BNL FNAL LBNL SLAC DOE Review 09 July

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BNL - FNAL - LBNL - SLAC DOE Review ‘ 09 July 13 -14,

BNL - FNAL - LBNL - SLAC DOE Review ‘ 09 July 13 -14, 2009 FNAL Long Quadrupole Giorgio Ambrosio OUTLINE: - Status - Coil, Instrum & QP, Structure, Test Prep. - Plans - Schedule and budget DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole 1

Long Quadrupole Main Features: • Aperture: 90 mm • magnet length: 3. 6 m

Long Quadrupole Main Features: • Aperture: 90 mm • magnet length: 3. 6 m Target: • Gradient: 200+ T/m Goal: • Demonstrate Nb 3 Sn magnet scale up Timeframe: – 1 st Long Quad test by the end of 2009 – 2 nd Long Quad test in Spring 2010 LQ Design Report available online at: https: //plone 4. fnal. gov/P 1/USLARP/Magnet. RD/longquad/LQ_DR. pdf G. Ambrosio - Long Quadrupole DOE Review 09 - FNAL, July 13 -14, 2009 2

LQ WBS • Coils are being fabricated at FNAL and BNL F. Nobrega (FNAL),

LQ WBS • Coils are being fabricated at FNAL and BNL F. Nobrega (FNAL), and J. Schmalzle (BNL) • Quench protection and instr. design & proc. at LBNL H. Felice • Shell structure: design, procur. & assembly at LBNL P. Ferracin • Collar structure: procurement at FNAL (STOPPED) F. Nobrega • All LQ models to be tested at FNAL G. Chlachidze DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole 3

Status Summary • 4 coils ~ready for LQS 01 assembly • Shell-structure is ready

Status Summary • 4 coils ~ready for LQS 01 assembly • Shell-structure is ready • Pre-assembly practice in progress – Readiness review: ~July 27 • Test prep ~completed – Readiness review TBD • LQS 01 test in October DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

COILS DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long

COILS DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Coil Fabrication • Coil fabrication is a labor intense work, using a lot of

Coil Fabrication • Coil fabrication is a labor intense work, using a lot of different tooling – – – Wind & Cure: 3 weeks Reaction: ~5 weeks Impregnation: 4 weeks Instrumentation: 2 weeks Shipment(s): 2 weeks each • Found and fixed several “bumps on the road” – See next slides • Long coil fabrication technology is improving – Last FY we fixed the HT, this FY the impregnation DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Discrepancy Reports We are implementing Discrepancy Reporting, formal (FNAL) and/or verbal (BNL, FNAL) minor

Discrepancy Reports We are implementing Discrepancy Reporting, formal (FNAL) and/or verbal (BNL, FNAL) minor DR: parts are missing or don't fit properly, revisions to drawings or traveler moderate DR: no permanent damage to the coil, change in process and/or part required severe DR: damage or irregularity to coil Discrepancy reports during winding & curing: DR's LQ 06 LQ 07 LQ 08 LQ 09 LQ 10 LQ 11 Total minor 7 2 3 1 1 15 moderate 1 4 2 2 0 2 11 severe 0 0 0 0 Total DR's 8 6 5 3 1 3 26 Discrepancy reports during reaction: Moderate/severe : 1 (coil #7) Discrepancy reports during impregnation: Severe : 2 (coils #6 and #9) DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Coil Fabrication Status – I • Found tension on conductor after coil #3 heat

Coil Fabrication Status – I • Found tension on conductor after coil #3 heat treatment • Performed analysis† • Developed solution for LQS 01 coils (gaps) Further analysis by Toohig fellow and core programs Coils 4 and 5 will be used for practice assembly Coils 6 to 9 will be used for LQS 01 †G. Ambrosio, et alt. , “Development and Coil Fabrication for the LARP 3. 7 -m Long Nb 3 Sn Quadrupole”, ASC 08 – To be Published in IEEE Trans. on App. Supercond. 8

Coil Fabrication Status – II • Coil #4: non effective mold-release Practice coils –

Coil Fabrication Status – II • Coil #4: non effective mold-release Practice coils – In use for practice assembly; Mold-release tested on coil #3 parts • Coil #5: leakage during impregnation incomplete impregnation – Used for QP heater tests; for practicing with 2 nd impregnation; in use for practice assembly • Coil #6: incomplete impregnation – Fixed by 2 nd impregnation; added soak time under pressure after impregnation • Coil #7: Power outage during HT stopped argon flow – Witness samples are OK; removed valves • Coil #8: No problem • Coil #9: Midplane insulation stuck to impregnation fixture – Repaired with room-temperature epoxy • Coil #10 & #11 in progress DOE Review 09 - FNAL, July 13 -14, 2009 Next coils should show that debugging is over! G. Ambrosio - Long Quadrupole

Instrumentation • Completed plan – LBNL: trace design, procur. , ID instr. – BNL

Instrumentation • Completed plan – LBNL: trace design, procur. , ID instr. – BNL & FNAL: trace installation, OD instr. • Revisions to traces and procedures – Based on practice coils and first production coils – Added trace QC tests – Additional insulation over ends • Decided and implemented qualification tests for production coils Modification required based on coils #4 and #5 feedback implemented in coil #8 and subsequent coils – Data shared on LARP plone • Test of protection heaters at LN on practice coil #5 – Successfully passed with large margin Test of coil#5 protection heaters at LN 10 DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Coil Readiness Review DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio

Coil Readiness Review DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

STRUCTURE DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long

STRUCTURE DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Structure Assembly • LQS structure has been fully assembled LQSD = LQS with Al

Structure Assembly • LQS structure has been fully assembled LQSD = LQS with Al dummy coils Yoke rod tension: 330 MPa Compressive force: 760 k. N DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Short Model Test at LN • 1 section (850 mm) was assembled with aluminum

Short Model Test at LN • 1 section (850 mm) was assembled with aluminum coils, pre-loaded and tested at LN σy σz MPa Meas. +138 ± 6 +41 ± 13 Target +142 +43 Meas. -231 ± 23 +74 ± 7 Target -247 +63 Comparison: measurements and target values after cool-down Shell Coil Dummy coil stress during cool-down to 77 K Axial Azimuthal DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

LQSD = LQ with Al Dummy Coil • Assembled and tested with many strain

LQSD = LQ with Al Dummy Coil • Assembled and tested with many strain gauges: – Structure: 10 stations at the center of each shell segment – Coils: 6 stations – Each station with y and z gauges with temperature compensators

LQ Shipping & Test prep. • LQSD (LQ w dummy coils) gave us an

LQ Shipping & Test prep. • LQSD (LQ w dummy coils) gave us an opportunity to check handling and transportation (LBNL FNAL) OK to go! 1. 9 K top head Handling & pivoting fixture LQSD Shipping fixture w shock absorbers Dedicated container on dedicated truck DOE Review 09 - FNAL, July 13 -14, 2009 pedestal G. Ambrosio - Long Quadrupole

LQSD LN Test Results • Measured values close to targets • Stress variations in

LQSD LN Test Results • Measured values close to targets • Stress variations in shell smaller than in TQS 02 – Shell roundness is better than in TQS 02 • Stress variations in coils larger than in TQS 02 – Due to shell ID variation (+/- 5 mil) from section to section σy σz MPa MPa Meas. +127 ± 18 +44 ± 14 TQS 02* +154 ± 27 +138 ± 19 Meas. -194 ± 25 +80 ± 24 TQS 02** -142 ± 13 -88 ± 20 Shell Meas. +127 ± 18 +44 ± 14 Target +133 +41 Coil Meas. -194 ± 25 +80 ± 24 Target -225 +66 Rod Meas. +195 ± 21 Target +191 *TQS shell 22 mm thick, LQS shell 20 mm thick DOE Review 09 - FNAL, July 13 -14, 2009 Meas. +195 ± 21 TQS 02*** +113 **TQS coils with Ti poles ***TQS rods made of aluminum G. Ambrosio - Long Quadrupole Note: LQSD has AL coils with higher module than TQS coils

Shell Readiness Reviews • LQS Structure Readiness Review – Hold at LBNL before CM

Shell Readiness Reviews • LQS Structure Readiness Review – Hold at LBNL before CM 12 (April 7, 09) • Recommendations: PASSED • Action items: – Compute with FEM analysis the coil stress variation due to longitudinal ID variations +/- 15 MPa • Next step: LQS 01 pre-assembly review – Possibly the week of July 27 DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Collar-based Structure • The test of a Long Quadrupole with Collar-based structure was in

Collar-based Structure • The test of a Long Quadrupole with Collar-based structure was in the plan approved by the LQ Support Structure Review (Nov. 07) • In the FY 09 budget we planned to complete LQC procurement as back-up ($190 k) • Based on recent DOE guidelines we decided to stop any LQC work. At this point: – Skin and yoke parts have been procured – Assembly tooling has been designed – Collars and tooling have not been procured (~$90 k) DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

TEST PREPARATION DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio -

TEST PREPARATION DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Test Preparation • Quench Detection System with Adaptive Thresholds – To allow using low

Test Preparation • Quench Detection System with Adaptive Thresholds – To allow using low threshold at high current avoiding trips due to voltage spikes at low current – Both DQD and AQD • Symmetric Coil Grounding – To reduce peak coil-ground voltage • LQ needs larger dump resistance than TQ magnets (60 vs 30 m. Ohm) • Active Ground Fault Monitoring System (Proposal) • Reconfiguration of the Magnet Protection System – Additional Heater-Firing-Units for all LQ heaters (16) • Modified Strain Gauge Readout System – To reduce noise and sampling time DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

LQSD Test Experience LQSD (Long Quad w dummy coils) test at LN was very

LQSD Test Experience LQSD (Long Quad w dummy coils) test at LN was very useful and successful for: – Practice LQS handling and connection to VMTF – Cooldown with limited temperature gradient (top-bottom) • 48 hrs of cool down will be necessary for LQS 01 to reach 4. 5 K if T (K) temperature constraint is ΔT<150 K: • Total of 4 days including overnight idling • It will take ~4 times longer if ΔT< 50 K ~ 30 hrs To 200 K – Strain Gauge readout systems • Comparison VMTF and portable LBNL systems: very good agreement Next: Test Readiness Review DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole ΔT=50 K 15 hrs ΔT=150 K 24 hrs

SCHEDULE BUDGET PLANS DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio

SCHEDULE BUDGET PLANS DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

LQS 01 Schedule • LQS 01 pre-assembly Readiness Review: ~July 27 • Start LQS

LQS 01 Schedule • LQS 01 pre-assembly Readiness Review: ~July 27 • Start LQS 01 test: October • Spare/LQS 02 coils in progress DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole 24

Latest FY 09 Budget Original FY 09 budget + carry forward: 2, 487 733

Latest FY 09 Budget Original FY 09 budget + carry forward: 2, 487 733 1, 116 638 +41% increase LQ coil cost: - Estimates with no contingency - FY 09 budget while plan was not defined - $5 M max for magnet R&D DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole 25

“Project” monitoring • Weekly LQ Task Leader meetings (video/phone) – Status, progress, issues –

“Project” monitoring • Weekly LQ Task Leader meetings (video/phone) – Status, progress, issues – All documents on LARP plone https: //plone 4. fnal. gov/P 1/USLARP/Magnet. RD/longquad/ • Expenses monitoring – Based on LARP finance status reports (irregular at year start) Estimated with linear spending in sub-tasks FNAL LQ coil Labor expenses Actual expenses Estimated with all spending at the end of each sub-task DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole 26

FY 10 Plans • Complete LQS 01 test, analysis and disassembly – Estimate: $168

FY 10 Plans • Complete LQS 01 test, analysis and disassembly – Estimate: $168 k (counting on FY 09 carry-forward) • LQS 01 b/02 assembly, test, disassembly & analysis – LQS 01 b = LQS 01 changing one/two coils • If LQS 01 will show limited performance (G < 200 T/m) – LQS 02 = LQS with a new set of coils – I would like to count on • Goal: demonstrate performance reproducibility contingency money for a possible 3 rd LQ test Estimate: $482 k • Complete coils #12 & #13; make two new coils – Estimate: $686 k Meetings, reports, Reviews; – Estimate: $90 k TOTAL FY 10 Budget: $1, 426 k DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

LQ FY 10 Schedule Q 1 • Start LQS 01 b/02 assembly: January 2010

LQ FY 10 Schedule Q 1 • Start LQS 01 b/02 assembly: January 2010 • Start LQS 01 b/02 test: April 2010 • Two spare coils after LQS 01 test feedback DOE Review 09 - FNAL, July 13 -14, 2009 Q 2 G. Ambrosio - Long Quadrupole Q 3 28

Conclusions • Four coils the and shell-structure are ready for the assembly of LQS

Conclusions • Four coils the and shell-structure are ready for the assembly of LQS 01 • The test facility upgrade is almost complete LQS 01 test planned in October 09 Most feedback after the test; nonetheless presently we can say that: – Long coil design and fabrication technology significantly improved – Long shell-structure was successfully assembled and tested at LN DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

Appendix DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long

Appendix DOE Review 09 - FNAL, July 13 -14, 2009 G. Ambrosio - Long Quadrupole

LQS 01 Readiness Reviews • GOAL: Assess readiness for LQS 01 assembly (by evaluating:

LQS 01 Readiness Reviews • GOAL: Assess readiness for LQS 01 assembly (by evaluating: choice of coils, structure, target pre-stress and assembly procedure) and test (test facility and test plan) • #1: “LQS structure and target pre-stress” – April 7, LBNL • #2: “LQ coil design and fabrication” – June 17, FNAL • #3: “LQS 01 pre-assembly” – end of July at LBNL • #4: “Test readiness and test plan” DOE Review 09 - FNAL, July#1 13 -14, 2009 Apr. 7, 2009 LQS 01 Readiness Review – LBNL, G. Ambrosio -–Long Quadrupole Introduction G. Ambrosio 31

Pre-load scenarios and comparison with TQS 02 (scaled) cases ey (293 K) ey (4.

Pre-load scenarios and comparison with TQS 02 (scaled) cases ey (293 K) ey (4. 5 K) σy (293 K) σy (4. 5 K) Microstrain MPa 240 T/m, σpeak_coil = 170 MPa +520 ± 190 +1860 ± 222 +40 ± 15 +165 ± 18 230 T/m, σpeak_coil = 160 MPa +386 ± 190 +1714 ± 222 +29 ± 15 +152 ± 18 220 T/m, σpeak_coil = 150 MPa +252 ± 190 +1567 ± 222 +19 ± 15 +139 ± 18 Shell TQS 02 a +1506 ± 284 +169 ± 30 TQS 02 b +1767 ± 333 +193 ± 37 TQS 02 c +1829 ± 334 +198 ± 43 TQS 02 d +1842 ± 319 +200 ± 37 Ti pole 240 T/m, σpeak_coil = 170 MPa -400 ± 157 -816 ± 231 -57 ± 12 -128 ± 24 230 T/m, σpeak_coil = 160 MPa -295 ± 157 -701 ± 231 -42± 12 -112 ± 24 220 T/m, σpeak_coil = 150 MPa -189 ± 157 -586 ± 231 -27 ± 12 -97 ± 24 TQS 02 a -960 ± 62 Paolo Ferracin -142 ± 13 04/07/2009 32

LQS 01 target pre-stress Scenario 2: pre-load for 230 T/m (13. 2 k. A)

LQS 01 target pre-stress Scenario 2: pre-load for 230 T/m (13. 2 k. A) • Shell – Strain • From 386 to 1714 µε – Stress • From 29 to 152 MPa • Coil pole – Strain • From -295 to -701 µε – Stress • From -42 to -112 MPa • Coil peak stress: 160 MPa Paolo Ferracin 04/07/2009 33