The Technical Division Overview Victor Yarba July 10

The Technical Division Overview Victor Yarba July 10, 2006 Fermilab Technical Division July 10, 2006 1

Technical Division Mission The research, development, design, fabrication or procurement, and testing of accelerator and detector components • • Support the Accelerator Complex Conduct Accelerator R&D – ILC, PD, LHC, LARP • Support Projects – CMS Muons, LHC Accelerator Project, Pierre Auger • Provide Lab-wide Services – Incoming inspection, material control, specialized machine shop TD is ~235 people accustomed to: • Working on technical HEP R&D devices • Responding to customer requirements • Preparing designs to be ‘production ready’, including integration w/ industry • Delivering on accelerator projects for Fermilab and other HEP labs Fermilab Technical Division July 10, 2006 2

TD Organization TD is a matrix organization Departments are grouped by specific functional skills Projects and Programs focus efforts to specific goals, using personnel from the departments Fermilab Technical Division July 10, 2006 3

The Magnet Systems Dept. Mission Ä Provide support for the Fermilab Accelerator complex Ä repair or refurbish existing accelerator components Ä design, fabrication and test oversight of new devices for improvements to the accelerator complex. Ä Develop, evaluate and improve technologies for future accelerators Ä development of new technologies in the area of superconducting and other structural materials and components; Ä magnet design, fabrication, test and analysis; Ä and magnetic measurement instrumentation. Ä Provide Other Services to the Division and Lab Projects Ä quality assurance/production control and document management services Ä tooling design and fabrication Ä project management ( LARP task leaders, ILC magnets, numerous completed projects for the Tevatron and elsewhere) Fermilab Technical Division July 10, 2006 4

Accelerator Support Project Workflow/Interactions • • Request received from customer (AD/MSD) Requirements defined and documented – – • • • Design specifications (MSD/AD) Procurement specifications (MSD/MCD) Fabrication specifications (MSD) Measurement requirements (MSD/T&I/AD) The design process is very iterative. Improvements occur throughout the entire life-cycle. Requirements reviewed (AD/MSD/MCD/T&I) Priorities set (AD/MSD) Devices designed (MSD/DDCIS/MCD/AD/T&I) Parts/assemblies procured/fabricated (MCD/MSD) Parts/assemblies inspected (MCD) Devices fabricated (MSD) Devices measured (T&I) Measurement data analyzed (MSD/T&I/AD) Devices delivered to customer Close out - records completed and lessons learned published Maintenance Fermilab Technical Division July 10, 2006 5

MSD Accelerator Support Projects Repair TEL 1 during shutdown New Or. Bump system Reshimming Tevatron dipoles Booster Corrector Package WQB quadrupoles Fermilab Technical Division July 10, 2006 6

LARP Model Magnet R&D Fermilab provides substantial contributions to developing LARP technology quads (TQ). Two technology quadrupole designs: • • TQS: mechanical structure based on thick Al shrinking cylinder (LBNL) TQC: mechanical structure based on stainless steel collar/yoke/skin support (Fermilab) Fermilab provides: • • MJR strand for TQS 01 and TQC 01 Resources for TQ tooling design and procurement in FY 04 -05 from base program Coil design and technology, and winds coils for TQS 01 and TQC 01 Model testing at 1. 9 K Status: TQS 01 built and tested TQC 01 near completion, test to follow Fermilab Technical Division July 10, 2006 7

Superconducting RF Dept. Mission Contribute to the advancement of conventional and superconducting Radio Frequency technology, from conceptualization through commissioning of components and assemblies, to be used in all aspects of beam acceleration, handling and detection. Work includes basic beam dynamic simulation, establishment of design requirements, engineering specifications, design and engineering to develop ‘build-to-print’ packages for procurement, development of prototypes, definition of work process control procedures, development of inspection criteria and fabrication procedures, and providing fabrication and production oversight. The department’s efforts will include follow-up for completed devices such as support of testing and analysis of test data in order to measure, characterize and optimize the performance of RF devices, and support of the installation and commissioning of such devices. It will also include basic material research and development, including the establishment of reliable and repeatable chemical processing recipes and procedures to achieve desired RF cavity accelerating gradients. Fermilab Technical Division July 10, 2006 8

ILC Type IV Cryomodule SRF Cavity Fermilab Technical Division July 10, 2006 9

Ion source R&D • Initial idea: multicusp, rf-driven, cesium enhanced source of H- (SNS, DESY). – – Output energy 50 ke. V Output peak current 12. 7 (38) m. A Pulse length 3. 0 (1. 0) ms Pulse rate 2. 5(10) Hz • Recent Developments: Plasmatron D. Moehs C. Schmidt H. Piekarz Fermilab Technical Division Dual. Plasmatron Source at MS 6. July 10, 2006 10

Test & Instrumentation Dept. Mission The Test and Instrumentation (T&I) Department of the Technical Division (TD) is a service and development organization. The department performs measurements and test of both R&D and production accelerator components, and develops technologically advanced instrumentation, control solutions, and cryo-mechanical systems for accelerator applications. The major customers of the T&I department are other TD Departments and TD Projects. The highest priority of the department is to provide efficient and effective support of testing programs to our customers through the products we deliver. These products are test data, instrumentation components, and systems for use within and outside the department. The two major accelerator technologies that the department supports are magnets (conventional and superconducting) and Superconducting Radio Frequency (SRF) cavities. Fermilab Technical Division July 10, 2006 11

IB 1 SRF Test Area Layout Vertical Test Area (FY 06) (Bare Cavities) Fermilab Technical Division Existing Cryo Piping Horizontal Test Area (FY 07) (Dressed Cavities) July 10, 2006 12

Material Control Dept. Mission The Material Control Department's purpose is to support the ongoing activities and projects with which the Technical Division is involved. We typically get involved early in a project estimating costs and providing expertise on manufacturing and quality engineering issues. As a project evolves, we initiate procurements for the parts, tooling, and supplies necessary to support the fabrication efforts. We provide source and incoming inspection services throughout the project. After items pass inspection, we provide storage and inventory control functions for devices such as accelerating structures, magnets, and their components. Additionally, we offer metrology and fabrication procurement services to Fermilab and to other National Laboratories. The Material Control Department is committed to ensuring that deliverable items meet our customer's specifications/requirements and that a safe work place is provided for our employees while protecting the environment. Fermilab Technical Division July 10, 2006 13

Quality Control The QC Group provides a wide variety of services with emphasis on precision metrology. • Inspection – At the Source – Incoming Inspection in IB 4 • Calibration – Periodic Calibration of Measuring & Test Equipment – Database of Calibrated Instruments Fermilab Technical Division July 10, 2006 14

Quality Control Capabilities • Mechanical Inspection – Coordinate Measuring Machines (4 Mechanical Cordaxes, 2 Optical OGP) – Laser Tracker • Magnetics Testing – Hysteresigraph – Ferrite/Permeability Indicator(s) • Leak Testing – Vacuum – Hydrostatic Fermilab Technical Division July 10, 2006 15

Quality Control Capabilities (cont’d) • Miscellaneous Capabilities – – Hardness Testing Surface Finish Measurement Ultrasonic Testing (flaw and thickness measurement) Coating Thickness Measurement Fermilab Technical Division July 10, 2006 16

Design Drafting Mission • Responsible for project design and drafting activities both within the Division and for outside 'customers'. • Interact with project engineers, physicists and managers in the development of component, assembly, and system designs. • Document control of all drawings, files, specifications, parts lists, releases, and change orders. • Home to the Lab CAD Manager (LCM). The LCM has responsibility for managing the CAD/CAM/CAE/PDM software for all of the divisions and sections of Fermilab Technical Division July 10, 2006 17

Computing & Information Systems Mission • Responsible for the computers, networks and administrative/user databases in the division. • Installation/maintenance and specification of desktop computing software and hardware, server systems • Support services such as printers/plotters and data backups and a division wide helpdesk • Long term planning, implementation and upkeep of all TD information systems • Responsible for TD computer security Fermilab Technical Division July 10, 2006 18

DD/CIS – Technical Support DD/CIS support includes; • CAD/CAM Software/Customization • Desktop applications • Web based server/client software • Printer/plotter support includes setup, installation and network availability for a variety of printers and plotters • Hardware/software computer support of the High Rise and Village Machine Shops • Maintaining a property database that contains information about all TD devices Fermilab Technical Division July 10, 2006 19

Machine Shop Mission • The mission of the Fermilab Machine Shop is to provide a range of onsite machine shop and welding capabilities coupled with quick response for: – Modification of existing components in support of accelerator and experiment operations. – Manufacturing of urgently needed details. – Machining of slightly radioactive materials (class I, II). – Development of prototypes and proof of principle concepts. – R&D associated with new machining technologies and processes. Fermilab Technical Division July 10, 2006 20

How the Shops Function • The Fermilab Machine Shops are comprised of a Main Shop and four Satellite Shops ranging from 1 to 4 Machinists in each shop. • Main Shop – The Main Machine Shop is equipped to handle large fabrications, special welding requirements, EDM, CNC machining and programming, prototype development, long and short run jobs, and perform radioactive machining. • Satellite Shops – Satellite Machine/Weld Shops are located in the major production and repair areas of the Laboratory. There are five Satellite Weld Shops. – Offer the convenience of not having to travel to the main shop. – Priority is established by the Group. Fermilab Technical Division July 10, 2006 21

Support Department Mission The Technical Division Support Department includes the Facilities Management Group and the Environment, Safety and Health Group. The department is a service organization which supports the mission of the Technical Division and Fermilab in every respect. Fermilab Technical Division July 10, 2006 22

Support Dept. Key Responsibilities • • • Environment, Safety & Health ES&H Training Emergency Management Facilities Management Infrastructure Improvements & Construction Projects Operational Readiness Reviews & Clearance Recommendations Fermilab Technical Division July 10, 2006 23

Quality Management in TD • Our quality program is organized around DOE O 414. 1 C • Similar to safety, quality is integrated into the work processes throughout the division • Every employee is responsible for assuring the quality of their work (TD-2010 section 1. 6. 1) • Peer review is central to the quality program • Management provides tools (systems) to aid employees in assuring quality (more on this topic this afternoon) Fermilab Technical Division July 10, 2006 24

Quality Management in TD • In addition to the integrated function, the division maintains a specific QC function in the Material Control Department (described earlier) – Incoming inspection (calibration, CMMs, mechanical inspections, leak checking, laser tracker) • The division also has a QA Manager, who is responsible for the overall quality program – He works with department and project leaders to help ensure that management systems are in place and effective in helping to assure quality Fermilab Technical Division July 10, 2006 25

In Summary • The Technical Division is responsible for the designs, development, manufacture, & testing of precision accelerator components requiring extremely tight tolerances • Quality Assurance is an important element in our Division’s programs, and is essential if we are to meet our mission requirements • A sound QA Program is in place and is central to the success of our organization Fermilab Technical Division July 10, 2006 26