LHQ STRUCTURE AND PRELIMINARY ASSEMBLY HIGHLIGHTS CM18 FNAL

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LHQ STRUCTURE AND PRELIMINARY ASSEMBLY HIGHLIGHTS CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient

LHQ STRUCTURE AND PRELIMINARY ASSEMBLY HIGHLIGHTS CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 1

CONTENTS 1. 0 Overview 2. 0 Coil Pack Sub-Assembly 2. 1 2. 2 2.

CONTENTS 1. 0 Overview 2. 0 Coil Pack Sub-Assembly 2. 1 2. 2 2. 3 Components Coil handling Assembly sequence 3. 0 Shell / Yoke Structure Sub-Assembly 3. 1 3. 2 3. 3 3. 4 Components Segment sub-assembly (basic) Segment sub-assembly (alternate method) Full-length assembly 4. 0 Magnet Assembly 4. 1 Coil axial preload highlights. 4. 2 Coil-Coil splice box (“Pizza-box”) installation. 5. 0 Outstanding Issues 6. 0 Next Steps CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 2

OVERVIEW LHQ - 3. 8 meter longitudinal extension of the 1 meter HQ Magnet.

OVERVIEW LHQ - 3. 8 meter longitudinal extension of the 1 meter HQ Magnet. - LQ assembly experiences and lessons-learned – applied. - Basic Structural Design: 4 -segment shell assembly. (as in LQ). - As an alternate design, a 3 -segment design is being considered (shown in this presentation). - Structurally, more efficient. - Less assembly tooling. - To validate this design, analysis required to rule out risk of axial “slippage” hindering desired stress distribution at cool down – inherent in long shell structures (LR Magnet). CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 3

COIL PACK SUB-ASSEMBLY 1. 0 Overview 2. 0 Coil Pack Sub-Assembly 2. 1 2.

COIL PACK SUB-ASSEMBLY 1. 0 Overview 2. 0 Coil Pack Sub-Assembly 2. 1 2. 2 2. 3 Components Coil handling Assembly sequence 3. 0 Shell / Yoke Structure 3. 1 3. 2 3. 3 3. 4 Components Segment sub-assembly (basic) Segment sub-assembly (alternate method) Full-length assembly 4. 0 Magnet Assembly 4. 1 Coil axial preload highlights. 4. 2 Coil-Coil splice box (“Pizza-box”) installation. 5. 0 Outstanding Issues 6. 0 Next Steps CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 4

COIL PACK COMPONENTS LOAD PAD-STACK (IRON & STAINLESS STEEL) COIL ALIGNMENT KEYS (G 10,

COIL PACK COMPONENTS LOAD PAD-STACK (IRON & STAINLESS STEEL) COIL ALIGNMENT KEYS (G 10, FULL LENGTH OF COIL) COLLAR-STACK (ALUMINUM) CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 5

ASSEMBLING THE COIL PACK HANDLING IMPREGNATED LHQ COILS LQ COIL (OUTER) LIFTING STRONGBACK WITH

ASSEMBLING THE COIL PACK HANDLING IMPREGNATED LHQ COILS LQ COIL (OUTER) LIFTING STRONGBACK WITH ADAPTER-BLOCKS FOR LHQ COILS’ OD (Note: Coil alignment keys not yet installed) LQ COIL (INNER) LIFTING STRONGBACK WITH ADAPTER-BLOCKS FOR LHQ COILS’ ID - Adapter blocks were designed to raise the coil above the work surface to facilitate the insertion of the attaching screws. (Lesson learned from LQ). CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 6

COIL PACK ASSEMBLY SEQUENCE - -Once the bottom-2 coil quadrants are placed, their alignment

COIL PACK ASSEMBLY SEQUENCE - -Once the bottom-2 coil quadrants are placed, their alignment keys top-2 areisplaced on the assembly and on the -After Before thecoil topquadrants collar-stack installed, “Fuji-Paper” tests are installed. alignment “donuts”, theirifcoil alignment keys are installed. performed to ascertain acceptable contact is attained between the collar-stack ID and the coil OD, as well as the collar sides and - -Teflon, cylindrical, alignment “donuts” (not shown) are and set on The collar-stacks arewhen bolstered coils thethe theside coil alignment keys collar against bolts arethe torqued. bottom-2 quadrants’ atengaged the ends, – to guide the placement and bottom row of collar. ID’s, bolts but not torqued. - Changesofinthe G 10 collar shim thickness’ can be considered. alignment top-2 quadrants. - At this point, as the collar-stacks are placed, the coil straingauges are hooked-up and monitored. COIL PACK ASSEMBLY-BASE -Bottom loadpad-stack -Bottom collar-stack. G 10 SPACER/INSULATOR - Part of each collar-stack CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 7

COIL PACK SUB-ASSEMBLY CONTINUITY IN ALIGNMENT: 1. 2. The coils, through the coil-alignment keys,

COIL PACK SUB-ASSEMBLY CONTINUITY IN ALIGNMENT: 1. 2. The coils, through the coil-alignment keys, are indexed by the ends of the bolted and torqued collars. The faceted collars are indexed by matching facets in the load pads. LOAD PADS COLLARS COIL-ALIGNMENT KEY CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 8

1. 0 Overview 2. 0 Coil Pack Assembly 2. 1 2. 2 2. 3

1. 0 Overview 2. 0 Coil Pack Assembly 2. 1 2. 2 2. 3 Components Coil handling Assembly sequence 3. 0 Shell / Yoke Structure 3. 1 3. 2 3. 3 3. 4 Components Segment sub-assembly (basic) Segment sub-assembly (alternate method) Full-length assembly 4. 0 Magnet Assembly 4. 1 Coil axial preload highlights. 4. 2 Coil-Coil splice box (“Pizza-box”) installation. 5. 0 Outstanding Issues 6. 0 Next Steps CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 9

SHELL / YOKE SEGMENT SUB-ASSEMBLY STRAIN-GAGE INSTRUMENTED ALUMINUM SHELL SEGMENT 43. 95” [1. 10

SHELL / YOKE SEGMENT SUB-ASSEMBLY STRAIN-GAGE INSTRUMENTED ALUMINUM SHELL SEGMENT 43. 95” [1. 10 m] long SEGMENT-LENGTH, YOKE TIE-RODS (PRE-TENSIONED WITH HYDRAULICS) ALIGNMENT BUSHING (IRON) - Aligns laminations YOKE LAMINATION (IRON) - 2. 00” [50. 8 mm] thick TAPERED ALIGNMENT PINS (Indexes grooves in yoke-stacks to precisionmachined grooves in shell ends. Also, the protruding pins facilitates segment-tosegment alignment at final assembly) IRON YOKE STACK (4 PER SEGMENT) 44. 00” [1. 11 m] long CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 10

SHELL / YOKE SEGMENT PRELOADING SEGMENT-LENGTH MASTER KEY SUB-ASSEMBLIES SEGMENT-LENGTH COIL PACK SUB-ASSEMBLY (Assembled

SHELL / YOKE SEGMENT PRELOADING SEGMENT-LENGTH MASTER KEY SUB-ASSEMBLIES SEGMENT-LENGTH COIL PACK SUB-ASSEMBLY (Assembled with a “DUMMY COIL” made of a machined aluminum tube. ) (4 Sub-assemblies) YOKE-GAP KEYS SHELL & YOKE STACKS WILL BE PRELOADED WITH SEGMENTLENGTH, WATER-PRESSURIZED BLADDERS (During bladder operations, the shell strain gauges are monitored to see if the nominal shell preload strain has been attained. ) (Inserted during pressurization and shimmed to lock yokestacks against the shell after bladders are depressurized - 4 each) SEPARATE SHELL AND 4 PREASSEMBLED YOKE STACKS CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 11

SHELL / YOKE SEGMENT PRELOAD ALTERNATE METHOD YOKE-GAP KEYS HYDRAULIC CYLINDER ARRAY (4 quadrants

SHELL / YOKE SEGMENT PRELOAD ALTERNATE METHOD YOKE-GAP KEYS HYDRAULIC CYLINDER ARRAY (4 quadrants of nine, 5 ton pancake cylinders) (Inserted during pressurization and shimmed to lock yokestacks against the shell after cylinders are depressurized - 4 each) YOKE PUSHERS (Machined aluminum blocks – 4 each) SEPARATE SHELL AND 4 PREASSEMBLED YOKE STACKS TAPERED ALIGNMENT PINS (To index yoke-stacks to matching grooves at shell ends. also used for segment-segment alignment – 4 each) CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 12

FULL-LENGTH SHELL / YOKE FINAL ASSEMBLY PROCESS: 1. Assembly is performed on an 8’x

FULL-LENGTH SHELL / YOKE FINAL ASSEMBLY PROCESS: 1. Assembly is performed on an 8’x 12’ granite surface plate. 2. All segment-length yoke tie-rods are removed. 3. The segment 2 air pallet is energized and segment 2 is maneuvered behind segment 1 to engage alignment pins. 4. Segment 3 is maneuvered behind segment 2 and alignment pins engaged. 5. All eight, full-length, yoke rods are inserted through all 3 segments and a hydraulic fixture is used to draw all segments together simultaneously and tension the rods. AIR-BEARING PALLETS CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 13

COIL PACK INSERTION IN SHELL / YOKE STRUCTURE LOAD KEYS (2) & ALIGNMENT KEY

COIL PACK INSERTION IN SHELL / YOKE STRUCTURE LOAD KEYS (2) & ALIGNMENT KEY (1) Provides alignment continuity between coil pack and shell/yoke structure. MASTER KEY SUB-ASSEMBLY (Eight 1. 6 m subassemblies) SHELL/YOKE SUB-ASSEMBLY COIL PACK SUB-ASSEMBLY CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 14

1. 0 Overview 2. 0 Coil Pack Assembly 2. 1 2. 2 2. 3

1. 0 Overview 2. 0 Coil Pack Assembly 2. 1 2. 2 2. 3 Components Coil handling Assembly sequence 3. 0 Shell / Yoke Structure 3. 1 3. 2 3. 3 3. 4 Components Segment sub-assembly (basic) Segment sub-assembly (alternate method) Full-length assembly 4. 0 Magnet Assembly 4. 1 Coil axial preload highlights. 4. 2 Coil-Coil splice box (“Pizza-box”) installation. 5. 0 Outstanding Issues 6. 0 Next Steps CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 15

COIL AXIAL PRELOAD ASSEMBLY – LEAD END PROCESS: ENDPLATE ASSEMBLY - End Plate Assembly

COIL AXIAL PRELOAD ASSEMBLY – LEAD END PROCESS: ENDPLATE ASSEMBLY - End Plate Assembly (with set-screw “bullets” installed) is assembled on axial rods so that the bullets contact the coil ends. The bullets are adjusted to orient the end plate parallel to the end of the coil pack. - Nuts and jam nuts are installed to secure the rods – axially. STRAIN-GAGE INSTRUMENTED AXIAL RODS (145. 9” [3. 71 m], 316 L stainless steel, 4 each) CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 16

COIL AXIAL PRELOAD ASSEMBLY – RETURN END PROCESS: - End Plate Assembly (with set-screw

COIL AXIAL PRELOAD ASSEMBLY – RETURN END PROCESS: - End Plate Assembly (with set-screw “bullets” installed) is assembled on axial rods so that the bullets contact the coil ends. The bullets are adjusted to orient the end plate parallel to the end of the coil pack. - Nuts and jam nuts are installed to secure the rods – axially. SET SCREW “BULLET” CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 17

COIL AXIAL PRELOAD – RETURN END AXIAL ROD TENSIONER RIG (25 TON CYLINDER) PROCESS:

COIL AXIAL PRELOAD – RETURN END AXIAL ROD TENSIONER RIG (25 TON CYLINDER) PROCESS: - The instrumented axial rods’ strains will be monitored during this process. - Hydraulic cylinder pushes against the backplate (tensioning the axial rods) and reacts against the return endplate, whose bullets push against the coil ends. - At the lead end of the magnet, the tensioned rods pull the lead endplate assembly against the coil ends. CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 18

COIL –COIL SPLICE BOX (“PIZZA-BOX”) INSTALLATION SUPPORT STRUT (Four G 10 assemblies) The struts

COIL –COIL SPLICE BOX (“PIZZA-BOX”) INSTALLATION SUPPORT STRUT (Four G 10 assemblies) The struts clamps, supports and guides each Nb. Ti coil lead into the pizza-box. CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 19

COIL –COIL SPLICE BOX (“PIZZA-BOX”) INSTALLED CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient

COIL –COIL SPLICE BOX (“PIZZA-BOX”) INSTALLED CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 20

1. 0 Overview 2. 0 Coil Pack Assembly 2. 1 2. 2 2. 3

1. 0 Overview 2. 0 Coil Pack Assembly 2. 1 2. 2 2. 3 Components Coil handling Assembly sequence 3. 0 Shell / Yoke Structure 3. 1 3. 2 3. 3 3. 4 Components Segment sub-assembly (basic) Segment sub-assembly (alternate method) Full-length assembly 4. 0 Magnet Assembly 5. 0 Outstanding Issues 6. 0 Next Steps CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 21

OUTSTANDING ISSUES (FOR DISCUSSION) 1. COLD-MASS COOLING PROVISIONS 1. 1 Bore cooling holes through

OUTSTANDING ISSUES (FOR DISCUSSION) 1. COLD-MASS COOLING PROVISIONS 1. 1 Bore cooling holes through pole segments and coil-alignment keys. (Each Coil) 1. 1. 1 Area criteria required - affecting size of each coil’s outer layer keyway width and depth (impacting pole segment profile, alignment key design & collar profile). 1. 2 Distribution in cold-mass 1. 2. 1 Area criteria required – possibly affecting final cross-section profiles in yokes & load pads. Nominal Diameter: 2. 00” [50. 8 mm] Nominal Diameter: ~1. 5” [38. 1 mm] (maximum per quadrant) (2 holes per yoke-stack) CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 22

OUTSTANDING ISSUES - ADDRESSED (FROM YESTERDAY’S WORKING GROUP 3) 1. COLD-MASS COOLING PROVISIONS –

OUTSTANDING ISSUES - ADDRESSED (FROM YESTERDAY’S WORKING GROUP 3) 1. COLD-MASS COOLING PROVISIONS – from 05/08 working group 1. 1 Bore cooling holes through pole segments and coil-alignment keys. (Each Coil) - No area criteria required – will use available holes in present design. 1. 2 Decision not to address the cooling holes for heat exchanger in the structure. 1. 3 Goal: demonstrate capability to insure adequate ground plane insulation. Important to set a target hi-pot voltage in agreement with CERN. CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 22 A

NEXT STEPS - Analyses to be performed - Shear analyses on coil alignment key

NEXT STEPS - Analyses to be performed - Shear analyses on coil alignment key to determine if a wider key is required. (Related issue of larger diameter bore cooling holes or segmented key. - Stress distribution analyses on the shell segment length to validate the 3 -segment assembly. - Implement suggested cooling and insulation features brought out in the Working Group – within the parameters of the LHQ goals. - Discussions with forum CM-18 FNAL LHQ 01, 3. 8 m Hi-gradient Quadrupole Ray Hafalia, Jr. 23