BNL FNAL LBNL SLAC Model Quadrupoles DOE Review
BNL - FNAL - LBNL - SLAC Model Quadrupoles DOE Review of the LHC Accelerator Research Program July 13 -14, 2009 Gian Luca Sabbi LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Presentation Outline 90 mm aperture Model Quadrupoles (TQ): • • • Design Features Progress since the last DOE review Next steps 120 mm aperture Model Quadrupoles (HQ): • • LARP DOE Review, July 13 -14, 2009 R&D Goals Coil and Structure Design Status of the HQ 01 model fabrication Work plan through FY 10 Model Quadrupoles Gian. Luca Sabbi, LBNL
LARP Technology Quadrupole (TQ) • Double-layer, shell-type coil • 90 mm aperture, 1 m length • Two support structures: - TQS (shell based) - TQC (collar based) • Target gradient 200 T/m TQC Winding & curing (FNAL - all coils) LARP DOE Review, July 13 -14, 2009 TQS Reaction & potting (LBNL - all coils) Model Quadrupoles Gian. Luca Sabbi, LBNL
TQ Status at the 2008 DOE Review • Two coil/model series using different wire design • 30 coils fabricated, distributed production line • 11 tests performed (FNAL, LBNL and CERN) • Surpassed 200 T/m with 10% margin (TQS 02 a/c) • All training quenches >200 T/m in TQS 02 c/d Issues: TQ 01 OST-MJR 54/61 TQ 02 OST-RRP 54/61 61 Results of TQS 02 c test (CERN) • Variability in the coil production process • Localized degradation, not systematic • Best results achieved by coil selection • Best results are still ~8% below SSL 1. 9 K SSL 4. 4 K For TQS 02 models: • Best results were obtained at 4. 4 K • Quench levels at 1. 9 K were 5 -10% lower LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
TQS 02 c Characterization at 1. 9 K Additional tests performed at CERN in September 2008: 200 T/m Interpretation: conductor instability at 1. 9 K, enhanced by local degradation: • Limiting quenches in the same coil & location (c 23 ramp) at 4. 5 K and 1. 9 K • 1. 9 K stability limit in magnet is lower (half) than expected from strand data LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
TQ Tests with OST-RRP 108/127 Strand Goal: verify conductor performance in a well defined magnet environment TQM 03 Model (FNAL core program) • Magnetic mirror for testing of single coils • Mechanical support through bolted shell • One virgin coil was recently tested: • 1. 9 K quench levels are well above 4. 5 K • Corresponds to expected margin increase TQS 03 Model (LARP + FNAL / LBNL core programs and CERN) • Full quadrupole coil in shell-based structure • Same preload as in previous TQS models • Four virgin coils, under testing at CERN: • Confirm expected improvement 4. 5 K to 1. 9 K • Verify reproducibility over a set of four coils LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
TQS 03 Performance Expectations Model XS Strand Ic Iss (k. A) Bss (T) A (12 T, 4. 4 K) 4. 4 K 1. 9 K TQS 02 555 13. 9 15. 4 12. 5 13. 7 TQS 03 454 13. 0 14. 4 11. 8 12. 9 LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Next Phase: 120 mm Quadrupoles • IR Studies show large aperture quads are required for L=1035 cm-2 sec-1 • Phase 1 (L=2 1034 cm-2 sec-1) will use Nb. Ti Quads with 120 mm aperture • The same aperture was chosen for the next series of Nb 3 Sn models (HQ) Aiming at: • Full qualification based on Phase 1 luminosity requirements • Providing performance reference for Phase 2 upgrade design LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
HQ Progress since the 2008 DOE Review 2008 2009 June July Aug. Sep. Nov. Jan. Feb. Mar. Apr. June July Presented conceptual designs for 114 and 134 mm bore Selection of 120 mm quadrupole aperture for Phase 1 Practice cables fabricated, test windings completed Cable and coil cross-section geometry finalized Winding and curing tooling in procurement 3 D magnetic and coil design completed Mechanical analysis completed, shell in procurement Coil parts, reaction/potting tooling in procurement All structure components in procurement Two cable UL fabricated (modified 54/61) (Practice) coil 1 winding/curing completed Reaction and potting tooling received Three cable ULs fabricated (modified 54/61) Coil 1 reaction and coil 2 winding completed Design and fabrication timeline is comparable to Nb. Ti technology LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
HQ Task Distribution by Laboratory • • • • Cable design and fabrication Magnetic design Mechanical design Coil parts design and procurement Quench protection and heaters Winding and curing tooling design Reaction and potting tooling design Instrumentation traces Coil winding and curing Coil reaction and potting Coil handling and shipping tooling Structure fabrication and test Magnet assembly Magnet test LARP DOE Review, July 13 -14, 2009 Model Quadrupoles LBNL FNAL & LBNL FNAL LBNL & FNAL BNL LBNL & LBNL FNAL Gian. Luca Sabbi, LBNL
HQ Design Features and Parameters • Coil peak field of 15. 1 T at 219 T/m (1. 9 K un-degraded SSL: 19. 5 k. A) • 190 MPa coil stress at SSL (150 MPa if preloaded for 180 T/m) • Stress minimization is primary goal at all design steps (from x-section) • Coil and yoke designed for small geometric and saturation harmonics • Full alignment during coil fabrication, magnet assembly and powering LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Coil and Cable Design Coil parameters: • 120 mm aperture, 2 layer • One wedge in each layer • 46 turns/quadrant Cable parameters: • 35 strands, 0. 8 mm diam. • Width: 15. 15 mm • Mid-thickness: 1. 44 mm • Keystone angle: 0. 750 Cable insulation: • Glass sleeve, 0. 1 mm thick Test windings LARP DOE Review, July 13 -14, 2009 Sub-element deformation Model Quadrupoles Edge facets Gian. Luca Sabbi, LBNL
Magnetic Design and Field Quality • Reference radius 40 mm (2/3 aperture) • Small geometric harmonics (2 wedges) • Saturation b 6 ± 1 unit from 0 to 20 k. A • Optimized for 120 T/m gradient • End design optimized for minimum field • No additional spacers in the ends 120 T/m LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Mechanical Design Main structural components: • Aluminum shell: 25 mm thick, OD = 570 mm (same as LHC dipole) • 4 -split iron yoke • Iron pads provide space for axial rods and cooling channels • Iron masters house 50 mm wide bladders, loading and alignment keys • Aluminum collars align poles while transferring pre-load to the coils LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Mechanical Analysis Pre-loading for 219 T/m Pole contact pressure: • 140 MPa compression at 0 T/m • 20 MPa max. tension at 219 T/m Axial forces: • E. m. force: 1372 k. N • 620 k. N applied at 4. 2 K Mid-plane stress: • 193 MPa at 219 T/m 193 MPa @ 219 T/m LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Heaters and Instrumentation Traces Each layer has two independent heaters , voltage taps, z/q strain gauges Layer 1 heater parameters: (Revised) Layer 2 heater parameters: - 10. 79 mm wide - 2. 166 m long strip per side - Rstrip 300 K = 5. 7 ohms - Rstrip 4. 2 K = 3. 9 ohms - Istrip = 67 A => 75 W/cm 2 at 4. 2 K - 11 mm wide - 2. 213 m long strip per side - Rstrip 300 K = 5. 7 ohms - Rstrip 4. 2 K = 3. 9 ohms - Istrip = 67 A => 75 W/cm 2 at 4. 2 K L 2 heater layout Quench analysis: Heater delay: 15 ms for L 1, 20 ms for L 2 (including propagation time) Assuming 5 ms detection, 10 m/s quench propagation , Rdump=50 m. Ohm Hot spot temperature: 322 K at 4. 2 K SSL, 400 K at 1. 9 K SSL LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Coil and Structure Alignment is controlled at all steps Coil Fabrication: • Winding: mandrel to layer 1 to layer 2 • Alignment keys in curing cavity • Alignment pins for reaction / potting Structure pre-assembly: • Pins between shell and yoke • Aluminum collars and pole keys Assembly and pre-loading: • Master keys maintain alignment Cool-down and excitation: • Pole keys remain in compression LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Accelerator Quality in LARP Models Design Features LR SQ TQS/LQS TQC/LQC Geometric field quality Structure alignment √ Coil alignment √ √ Saturation effects √ √ HQ 1 HQ 2/QA √ √ √ √ Persistent/eddy currents End field margin √ √ Cooling channels √ Helium containment √ Radiation hardness LARP DOE Review, July 13 -14, 2009 √ √ √ Model Quadrupoles Gian. Luca Sabbi, LBNL
Progress on Coil Fabrication Layer 1 Winding Layer 1 Curing Layer 2 Winding LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Progress on Coil Fabrication (2/2) Reaction tooling Preparations for coil transfer Practice coil 1 in reaction tooling LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Practice Coil 1 Reaction • Step 3 temperature is increased from 640 C in TQ to 665 C in HQ • 15 T critical current is about half of 12 T different trade-offs LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Practice Coil Experience In progress: • Improve fitting of outer layer parts • Revised length/angle of flexing cuts • Modifications for heaters, splices Coil-spacer fit Flexing cuts To be addressed: • Step between layers after curing • Axial gaps during winding • End shoe holders during reaction Instrument. wire reliefs Nb 3 Sn-Nb. Ti splice shims LARP DOE Review, July 13 -14, 2009 Layer 1 -2 step after curing Model Quadrupoles Gian. Luca Sabbi, LBNL
HQ Schedule FY 09 -FY 10 LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
HQ Budget in FY 09 and FY 10 FY 09 K$ FNAL LBNL Total Labor M&S FY 08 C. F. 46 5 0 -50 86 50 137 Initial 173 132 737 253 362 177 1834 0 0 0 170 0 -170 0 Mid-year D (%) 0 HQ cabling (Materials R&D): +25 k$ for one additional run (108/127) Some adjustments under discussion for FY 09 -Q 4 to optimize schedule FY 10 K$ Prelim. FNAL LBNL Total Labor M&S 337 164 1227 159 273 22 D (%) 09 -10 2179 +10% Complete HQ 01; HQ 01 b retest (replacing 1 -2 coils); start HQ 02 coils Testing of single coils in the mirror structure is also being considered LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
HQ Optimization toward 2 -meter scale-up HQ 01 models will establish baseline performance: • Mechanical support, quench training • Conductor performance, stress degradation • Quench protection and instrumentation • Field quality In the meantime, Phase 1 requirements will be better defined Parallel studies to understand implications for Nb 3 Sn magnets HQ 02 models will address key areas needing improvement • Field quality (geometric, saturation, magnetization) • Mechanical structure, alignment • Cooling, radiation hardness HQ optimization results will provide a basis for the 2 -m models (QA) LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
Summary TQ Model Quadrupoles: • Surpassed 200 T/m performance target with 10 -15% margin • Provided technology basis for Long Quadrupoles (LQ) • Further optimization and conductor studies are in progress HQ Model Quadrupoles: • Significant increases in field, force and stress levels • Harness the full potential of Nb 3 Sn for the LHC upgrade • Key step forward toward an accelerator quality design • Phase 1 specifications will guide further optimization • Optimized HQ will provide technology basis for 2 -m QA LARP DOE Review, July 13 -14, 2009 Model Quadrupoles Gian. Luca Sabbi, LBNL
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