tolerances by rotation < 0.1 mmSymmetrical tolerances of both solenoids 2 ‰(magnetic fields integrated)


Technologies: Welding

Welding process and Material Thickness

TIG(Tungsten-Inert-Gas)

LB-MAG

Thickness:1 – 60 mm



MAG(Metal Active

Gas)

Welding Base Material

AusteniticSteel C-SteelsNickel-Basic

Steels


Technologies: Soldering & Brazing

Soldering Process

Soldering withlocal heating

InductionSoldering

Thickness:0.5 – 4 mm

Thickness:0.5 – 4 mm

Cu-Cu, brass-Cu, steel

Brazing Process

Brazing withlocal heating

FurnaceBrazing



Cu-Ni-alloy, Cu-Cu, brass-Cu,brass-stainless steel


Technologies: Tests & Measurements

Cryofree Test Station

LN2 Test Station for potentialbreaks

Permeability Measurements

Impulsed Voltage Generator

Non Destructive Test

Visual Test (VT)Penetrant Test (PT)Leak Test (LT)Helium-LT (10-10 mbar l/s)Bubble-LT (10-3 mbar l/s)Acoustic Emission Testing (AT)Radiographic Test (RT, X-Ray, LinAc)Ultrasonic Test (UT)Magnet Powder Test (MT)Hardness Test (HT, Vickers)

Geometrical Measurements

LasertrackerFaro-Arm


Magnet-Technology – YOUR Team

WEMAKE

COOPERATIONWORK!


Contact

Bilfinger Noell GmbHAlfred-Nobel-Str. 2097080 WürzburgGermany

Phone +49 931 903-0Fax +49 931 [email protected]

Registered at Local Court Würzburg, HRB 7156VAT-Id. No.: DE211420259

Executive Management:Dr. Ronald Hepper, ChairmanRoland Pechtl


bilfinger noell gmbh, magnet technology...information security management system iso 27001: 2005...

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