edm magnetic shielding (wbs 5) and magnets (wbs 6) b. filippone and b. plaster caltech internal cost...

EDM Magnetic Shielding(WBS 5)

and Magnets(WBS 6)

B. Filippone and B. PlasterCaltech

Internal Cost and Schedule Review

February 11, 2004

Basic Magnetic Specifications

• DC Magnetic field of 1-10 mGauss with 0.1% uniformity over volume of measurement cell (50 cm x 12 cm x 7.6 cm)

• Compensated dressed spin field of ~0.1 Gauss at 1-10 kHz

• Time stability of < 10-6/sec

Present Magnetic Shielding Baseline Concept

cos θ coil:

r ~ 61cm; ℓ ~ 393cm

4K ferromagnetic shield: r ~ 61cm; ℓ ~ 400cm

superconducting shield: r ~ 63cm; ℓ ~ 400cm

4-layer µ-metal shielding

configuration

[J. Boissevain]

Estimated WBS 5 Base Costs

• 300K ferromagnetic shields– Cylindrical µ-metal shields with end-caps; take

baseline 62 mils• Larry Maltin (President of Technical Products at Amuneal):

– “…confident that we could engineer, fabricate, anneal, and install such a [sized] shield…”

• CIT Geophysics recently accepted delivery from Amuneal of ~1/3 EDM scale vertical 4-layer shield system

• Cost estimate with end caps: $610,000 for 4• ~12 month lead time (freight truck shipping) and will

require some on-site assembly• 4-layer structure estimated to weigh ~ 5.5 English tons• For larger spacing between layers: $700,000

Shield Optimization

r = 107cm, 111 cm, 114 cm, 118 cm (nominal design)

r = 107cm, 115 cm, 125 cm, 135 cm r = 107 cm, 120 cm, 135 cm, 150 cm

Estimated Base Costs

• 4K ferromagnetic shield– Mu-metal does not work well at 4K– Cylindrical

• 20 mil thickness

– Cryoperm option (proprietary alloy)• Based on previous quotes • r ~ 60cm, ℓ ~ 400cm: $60,000

– Metglas option (metallic glass – rapid solidification)

• Honeywell quote: $515/kg• 20 mils thick will require ~70 kg → $40,000• Al cylinder support frame: $8,000 ~5 miles of 2-inch wide Metglas strips

Estimated Base Costs

• Superconducting shield– No experience yet– Pb sheet or cast Pb with Al frame

• Will require design & engineering efforts– Estimate: $100,400

• Other Shielding: e.g. External “Room-sized” (3x7x5 m3)Fe/mumetal shield – Estimate for box-type shield: $75,000

Estimated Base Costs• AC demagnetization circuit for the ferromagnetic shields

– Demagnetizing prototype Cryoperm and µ-metal shields has proven to be difficult (need some R&D)

– High-power, variable-frequency, programmable AC power supply: $25,000

– Demagnetization circuit supplies: $5,000

• Technical/Engineering/Machining work at Caltech – Support for design engineer and machinist for assistance with

integration of shielding with experiment– Estimated total labor costs: $100,500

• Note: We did not include expenses related to materials/construction of support structures for the shielding (only for design engineering)

(in WBS 12.4)

Total Costs Roll Up

WBS 5: Magnetic Shielding5.1 4-Layer Ferromagnetic Shield $1,001,097 37%

5.2 Superconducting Shield $142,800 40%

5.3 3K Ferromagnetic Shield $79,056 22%

5.4 Other Shielding (e.g., “room-sized”) $100,440 24%

5.5 Magnetic Penetrations $49,075 42%

5 TOTAL $1,372,468

Contingency

[Pre-Proposal: $581,000]

Note: original 4 layer shield = $250,000

Difference from large increase in size due to spin dressing coils and upper cryostat shield

Price of Nickel impacts cost of metal

London Metal Exchange 1998-2005 ($/ton)

Proposed Schedule• Personnel during construction phase (1.5 FTE): 1 faculty; 1

post-doc; 1 design engineer; 1 machinist; undergraduate student(s) and/or 1 graduate student

• Estimated Timeline (assuming funding available FY2007)

2007

2008

2009

2010

Finalize shield design/geometry

Finalize/integrate support structure

Procure ferromagnetic shields

Design/Construct superconducting shield

Procure AC demagnetization equipment

Install all magnetic shielding

Install/test AC demagnetization circuit

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• Magnets to be constructed– cos θ coil for static field

• 1-20 mGauss DC field; ±0.1% spatial uniformity; 10-6 temporal stability

– Solenoid as “π/2 r.f.” 3He and neutron spin-flip coil• 0.1 mGauss AC field; 3.165 Hz; 1.58 second duration

– Spin-dressing cos θ coils• Field parameters to match 3He and neutron precession frequency

– 3He spin holding coil (surrounds 3He collection cell)

• Accompanying instrumentation needs– Highly-stable AC and DC power supplies– Mapping hardware and probes for field monitoring

• Labor costs (design engineering and machining/construction) and raw materials will comprise the core costs for WBS 6– As opposed to mostly procurement costs for WBS 5

Magnets (WBS 6)

Basic B-Field Concepts

x

y

3He spin holding coil

Estimated Base Costs

• Design and construction of static cos θ coil: $130,000– ~⅛-scale prototype already constructed

at Caltech → have acquired experience with design and machining efforts

• Design engineering/integration labor costs: $20,000

• Materials and supplies: $30,000• Machining/production labor costs:

$80,000– Assuming out-sourcing; in-house could lead

to reduction

• Design and construction of “π/2 r.f.” solenoid: $20,000– Solenoid → design and construction

should be simpler (in principle)• Design engineering/integration labor

costs: $5,000• Materials and supplies: $10,000• Machining/production labor costs: $5,000

Estimated Base Costs• Construction/integration of spin-dressing coils:

$150,000– Prototype AC cos θ coils to be built as part of the 2005-2006

R&D efforts at Caltech• Design engineering/integration labor costs: $20,000• Materials and supplies: $50,000• Machining/production labor costs: $80,000

– Assuming out-sourcing; in-house could lead to reduction

• AC and DC power supplies: $85,000– Require highly-stable power supplies and stabilization circuits

• DC power supply with accompanying stabilization circuit and control

for the static cos θ coil: $30,000• Low-frequency AC power supply for “π/2 r.f.” spin-flip solenoid:

$10,000• 3He spin holding coil: $10,000• High-frequency AC power supply for spin-dressing coils: $20,000• Computer-controlled interface for all power supplies: $15,000

– Possibly coupled to AC demagnetization circuit in WBS 5

Estimated Base Costs• Design &construction of 3He spin holding cos θ coil:

$130,000• Design engineering/integration labor costs: $20,000• Materials and supplies: $30,000• Machining/production labor costs: $80,000

– Assuming out-sourcing; in-house could lead to reduction

• Mapping hardware and probes for (possible) in-situ real-time field monitoring: $80,000– DC field profile independent of 3He co-magnetometry– Appropriate tuning of AC fields

• Computer-controlled positioning/stepping hardware and readout (difficulties due to the cryogenic environment): $50,000

• Engineering for integration: $10,000• Cryogenic 3-axis fluxgate magnetometers and probes: $20,000

Total Costs Roll Up

WBS 6: Magnets6.1 Constant Field cos θ Coil $173,342 34%

6.3 r.f. Spin-Flip Coil $29,587 34%

6.5 Spin Dressing Coils $202,286 34%

6.7 3He cos θ holding coil $173,342 34%

6.9 Field Monitors $120,984 42%

6.2,6.4,6.6,6.8 Power Supplies $110,160 20%

7 TOTAL $809,701

Contingency

[ Pre-Proposal: $388,000 ]

Difference due to adding Spin Dressing coils and 3He holding coil

Proposed Schedule• Personnel during construction phase (2.0 FTE): 1 faculty; 1

post-doc; 1 professional staff member; 1 design engineer; 1 machinist; 1 graduate student; undergraduate student(s)

• Estimated Timeline (assuming funding available FY2007)2007

2008

2009

2010

Finalize magnet parameters/geometry

Construct/test static cos θ coil

Construct/test “π/2 r.f.” spin-flip coil

Construct/test spin-dressing coils

Procure/test AC and DC power supplies

Design field monitors

Procure magnetometer/probes

Install all magnets

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