BNL FNAL LBNL SLAC Magnet RD Plan for

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BNL - FNAL - LBNL - SLAC Magnet R&D Plan for 2011 -2013 Gian.

BNL - FNAL - LBNL - SLAC Magnet R&D Plan for 2011 -2013 Gian. Luca Sabbi LARP Collaboration Meeting 15 SLAC, November 1 st, 2010 LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Outline • Magnet R&D Program components • Progress since CM 14 • Preparing for

Outline • Magnet R&D Program components • Progress since CM 14 • Preparing for the 2013 technology selection Ø Ongoing activities (Materials, LQ, HQ) Ø New activities (LHQ, HL-LHC Design study) • MS parallel session organization Ø Working group participants/agenda • Summary LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Program Components 1. Materials R&D: • Strand specification and procurement • Cable fabrication, insulation

Program Components 1. Materials R&D: • Strand specification and procurement • Cable fabrication, insulation and qualification • Heat treatment optimization Ongoing 2. Technology development with Racetrack Coils: • Subscale Quadrupole (SQ) • Long Racetrack (LR) Completed 3. Cos 2 q Quadrupoles with 90 mm aperture: • Technology Quadrupole (TQ) • Long Quadrupole (LQ) Completed ~75% 4. Cos 2 q Quadrupoles with 120 mm aperture: • High-Field Quadrupole (HQ) • Long High-Field Quadrupole (LHQ) LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans ~30% Starting Gian. Luca Sabbi

Magnet Development Chart Completed Ongoing Starting LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans

Magnet Development Chart Completed Ongoing Starting LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Magnet Series SM SQ TQS LQS-4 m LR TQC LARP CM 15, SLAC, 11/1/2010

Magnet Series SM SQ TQS LQS-4 m LR TQC LARP CM 15, SLAC, 11/1/2010 HQ Magnet R&D Plans Gian. Luca Sabbi

Magnet Tests in the last 12 months Dec. 2009 Feb. 2010 LQS 01 a

Magnet Tests in the last 12 months Dec. 2009 Feb. 2010 LQS 01 a (first Long Quadrupole) - FNAL • Achieved target gradient of 200 T/m TQS 03 c (high stress) - CERN • 88% SSL w/200 MPa average coil stress TQS 03 e (cycling) - CERN • No degradation after 1000 cycles ---------------------------------------------- CM 14 May 2010 June 2010 July 2010 Oct. 2010 LARP CM 15, SLAC, 11/1/2010 HQS 01 a (first High-Field Quadrupole) - LBNL • >155 T/m @4. 5 K, already above Nb. Ti limit @1. 9 K HQS 01 b (revised coil-structure shims) - LBNL • First Quench >150 T/m (78%); insulation failure LQS 01 b (revised coil-structure shims) - FNAL • Rapid training to >220 T/m @4. 5 K; retained at 1. 9 K HQS 0 c (two new coils) - LBNL • Insulation OK, but lower quench levels (~135 T/m) Magnet R&D Plans Gian. Luca Sabbi

Next Milestone: 2013 Technology Selection • Consensus within LARP/DOE and with CERN on the

Next Milestone: 2013 Technology Selection • Consensus within LARP/DOE and with CERN on the basic strategy: Ø Aperture: build on existing platforms (90 mm & 120 mm) Ø LQ for reproducibility, length effects, process optimization Ø Short HQ models for high field and accelerator quality Ø Long HQ (LHQ) to demonstrate scale-up of 120 mm design • CERN will proceed with 120 mm aperture, 2 m long Nb. Ti models Ø Direct performance comparison will be a key input for TS • Several critical questions need to be addressed: Ø Accelerator quality targets and platform (1 -m or 2 -m models) Ø LHQ length and strategy for scale-up to production length Ø R&D coordination with CERN, EU, Japan programs • Need official protocol to guide design decisions & R&D priorities Ø A CERN-US working group has been formed to define it LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Materials Procurement and R&D • Conductor Procurement Ø Conductor availability still limiting cable R&D/production

Materials Procurement and R&D • Conductor Procurement Ø Conductor availability still limiting cable R&D/production Ø Significant orders placed in FY 10 – all 108/127, Ta-doped Ø Expect strand inventory ok after 2/2011, cable to follow Ø Rapidly increasing demand (ITER+HEP) is an issue • Cable insulation Ø Fiber Innovation S-glass sleeve was used in all LARP magnets Ø FI production line has been discontinued Ø Several options are being investigated: • For R&D: alternative vendors/materials for sleeve • For production: direct braiding or tape wrap Ø Need to fully qualify one or more alternative solutions LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Cable R&D and Production Significant and positive experience in LARP: TQ (30 UL, 65

Cable R&D and Production Significant and positive experience in LARP: TQ (30 UL, 65 m); LQ (18 UL, 200 m); LR (3 UL, 200 m); HQ (14 UL, 100 m) Good results with 2 -step process: first pass, anneal and re-roll Ø However, labor intensive and difficult to integrate cores Several R&D runs were carried out in FY-2010: Ø Two-pass Ti-doped 108/127 (qualify for future use) - coil 11 Ø One-pass w/pre-annealed wire (lower cost, SS core) - coil 13 Ø One-pass w/SS core (control of dynamic effects) - coil 12 • These cables are being used/tested in HQ 1 -meter coils • Need to converge on a final design for HQ and LHQ LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

LQ Status and Next Steps • Fully reproduce performance of the TQ short models

LQ Status and Next Steps • Fully reproduce performance of the TQ short models Ø Higher gradient (220 T/m in TQS 02, 240 T/m in TQS 03) Ø Fast training (plateau in 5 -10 quenches, no retraining) Ø Clear progress already demonstrated in LQS 01 b • Systematic analysis of coil length effects Ø Detailed modeling of the reaction process Ø Understand/optimize coil strain state after reaction • Design and process optimization for construction Ø Coil size control/reproducibility Ø Protection heater design, esp. for inner layer Ø One-side loading with 4 m keys/bladders Ø Cable insulation techniques for production LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

LQ Plan 2010 -12 LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca

LQ Plan 2010 -12 LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

HQ insulation failure: Review comments • Work is now beginning to understand the causes

HQ insulation failure: Review comments • Work is now beginning to understand the causes of the failure and remedy those causes in the design or in the fabrication procedures. This effort is of course the highest priority of the LARP team and is being approached in that way. • The recent failure of HQ 2 raises an urgent need to understand its origins and modify design or fabrication to remedy them. • The team is responding with urgency and effective organization to this challenge, such failures are part of R&D, and this should be seen as simply a step towards ultimate success. LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

HQ Status and Next Steps Electrical integrity issues: • HQ 01 c test shows

HQ Status and Next Steps Electrical integrity issues: • HQ 01 c test shows that the failure analysis and new QA is working – program can proceed by coil selection and process improvements • HQ 01 c test also confirms focus on coil design and fabrication • In parallel: coil design modifications for improved robustness Short model R&D using baseline, alternative and mirror structures: Ø Feedback on cable/coil design and fabrication Ø Pre-load targets & uniformity, quench performance Ø Quench protection and thermal studies Ø Design features for production and accelerator integration Ø Field quality characterization and optimization Ø Performance verification for 2 half-length coils in one structure LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

HQ Plan 2010 -12 LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca

HQ Plan 2010 -12 LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Status of HQ Scale-up planning • Ongoing planning discussions by LARP magnet steering committee,

Status of HQ Scale-up planning • Ongoing planning discussions by LARP magnet steering committee, Luminosity Task force, CM 14, DOE Review, US-CERN WG • Decision timeline: balance long lead times with the requirement of a strong foundation from technical and programmatic standpoint • Expected magnetic length of HL-LHC IR Quads in the range of 7 -10 m • Full-length quad preferred for project, half-length can be considered • Full-length models not feasible for LARP, especially on TS time scale • Converging on two options: LQ length or slightly above (4. 5 m total) • Key considerations: ØInfrastructure and resource/material availability ØTrade-offs between length, schedule, cost, risk ØIntegration with APUL, DS dipole, base programs LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

HL-LHC WP 3. 2 (Nb 3 Sn Quadrupoles) • 36 man-months over 3 -4

HL-LHC WP 3. 2 (Nb 3 Sn Quadrupoles) • 36 man-months over 3 -4 years • Consistent with FY 11 MS funding allocation (~0. 8 FTE) • WBS options: MS design studies or JIRS LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

From LARP R&D to HL-LHC Construction • Assuming technology decision at the end of

From LARP R&D to HL-LHC Construction • Assuming technology decision at the end of 2013 and installation in 2020 • 3 years for coil fabrication requires 2 production lines of full length coils • 64 full length coils required i. e. one new coil completed every ~2 weeks LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Length considerations for the IR upgrade • HQ short sample gradient is 200 T/m

Length considerations for the IR upgrade • HQ short sample gradient is 200 T/m @ 4. 5 K & 220 T/m @ 1. 9 K • Assume operation at 170 T/m and same basic layout as baseline LHC magnet length is ~7. 4 m (Q 1 & Q 3), 6. 4 m (Q 2 a & Q 2 b) • Half length elements: ~4. 1 m (Q 1/Q 3), ~3. 5 m (Q 2 a/b) w/10% factor Technical comparison: - Full length elements are clearly preferred for optimal IR performance - Full length elements should be less costly for production Ø However, they require new infrastructure - Full length elements need to be demonstrated experimentally Ø This can impact the schedule and decision process - Half-length elements could be considered as a fall-back solution Ø Loss of efficiency is 5 -15% depending on implementation LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

MS Parallel Session Organization Tuesday morning: working group meetings (3+3 sessions): • 9 (8:

MS Parallel Session Organization Tuesday morning: working group meetings (3+3 sessions): • 9 (8: 30) to 10: 30 Ø A 1 A Ø A 1 B Ø A 1 C HQ coil, current design HQ structures Medium term plans Helene Felice Paolo Ferracin Giorgio Ambrosio HQ coil, new design Magnet testing Materials Helene Felice Guram Chlachidze Arup Ghosh • 10: 50 to 12: 20 Ø A 2 A Ø A 2 B Ø A 2 C Tuesday afternoon: WG reports and general discussion Check CM 15 agenda in indico for meeting room and remote connection info LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

Proposed WG participants • A 1 A (HQ coil, current design): Helene Felice (coordinator),

Proposed WG participants • A 1 A (HQ coil, current design): Helene Felice (coordinator), Rodger Bossert, Dan Cheng, Dan Dietderich, John Escallier, Ray Hafalia, Maxim Martchevskii, Fred Nobrega, Tiina Salmi, Jesse Schmalzle, Xiaorong Wang • A 1 B (HQ structures): Paolo Ferracin (coordinator), Mike Anerella, Dariusz Bocian, Shlomo Caspi, John Cozzolino, Paolo Ferracin, Attilio Milanese, Soren Prestemon • A 1 C (Medium term plans): Giorgio Ambrosio (coordinator), Arup Ghosh, Mike Lamm, Gian. Luca Sabbi, Bruce Strauss, Peter Wanderer, Sasha Zlobin, Ezio Todesco • A 2 A (HQ coil, new design): Helene Felice (coordinator), Giorgio Ambrosio, Dariusz Bocian, Rodger Bossert, Shlomo Caspi, Paolo Ferracin, Fred Nobrega, Jesse Schmalzle, Attilio Milanese • A 2 B (Magnet testing): Guram Chlachidze (coordinator), John Escallier, Mike Lamm, Maxim Martchevskii, Joe Muratore, Tiina Salmi, Peter Wanderer, Xiaorong Wang • A 2 C (Materials): Arup Ghosh (coordinator), Emanuela Barzi, Dan Cheng, Dan Dietderich, Soren Prestemon, Gian. Luca Sabbi, Bruce Strauss, Ezio Todesco, Sasha Zlobin LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi

WG Agenda Topics (1/2) A 1 B – HQ Structures • • • Discuss/compare

WG Agenda Topics (1/2) A 1 B – HQ Structures • • • Discuss/compare design features and FEA results for the two structures (follow up from 9/24 video meeting) Possible synergies, e. g. use of new bladders or collared coil in current structure Options/plans for testing two coils in the same structure (to check the performance using half-length coils) Options/plans for a test that will incorporate a pressure vessel over the aluminum shell Heat transfer calculations and design features for improved cooling A 1 C – Medium term plans • • LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans US contributions to the LHC upgrades in Magnet Systems (APUL, LARP, 11 T dipoles): coordination of goals and resources LHQ goals, schedule, effort distribution, budget envelope Selection of a suitable length for LHQ Field quality studies: determine if 1 -m models are sufficient LARP support of HL-LHC design study Options for adding a winding/curing production line for HQ coils Radiation studies Gian. Luca Sabbi

WG Agenda Topics (2/2) A 2 A – HQ Coil, new design A 1

WG Agenda Topics (2/2) A 2 A – HQ Coil, new design A 1 C – Materials • • Conductor characterization/QA. Protocol for verification of as-delivered strand, cable qualification, coil witness samples. Match to LQ/HQ schedule. Work plan at each lab. • Confirm cable production schedule for LQ/HQ in FY 11, matched to conductor delivery and coil fabrication schedule • Status of cored cable R&D, next steps leading to integration in HQ coil fabrication • Cable insulation plan, in particular regarding evaluation and transition to new options • Cables for LHQ (consider two cases, 3. 3 m coil length - same as LQ - and 4 m coil length). Assume 2 UL in FY 11, 4 in FY 12, 4 in FY 13. Are current procurements able to sustain production, in addition to LQ/HQ? Can we get a reasonable yield from the conductor inventory, given typical strand piece length? Based on past experience, what yield can we expect taking into account production issues (crossovers, etc) Discuss/compare design features and FEA results for the two structures • • • Cross-section: how to adapt to new insulation thickness, adjust cable thickness to include core and to account for growth in radial coil size Increased insulation thickness between layers and between coil and parts Changes in end part design for better fit Axial shift to mitigate insulation issues next to end shoes Optimization of end field quality Changes in the inter-layer ramp to increase the true straight section length Schedule for implementing design changes; Target coil number for new design A 1 B – Magnet testing • • • Test requirements for the long HQ (consider two cases, 3. 3 m coil length - same as LQ - and 4 m coil length): possible facilities and required upgrades. Large diameter probes for field quality measurements: probe fabrication, anti-cryostat/header modifications, possibility to perform measurements in LHe. Magnet protection from shorts/ground faults Quench Detection Electrical QA: status, analysis etc. LARP CM 15, SLAC, 11/1/2010 Magnet R&D Plans Gian. Luca Sabbi