Long Coil Manufacturing Plan and QA/QC by US HL-LHC-AUP Fred Nobrega / Jesse Schmalzle International Review of the MQXF Inner Triplet Quadrupoles for HL-LHC CERN, June 7-10, 2016

logo area Outline of Talk  Coil requirements & specification  Manufacturing plan Project Coil  Quality Assurance / Quality Control  Risks and mitigation plans Fred Nobrega - MQXF International Review, June 7–10, 20162

 MQXFA Functional Requirements US HiLumi DocDB #36  MQXF Design Report 1 st generation design: LARP DocDB # nd generation design in progress  MQXFS/A tests  MQXF Coil Requirements Come from documents and results noted above and is currently being developed 3 Requirements Fred Nobrega - MQXF International Review, June 7–10, 2016

logo area Coil Requirements  Field Quality # of turns, parts and insulation dimensions as per Design Report and Drawings  Radiation hardness All materials should withstand 30 Mgy  Splice resistance < 1.5  ohm Using CERN approved materials  Quench detection and protection Two voltage taps across each Nb 3 Sn-NbTi splice o Prototypes use more voltage taps Quench heaters on outer and inner surface of coil Fred Nobrega - MQXF International Review, June 7–10, 20164

logo area Coil Requirements  Cooling Provisions: Polyamide-free area: 40% inner coil surface Free passage through the coil pole and subsequent G-10 alignment key equivalent of 8 mm diameter holes repeated every 50 mm  Overall dimensions: Overall tolerance: TBD o CMM data + FEM + MQXF tests  Req. Left-Right asymmetry tolerance: TBD o CMM data + FEM & FQ Simul. + MQXF tests  Req. Fred Nobrega - MQXF International Review, June 7–10, 20165

logo area Coil Requirements  MQXF Functional Req. not finalized  Electrical QA plan (draft) LARP DocDB #1111 o Coil-Heaters HiPot: 2.5 kV o Impulse test: 2.5 kV Fred Nobrega - MQXF International Review, June 7–10, 20166

logo area Project Manufacturing Plan Overview  Coil fab at both FNAL and BNL  ship to LBNL  Magnet assembly at LBNL, ship to BNL for cold test then shipped to FNAL.  FNAL assembles and tests cold mass then ships to CERN to cryostat. Fred Nobrega - MQXF International Review, June 7–10, Magnets Liquid Helium Containment Vessel Cold Mass Assembly

logo area Manufacturing Plan Fred Nobrega - MQXF International Review, June 7–10, FY17FY18 FY19FY20 FY21FY22 FY23FY24 FNAL Coils BNL Coils LBNL Structure Assembly BNL Vertical Test FNAL Cold Mass Assembly FNAL Cold Mass Test Delivery to CERN LARP Project OCT 2016 Today

logo area FNAL Production Coils Fred Nobrega - MQXF International Review, June 7–10, FY18 FY19 FY20FY21 FY22 LARP Rate (1 coil every 50 days) Intermediate Rate (1 coil every 25 days) Peak Rate (1 coil every 16 days) Add Tooling + Techs

logo area Coil Fabrication Steps and Tooling Usage Fred Nobrega - MQXF International Review, June 7–10,  Series Production Estimate: It takes an average of 2 technicians working 80 days to fabricate a coil (~0.7 FTE-years)

logo area Coil Production Rate Analysis  Number of concurrent steps depend on tooling and number of technicians  Two production sites are used (BNL and FNAL)  Production Rate (per site) LARP Rate: 1 coil every 50 working days per site Increase rate x2: add 1 reaction tooling set, 1 impregnation tooling set, and 3.6 FTEs of technicians Increase rate x3.1: add one mandrel, 2 reaction tooling sets, 1 impregnation tooling set, and 7.7 FTEs o This is the Peak rate assumed for project (1 coil every 16 days per site) 11 LARP Rate Peak Project Rate Fred Nobrega - MQXF International Review, June 7–10, 2016

logo area Coil Winding Assembly Drawing Fred Nobrega - MQXF International Review, June 7–10,

logo area Coil Parameters  2 layer spliceless cos-theta coil with inner/outer radius of 75/ mm, with cable using 40 x 0.85 mm strand and is mm wide.  QXFA magnetic length is K. Fred Nobrega - MQXF International Review, June 7–10,

logo area Coil Winding and Curing  6 coils wound and cured at Fermilab. Cable tension kg depending on turn.  Curing cycle 150° C for 90 minutes in closed cavity with CTD-1202X ceramic binder. Fred Nobrega - MQXF International Review, June 7–10,

logo area BNL Winding & Curing Tooling Status Fred Nobrega - MQXF International Review, June 7–10,  Winding machine and curing press exist.  QXF winding and curing tooling preliminary design complete.  Detailed W/C tooling design planned for FY17.  Tooling fabrication planned for FY17.

logo area Coil Reaction  Reaction cycle is in an argon atmosphere and at 210° C for 72 hours, 400° C for 48 hours and 650° C for 48 hours. The heat treatment lasts about 9 days including ramp up and cool down. Fred Nobrega - MQXF International Review, June 7–10,

logo area BNL Reaction Tooling Status  Reaction oven extension is needed to accommodate 4.2m coils. Extension fabrication is well underway, expected delivery is mid June. Existing Oven Extension under fabrication Fred Nobrega - MQXF International Review, June 7–10,

logo area Coil Impregnation  Impregnation is with CTD101K in the 7 m long IB2 vacuum oven at  m Hg with epoxy temperature of 60  C.  Curing is the same oven at 125  C for 16 hours using external heaters mounted on the tooling. Fred Nobrega - MQXF International Review, June 7–10,

logo area BNL Impregnation Tooling Status  Existing vertical impregnation station will accommodate 4.2 m coils.  Existing fixture lifting / rotating beams are suitable for 4.2 m coils. Fred Nobrega - MQXF International Review, June 7–10, Impreg fixture being lowered into vacuum tank

logo area FNAL Production Status  Fabrication of 2 prototype (4m) coils are in progress (QXFP03 & QXFP05). QXFP03 is being prepped for impregnation. QXFP05 is being prepped for reaction. Fred Nobrega - MQXF International Review, June 7–10,

logo area FNAL Production Status  QXFA101, first 4.2 m coil Cabling complete and being sent to vendor for insulation braiding. Coil winding mandrel rework for longer length Winding at to begin in July Fred Nobrega - MQXF International Review, June 7–10,

logo area BNL Production Status  Reaction and Impregnation of 2 prototype (4m) coils has been competed (QXFP01 & QXFP02). QXFP01 is assembled in the mirror. QXFP02 is one of the coils planned for the first magnet assembly.  Reaction of a 3 rd coil has been completed (QXFP04), prep for impregnation work is underway. Fred Nobrega - MQXF International Review, June 7–10, (Parts procurement & Winding and Curing at FNAL)

logo area BNL Tooling Status  Existing coil lifting beam is suitable for 4.2 m coils.  Existing coil shipping fixtures (2) will accommodate 4.2 m coils. Fred Nobrega - MQXF International Review, June 7–10,

logo area Quality Assurance / Quality Control Fred Nobrega - MQXF International Review, June 7–10,

logo area Traveler’s & Discrepancy Repots  All major fabrication steps are in travelers. The level of detail varies with the operation complexity.  Discrepancy reports (DR) are generated whenever a step within traveler is not met, a parameter is out of range, or if damage is observed to coil or tooling.  DR’s are used to help prevent future occurrences of the event and to document lessons learned. Fred Nobrega - MQXF International Review, June 7–10,

logo area Coil QXFP01A CMM  Each box is 100 microns (4 mils)  Inspected cross sections include strain gauge locations and end regions. Fred Nobrega - MQXF International Review, June 7–10,

logo area Sample CMM Wedge Inspection Fred Nobrega - MQXF International Review, June 7–10, SURFACE PROFILE 1054 MM FROM END EXAGGERATION X 100 EACH SQUARE=.010  m

logo area Sample CMM Wedge Inspection Fred Nobrega - MQXF International Review, June 7–10, SURFACE PROFILE 533 MM FROM END EXAGGERATION X 100 EACH SQUARE=.01  m

logo area Operating Procedures  Controlled documents  Revision change tracking  Reviewed and approved Hazard Analysis and Operational Readiness Clearances used as needed for new or changed equipment. Fred Nobrega - MQXF International Review, June 7–10,

logo area Project Risk Mitigation Planning  Currently have a risk register & mitigation plan Iterative and evolving, part of coil portion shown. Fred Nobrega - MQXF International Review, June 7–10, Coil CO-01AmbrosioThreatCoil FailureRejection of non-conforming coil Nb3Sn coils are not a mature technology with a long track record of high-yield production. The manufacturing of these coils is a complex process, and failures can occur along the way resulting in a non-conforming coil that has to be scrapped. Examples are: hipot failure once the coil has been impregnated, other examples? A coil may be rejected during the coil manufacturing process, or after the coil has been installed in a magnet and vertically tested. The sooner a bad coil is identified, the less cost and schedule delays are incurred in the project. The cost of a coil is $TBDK, and it takes 80 working days to fabricate. Additional cost and schedule delays are incurred if a magnet is assembled with a bad coil. The cost and schedule for magnet assembly re-work and test has to be added in this case. The project baseline includes the fabrication of 10 extra coils (12.5%) to mitigate the risk of anticipated coil failures. More failures are expected during the intial phase of production lines. A rigorous QA/QC program will be put in place to minimize failures and attempt to catch bad coils as early as possible during the manufacturing process to mitigate cost and schedule impact, however some coil failures (percentage?) may not be detected until after magnet assembly and during vertical testing. The baseline plan includes 100% magnet assembly vertical testing at the BNL test facility. Coil failures detected at this stage are costly and will require a magnet assembly re-work to swap the bad coil and a vertical re-test. CO-02 Yu (FNAL); Schmalze (BNL) Threat Winding Machine Failure Unscheduled downtime of the FNAL or BNL winding machines There are two coil winding machines in the U.S. qualified for making the US-HiLumi cable: one at BNL, and another at FNAL. During peak production, nearly 15 coil windings in a year will be done in each machine. Coil winding takes approximately 16 working days, resulting in practically 100% occupancy of the winding machine. Given the very high winding machines occupancy, there is very little tolerance for unscheduled machine downtime during peak production years. Downtime of a few weeks will cause project schedule delays. Both machines have been (are being?) recently refurbished to replace obsolete components and would have been demonstrated during the long prototype coil manufacturing. Scheduled maintenance will be performed to minimize the risk of failures. However, if the machine fails in such a way that the time it will take to repair will cause project schedule delays, the winding crew (2 techs) from one site (e.g., FNAL) could temporarily relocate to the other site (e.g., BNL) and work a second shift to keep up the coil winding production while the machine is being repaired. The wound coil will then have to be shipped to continue the coil manufacturing process in the original site. The crew temporary relocaton and additonal shipment will add cost to the project, but a schedule delay could be averted. As a last resort, the winding crew could temporarily relocate to CERN to use their winding machine on a second shift, which should also be ready to manufacture the US-HiLumi cable. Risk ID Risk Owner Risk Type Risk TitleRisk DescriptionDetailed Risk CauseDetailed Risk EffectInitial Response Plan

logo area Coil Shipping  Dedicated truck point to point.  Coil shipping with accelerometers mounted on the coil and ShockWatch Indicators on the crate. Fred Nobrega - MQXF International Review, June 7–10,

logo area Long Coil Manufacturing at Brookhaven & Fermilab National Laboratories Fred Nobrega - MQXF International Review, June 7–10,