BNL FNAL LBNL SLAC LARP Magnet Systems Summary
BNL - FNAL - LBNL - SLAC LARP Magnet Systems Summary and HL-LHC Plans Gian. Luca Sabbi DOE Review of the LARP Program June 1 st, 2011 DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
R&D Status - Conductor Strand design and fabrication: + RRP 54/61 provided a good basis for LARP magnet R&D + New RRP 108/127 shows improved stability - Limited performance windows and engineering space - Only one source and procurement lead time is 12 (15) months - Relatively short minimum piece length (ok for present needs) - R&D toward improved strands is underway, but time is limited Cable design and fabrication: + Three cable designs developed (LR, TQ/LQ, HQ) + Fabricated ~8 km of cable with minimal losses: TQ (30 UL, 65 m); LQ (18 UL, 200 m); LR (3 UL, 200 m); HQ (14 UL, 100 m) - Significant progress in demonstrating cored cables for control of inter-strand resistance but not yet incorporated in quadrupole DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
LARP Conductors Three strand designs, all from Oxford Superconducting Technology: • MJR 54/61: TQS 01, TQC 01, SQ • RRP 54/61: LR, TQ 02, LQS 01(2), HQ 01 a/b/c/d • RRP 108/127: TQS 03, HQ 01 a/b/c/d, (LQS 03) RRP 54/61: J Production wire, highest Jc, long piece length, best characterized Large sub-elements, flux jumps esp. in larger diameter wires RRP 108/127: J Deff reduced by 30%, very good results in TQS 03 Lower Jc for same RRR, not fully optimized for production Limited time window (~2 years) to incorporate new designs: • Ti-doped RRP: HQ cable/coil fabricated for evaluation • RRP 217: Requires R&D but strand is available for a coil DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
R&D Status – Mechanical Issues Support structure and macroscopic properties: + Detailed FEA modeling capabilities and high quality SG data Mechanical support issues are quickly understood and corrected Examples: Ti poles (TQ), segmented shell (LR), coil oversize compensation (LQ), alignment shims and stress uniformity (HQ) Stress limits: + Excellent performance in TQS 03 up to ~200 MPa average + No degradation in TQS 03 after 1000 current cycles - Several cases of stress-induced degradation and instability Microscopic properties and strain state: - No quantitative modeling of the reaction process (incl. properties) - Effect of design/fabrication changes cannot be accurately predicted Need to allow time for iterations in developing new designs DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
TQ Mirror study: stress-driven instability TQM 03 uses RRP 108/127 conductor TQM MIRROR FNAL core program Predicted Cold stress (MPa) TQM 01 90 TQMO 2 110 TQM 03 a 100 TQMO 3 b 145 TQM 03 c 185 DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
R&D Status – Quench Performance Quench performance and training: + Optimized models approach (un-degraded) conductor limit + Fast training in optimized models - New designs generally require significant optimization work + Steady progress through systematic analysis and correction Quench protection: + Key parameters are known and understood Propagation, detection & heater delays, peak temperatures + Steady improvements in modeling and heater fabrication - Protection is intrinsically challenging - Quench process in superfluid He may compromise heaters on ID DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Pole Turn Quench Precursors DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
R&D Status – Accelerator Integration Alignment and field quality: - No coil alignment in LR, TQ, LQ models Neither during fabrication nor at assembly/excitation + Coil alignment features introduced in HQ models + Successful HQM test of cored cable to limit eddy currents Radiation and thermal management: + Thermal margins are intrinsically high compared to Nb. Ti - Heat transfer is limited due to epoxy impregnation - Epoxy is also the weak point in terms of radiation damage CTD 403 (cyanate ester) will be introduced in HQ coils + Field/aperture margin can be effectively used for absorbers DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Accelerator Quality in LARP Models Design Features LR SQ TQS/LQS TQC HQM Geometric field quality Structure alignment √ Coil alignment √ √ Saturation effects √ √ Persistent/eddy currents End field margin HQ 01 HQ 02/LHQ √ √ √ √ Cooling channels √ √ Helium containment √ √ Radiation hardness DOE Review, June 1, 2011 √ Summary and HL-LHC Plan √ Gian. Luca Sabbi
R&D Status – Production Readiness Magnet fabrication: + Demonstrated distributed production, extensive shipping + Successful length scale up in LR (x 10) and LQ (x 4) - Insulation failure in recent HQ 01 b test Controlled by improved QA in HQ 01 c (ok for near term) Next: design changes focusing on reliability vs. performance Series Production - Larger billet size for throughput and cost (10 tons in 4 years) - Increased piece length for efficient strand use Required cable UL is ~1 km for full length quadrupoles - Need 8 -10 m coil fabrication infrastructure for full length quads …and two coil production lines to meet production schedule DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
2010 Review Comments - Planning • Develop a strategic plan that supports the LHC schedule, and meets the FY 11 budget; and work with DOE and CERN to establish a formalism for the dialog and protocol which will provide the needed specifications in time to meet agreed upon milestones. Ø Establish a dialogue with CERN to address and settle the quadrupole length question, then prepare a detailed proposal to DOE for a long HQ project. Ø Request a letter from CERN to DOE stating that Nb 3 Sn Technology is the primary candidate for IR Quadrupoles of LHC Upgrade Project. Ø Initiate an aggressive request for funding to respond to the pre-project stages of the LHC Upgrade Project. • Additional rigor is needed (…) to decide when to move into a production (or project) phase, and to delineate funding between the two activities. • DOE should develop a protocol such that requests for collaboration, that are out of the existing list of LARP projects, can be responded to. DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
R&D and Construction Planning • A CERN-US working group was established in August 2010: ØComposition: 3 US (BNL, FNAL, LBNL) and 2 CERN members • Goals: Ø Discuss requirements and development plans for Nb 3 Sn Ø Present recommendations to LARP, DOE, CERN management • Report circulated and approved after minor changes • Main topics covered: Ø Magnet tests and success criteria for technology demonstration Ø Contributions from US and CERN in the next R&D phase Ø Infrastructure requirements for prototyping and production Ø Baseline and backup options for final design and production DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Technology Selection Strategy General approach and main R&D components: • • Build on existing platforms (90 mm & 120 mm aperture) 4 -meter long LQ for reproducibility, length effects, process optimization 1 -meter long HQ models for high field and accelerator quality 4 -meter long LHQ to demonstrate scale-up of 120 mm design Success criteria: • • • Target operational quench level will be defined as 80% of SSL Achieve operational level in 3 quenches, and +10% in 10 quenches After thermal cycle, achieve operational level at first quench Technical guidelines for field quality measurements were provided Detailed field quality requirements from HL-LHC Design Study CERN will proceed with 120 mm aperture, 2 m long Nb. Ti models • Direct performance comparison will be a key input for TS DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
CERN participation Several key contributions by CERN were agreed to as part of this plan: R&D and design phase: • HL-LHC Design Study: o Finalize basic requirements (esp. aperture) by end of 2012 o Radiation and heat transfer studies • Conductor and materials development (with EU programs) • Participation in HQ model testing, assembly and fabrication (preparation for prototyping and production) Infrastructure and prototyping phase: • Procure 10 m coil infrastructure at CERN by 2013 (already planned) • Full length prototype will be built by a combined US-CERN team with target completion by the end of 2015 Production and installation phase: • CERN to participate in production & lead integration/installation DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Design Study (Nb 3 Sn Quadrupoles) Proposal approved by EU in April 2011 • 54 man-months over ~4 years • FY 11 MS funding allocation includes ~0. 7 FTE • WBS: MS design studies • Studies of radiation impact on magnet components are a key area of work for WP 3 • Energy deposition analysis is part of LARP/AS scope DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Quadrupole Design Optimization High field technology provides design options to maximize luminosity DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
LHC Schedule DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
IR Quad Schedule • Coil fabrication drives production schedule. Assuming 2 parallel lines, 64 full length coils • DOE approval process (CD-n reviews) should start soon to allow project start in 2015 DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
IR Quad Aperture, Gradient and Length • While DS will finalize IR design and magnet parameters, some initial reference is needed to guide both the DS and near term magnet R&D • Assuming 120 mm aperture, 170 T/m gradient, current layout: magnet length is ~7. 4 m (Q 1 & Q 3), 6. 4 m (Q 2 a & Q 2 b) • If aperture increases to 150 mm magnet length increases to about 10 m • Full length elements are clearly preferred for optimal IR performance and should be more efficient to fabricate (cost and time) • However, they pose a challenge because of new infrastructure required and need for experimental demonstration on the relevant time scale Accounted for in the proposed schedule and decision process • Half-length elements may represent a viable backup solution R&D to include a test of two 1 m coils in the same structure DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Construction Schedule Considerations • Define production line: complete set of winding, curing, reaction, potting infrastructure, tooling, crew for full-length (8 -10 m) coils • Assuming that a production line delivers one coil every four weeks: 64 coils ~8 m long: ~5 years with 1 production line ~2. 5 years with 2 production lines • One year from coil production to magnet production completion • One additional year for spares (assume 20 magnets, 80 coils) Ramp-up time will depend on availability of infrastructure and conductor: • Preliminary estimate for infrastructure upgrades for 1 production line (BNL): 2. 8 M$ for 6 m coil fabrication; 3. 5 M$ for 8 m coil fabrication • Conductor procurements for prototypes and production start need to start ~2 years early (long lead time, cabling/test, limited production volume) DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
FY 11 Budget (10/1) and Expenses (4/30) DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Mid-Year Budget Revision (DS+HQ) DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Mid-Year Budget Revision (LQ & LHQ) DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Mid-Year Budget Revision • Significant redistribution and prioritization to align funding with evolving requirements (HQ corrective actions and LHQ start after length decision) • Mid-year contingency request included priority 1 items • Priority 2 -3 will become part of the FY 12 plan DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Initial (2010) LHQ Cost Estimate* * Need to update based on detailed design and latest plan DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Medium Term Budget Scenarios • LARP MS at FY 09 level (~6. 9 M$) FY 12 -15 • Augmented: FY 09 level +8 M$ (total) FY 12 -15 -700 k$ FY 09 -11 ? DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
Summary • A large knowledge base is available after 6 years of fully integrated effort involving three US Labs and CERN - Steady progress in understanding and addressing R&D issues • The Nb 3 Sn development plan aims at demonstrating readiness for a technology decision and construction initiation in 2015 • Systematic testing of LARP Nb 3 Sn models and CERN Nb. Ti models will provide a direct comparison for the technology selection • Key elements of the R&D and construction plan have been discussed, and recommendations presented to US and CERN management • The plan includes close participation and direct contributions by CERN • Detailed planning and approval process needs to start in the near future to allow upgrade project start in 2015 DOE Review, June 1, 2011 Summary and HL-LHC Plan Gian. Luca Sabbi
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