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Bilfinger Noell GmbH
Bilfinger Noell GmbH Page 2
Contactus!
CompanyOverview
Projects&
Products
NOELL
Technologies
Contact NOELL Magnet Technology
Page 3
• Division Magnet Technology
• Head of Sales Department
• Phone: +49 (0) 931-903-6031
• E-Mail: [email protected]
Michael Gehring
Bilfinger Noell GmbH
Company Overview
Page 4
Customers &Productsworldwide
Site &Location
Software -Capabilities
CertifiedQuality &Safety
DistinguishedQuality
Member ofBilfinger SE
We are MagnetTechnology
CompanyOverview
Bilfinger Noell GmbH
Bilfinger Noell: Member of Bilfinger SE
Page 5
Nuclear Services Nuclear TechnologiesMagnet Technologies
Business Segment Engineering & Technologies (E&T)
Bilfinger Noell GmbH
Bilfinger SE
Bilfinger Noell GmbH
We are Magnet Technology
Page 6
• Physicists, Engineers andTechnicians work hand-in-hand
• More than 30 years magnettechnology experience
• Cooperation with researchinstitutions and industry
WEMAKE
RESEARCHWORK!
Bilfinger Noell GmbH
Site and Location
Page 7
Office
2. Workshop: 1.000m²Components
1. Workshop: 2.100m²Prototyping
3. Workshop: 1.100m²Production
Bilfinger Noell GmbH
Software - Capabilities
Page 9
CAD CAE Yourdesign
AutoCAD Mechanical ©
CATIA V5 ©
PDMS AVEVA ©
Autodesk Inventor ©
Microstation ©
ANSYS ©
Vector fields Opera ©
Mathematica ©
FEMM ©
LabVIEW
Bilfinger Noell GmbH
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
Page 10Bilfinger Noell GmbH
Distinguished Quality
Page 11
Golden Hadron Award(LHC)
AREVA OL3 Safety Award(HSE)
Best result for suppliers:„Top AREVA Supplier“
Bilfinger Noell GmbH
“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
Page 12
Components
FunctionalSystems
SmallSeries
Prototypes &SpecialDesigns
Studies Large ScaleProjects
Projects&
Products
Bilfinger Noell GmbH
Large Scale Projects: Overview
Page 13
HERA1986 FAIR
2012
W7-X1998
LHC1999
WEMAKE
PROJECTSWORK!
Bilfinger Noell GmbH
QDM2018
Large Scale Projects:SIS 100 Dipoles for the FAIR Project
Page 14
Fast rampingà 4 T/s
111 fast ramped magnets with a superferricdesign
Conductor
Length
Magnetic Field
NbTi
~ 3 m
1.9 T
Bilfinger Noell GmbH
Large Scale Projects:Non-Planar Coils for Wendelstein 7-X
Page 15
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
Bilfinger Noell GmbH
Large Scale Projects:Dipoles for Large Hadron Collider
Page 16
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
Bilfinger Noell GmbH
Large Scale Projects:Quadrupoles for HERA
Page 17
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
Bilfinger Noell GmbH
Large Scale Projects:SIS100 QDM and MDP for FAIR project
Page 18
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
Bilfinger Noell GmbH
12 missing Dipoles
Length of a dipole
Total weight of a module
4.0 m
1.9 t
Components: Overview
Page 19
Components COLD-DIAG
PotentialBreaks
EDIPO
BusbarsJET
CoilSystem
TJ
Bilfinger Noell GmbH
CNRS
RFX
Components: COLDDIAG
Page 20
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
Bilfinger Noell GmbH
Components: Potential Breaks
Page 21
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
Bilfinger Noell GmbH
Components:Nb3Sn-Dipole Magnet for ITER Conductor Tests
Page 22
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
Bilfinger Noell GmbH
Components: Torus and support structure for RFX
Page 23
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
Bilfinger Noell GmbH
Components: Central Coil System for Stellarator TJ-II
Page 24
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)
Bilfinger Noell GmbH
Components: Water-cooled busbars for the JET divertor
Page 25
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
Bilfinger Noell GmbH
Components:Pancakes for 43T Hybrid Magnet
Page 26
Outsert for High Field Magnet
Bilfinger Noell GmbH
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
Page 27
Idea ConceptualDesign
EngineeringDesign Prototyping Your
Product
SC Undulators SC Undulator/Wiggler
VATESTA Spin-EchoSpectrometers PERC
WEMAKE
PRODUCTSWORK!
Bilfinger Noell GmbH
Functional Systems:PERC
Page 28
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
Bilfinger Noell GmbH
Functional Systems:NSE-Spectrometer
Page 29
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
Bilfinger Noell GmbH
Functional Systems:Solenoids for Spin-Echo Spectrometer
Page 30
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 temperature
Operating current
NbTi, Ø 0.5 mm²
1.4 T
4 K
250 A
Bilfinger Noell GmbH
Functional Systems:VATESTA
Page 31
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
Bilfinger Noell GmbH
Functional Systems:Superconducting Undulator SCU15
Page 32
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
Operating temperature
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
Bilfinger Noell GmbH
Functional Systems:Superconducting Undulator SCU20
Page 33
Cryogen free magnet
End field correction, high precision
Conductor
Period length
Active length
Dimensions of gap
Magnetic field
Design beam heat load
Numbers of cryocoolers
Operating temperature
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
Bilfinger Noell GmbH
Functional Systems:Superconducting Undulator SCU15-2
Page 34
Cryogen free magnet
End field correction, integral field compensation,low phase error
Conductor
Period length
Active length
Dimensions of gap
Magnetic field
Design beam heat load
Numbers of cryocoolers
Operating temperature
NbTi
15 mm
1.5 m
7 mm
0.7 T on axis
4 W
4
4.2 K
In cooperation with
Bilfinger Noell GmbH
Functional Systems:Superconducting Undulator SCUW
Page 35
End field correction, integral field compensation
Conductor
Period length
Active length
Dimensions of gap
Magnetic field
Design beam heat load
Numbers of cryocoolers
Operating temperature
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
Bilfinger Noell GmbH
Small Series: Overview
Page 36
Trim Coils forW7-X 2004
In-vessel Saddle Coilsfor ASDEX Upgrade2008
Undulators,FLASH II
PM-UndulatorsPETRA III, FLASH2008
WEMAKE
YOUR SERIESWORK!
Bilfinger Noell GmbH
Small Series:In-vessel saddle coils for ASDEX Upgrade
Page 37
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
Bilfinger Noell GmbH
Small Series:Trim Coils for the W7-X-project
Page 38
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
Bilfinger Noell GmbH
Small Series:Permanent Magnetic Undulators for PETRA III and FLASH
Page 39
11 undulators within 11 months
Aluminium girder
Length
Variaton of the gap
2 m
10 mm to 200 mm,Precision and reproducibility of1 µm
Bilfinger Noell GmbH
Small Series:Undulators for FLASH II
Page 40
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
Bilfinger Noell GmbH
Prototypes & Special Designs: Overview
Page 41
TFMC
HTS Undulator
SIS 100 DEMO Coil W7-X
Dipole andComponents for LHC
PM Undulators
Current Leads LHC
SC UndulatorsPENeLOPE
FTC
WEMAKE
PROTOTYPESWORK!
Bilfinger Noell GmbH
TF Test Chamber
PENeLOPE - a Precision Experiment on the NeutronLifetime Operating with Proton Extraction
Page 42
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
Bilfinger Noell GmbH
Copyright: TUM
Prototypes & Special Designs:Cold-Test Facility and Development of Coil-Bedding
Page 43
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
Bilfinger Noell GmbH
Prototypes & Special Designs:Final Acceptance Test Chamber
Page 44
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
Bilfinger Noell GmbH
Prototypes & Special Designs:SIS 100 Fast Ramping Superferric Dipole
Page 45
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
Bilfinger Noell GmbH
Prototypes & Special Designs:SC Undulators
Page 46
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
Bilfinger Noell GmbH
Prototypes & Special Designs:HTS Undulator
Page 47
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
Operating temperature
YBCO
68 mm
1.45 T
550 A
4 K
Bilfinger Noell GmbH
Prototypes & Special Designs:TFMC Toroidal Field Model Coil
Page 48
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
Bilfinger Noell GmbH
Prototypes & Special Designs:DEMO coil for the W7-X project
Page 49
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
Bilfinger Noell GmbH
Prototypes & Special Designs:Dipole and Components for the LHC
Page 50
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
Bilfinger Noell GmbH
Prototypes & Special Designs:Permanent Magnetic Undulators for XFEL
Page 51
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
Bilfinger Noell GmbH
Prototypes & Special Designs:600 A HTS Current Leads for the LHC
Page 52
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
Bilfinger Noell GmbH
Picture: ATZ
Studies: Overview
Page 53
FeasibilityStudies
IndustrializationStudies
Cost & ScheduleStudies
Bilfinger Noell GmbH
Studies: Feasibility
Page 54
„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)
Bilfinger Noell GmbH
Studies: Industrialization
Page 55
„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“
Bilfinger Noell GmbH
Studies: Costs & Schedule
Page 56
„ITER Central Solenoid coil cost estimate“
„Toroidal Field coils for JT60-SA – technologies,Time Planning, Cost Structure“
Bilfinger Noell GmbH
Technologies: Overview
Page 57
Technologies
WindingGeometry
Highprecision
fabrication
DifferentConductors
Insulation
Cryotechnology
WeldingSoldering/Brazing
Tests andMeasurement
Calculation &Design
WEMAKE
TECHNOLOGYWORK!
Bilfinger Noell GmbH
Technologies: Calculation & Design
Page 58
Ø Dynamic
Ø Electromagnetic
Ø Multiphysics
Ø Structural
Ø Thermal
Ø 2 D
Ø 3 D
Calculation Design
Bilfinger Noell GmbH
Technologies: Winding Geometry
Page 59
Portal Winding Machine (LHC)
Solenoid-Winding (NSE)
CICC with stainless steel mantlewinding (EDIPO)
3D-Winding (W7-X)
Bilfinger Noell GmbH
Technologies: Different Conductors
Bilfinger Noell GmbH Page 60
Cu
NbTi
Nb3Sn
HighTemperature
SC (HTS)
LowTemperature
SC (LTS)
PermanentMagnets
Copper
Conductorprofiles HTS
Technologies: Insulation
Page 61
Vacuum-Pressure-Impregnation (VPI)
Paschen test for failurediagnostic Prepreg-Insulation
Bilfinger Noell GmbH
Technologies: Cryotechnology
Page 62
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
Bilfinger Noell GmbH
Technologies: High Precision Manufacturing
Page 63
SC Undulator production
SC Undulator production
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)
Bilfinger Noell GmbH
Technologies: Welding
Page 64
Welding process and Material Thickness
TIG(Tungsten-Inert-Gas)
LB-MAG
Thickness:1 – 60 mm
Thickness:1 – 40 mm
Thickness:3 – 25 mm
MAG(Metal Active
Gas)
Welding Base Material
AusteniticSteel C-SteelsNickel-Basic
Steels
Bilfinger Noell GmbH
Technologies: Soldering & Brazing
Page 65
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
Thickness:1 – 4 mm
Thickness:1 – 4 mm
Cu-Ni-alloy, Cu-Cu, brass-Cu,brass-stainless steel
Bilfinger Noell GmbH
Technologies: Tests & Measurements
Page 66
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
Bilfinger Noell GmbH
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
Page 68Bilfinger Noell GmbH