DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Magnet Systems Summary Progress and Plans GianLuca Sabbi DOE Review of the LHC Accelerator Research Program FNAL, July 15, 2010 BNL - FNAL - LBNL - SLAC

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Overview Magnet Program components FY10 highlights Program organization Progress on key technical issues LARP plans in the new IR upgrade scenario  Near term ( )  Medium term ( )  From R&D to construction Financial status and funding scenarios Summary

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans LARP Magnet Development Chart Length scale-up High field Accelerator features

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans FY10: a year of outstanding results Dec First Long Quadrupole (LQS01a) test Achieved target gradient of 200 T/m Dec TQS03c high stress test (CERN) 88% SSL w/200 MPa average coil stress Feb TQS03e cycling test (CERN) No degradation after 1000 cycles May 2010 First High-Field Quadrupole (HQS01a) test >155 already above NbTi June 2010 HQS01b test (revised coil-structure shims) First Quench >150 T/m, 78% of SSL July 2010 LQS01b test (revised coil-structure shims) Underway; rapid training to >220

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Program Organization

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans A fully integrated program: HQ example Cable design and fabricationLBNL Magnetic design & analysisFNAL, LBNL Mechanical design & analysis LBNL Coil parts design and procurementFNAL Instrumentation & quench protectionLBNL Winding and curing tooling designLBNL, FNAL Reaction and potting tooling designBNL Coil winding and curingLBNL Coil reaction and pottingBNL, LBNL Coil handling and shipping toolingBNL Structures (baseline, revised, mirror) LBNL, BNL, FNAL Assembly (baseline, revised, mirror) LBNL, BNL, FNAL Magnet testLBNL, CERN, FNAL Accelerator IntegrationBNL, LBNL, FNAL

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans HQ schedule from 2009 DOE review 7/2009 DOE Review 7/2010 DOE Review: HQ01a/b tests completed Coils 9-10 in fabrication

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Fabrication and Test Database (1/3) Sub-scale Quadrupole (FNAL, LBNL) Five tests at 4.5 K, two tests at 1.9K Verified capability to reach SSL (stress, heat treatment, stability) Detailed FEA models and comparison with strain gauge data Quench propagation/protection studies; effect of axial pre-load Sub-scale Magnet (BNL) Two coils using existing tooling One test at 4.5 K in existing structure Coil technology transfer, conductor performance verification Long Racetrack (BNL, LBNL) 2 tests at 4.5 K Coil scale-up from 30 cm to 4 m: tooling, process Shell structure scale-up; one piece or segmented shell

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Fabrication and Test Database (2/3) Technology Quadrupole (FNAL, LBNL + CERN) More than 15 models tested at LBNL, FNAL and CERN Three main generations using different wire designs TQ01: MJR 54/61; TQ02: RRP 54/61; TQ03: RRP 108/127 More than 30 coils fabricated using a distributed production line FNAL: winding and curing; LBNL: reaction and potting Two structure designs, collar-based and shell-based Model assembly/disassembly performed at three different Labs Conductor, mechanical, quench protection studies Investigation of stress limits at CERN (engineering design space) Cycling test at CERN (1000 cycles with quenches every ~150)

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Fabrication and Test Database (3/3) Long Quadrupole (BNL, FNAL, LBNL) First test Dec. 2009, second test underway with improved preload 10 coils completed, 3 more under fabrication using RRP 54/61 Three labs fully participate in fabrication and test activities FNAL: winding and curing FNAL+BNL: reaction and potting LBNL: instrumentation, structure, assembly; FNAL: test High-Field Quadrupole (BNL, FNAL, LBNL + CERN) Optimized field quality (geometric and saturation harmonics) Alignment during coil fabrication, assembly and excitation 7 coils completed, 3 more under fabrication Two tests completed, second test w/improved preload & alignment

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Progress on Key Technical Issues (1/5) Strand design and fabrication: + Solid performance from RRP 54/61 in LR, TQ, LQ, HQ models + New RRP 108/127 shows improved stability and robustness - Only one vendor and production cycle is 12 (15) months - Piece length (esp. 108/127) not yet sufficient for efficient production Cable design and fabrication: + Three cable designs developed (LR, TQ/LQ, HQ) + More than 7 km of cable fabricated with minimal losses - Control of inter-strand resistance not yet incorporated in magnets Conductor performance: + Demonstrated capability of achieve full conductor potential + Demonstrated excellent tolerance to high stress levels + Stability margins always sufficient to reach performance goals

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Progress on Key Technical Issues (2/5) Quench performance and training: + Achieved high gradient - TQ: 238 T/m, LQ: 225 T/m, HQ:156 T/m + Fast training in optimized models (SQ, LR, TQ, LQ, HQ) + Steady progress through systematic analysis and correction Magnetic and mechanical design: + Complete FEA modeling capabilities and high quality data Performance issues can be quickly understood and corrected + Further optimization underway for integration and production Stress limits: + Satisfactory performance up to ~250 MPa peak, ~200 MPa average + No degradation in TQ after 1000 cycles

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Progress on Key Technical Issues (3/5) Coil fabrication technology: + Steady improvement in tooling and procedures First usable coil in a new design: #5 in TQ, #5 in LQ, #1 in HQ + Distributed coil fabrication shows flexibility, robustness - However: insulation failure in recent HQ test + Successful length scale-up in LR and LQ - However: Full coil modeling framework is not yet available Quench protection: + Key parameters are well 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

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Alignment and field quality: - No coil alignment in LR, TQ, LQ models Neither during fabrication nor at assembly/excitation + Encouraging results TQ magnetic measurements Systematic are reasonably well understood Random within a factor of ~3 from typical NbTi + Coil alignment features introduced in HQ models - Dynamic effects are not yet controlled Cables with cores will be introduced in HQ models Accelerator integration: + Studies underway to further optimize alignment, field quality, cooling, heat ransfer, radiation damage etc. Need to work with CERN on design requirements and options Progress on Key Technical Issues (4/5)

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Radiation and thermal management: + Thermal margins are intrinsically high compared to NbTi - Heat transfer is limited due to epoxy impregnation - Epoxy is also the weak point in terms of radiation damage + Field/aperture margin can be effectively used for absorbers Production issues: + Demonstrated distributed production, extensive shipping - Insulation failures observed in recent HQ tests Need more focus on reliability vs. performance; better QA + Good results at NEEW to weave insulation directly on cable + Timeline from specifications to test is similar to NbTi - Current infrastructure is limited to 4 (6) m coil length Progress on Key Technical Issues (5/5)

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Summary – Technical Progress A large knowledge base is available after 5 years of fully integrated effort involving three US Labs and CERN Demonstrated fundamental aspects of Nb 3 Sn technology: - Conductor & structure performance, length scale-up Steady progress in understanding and addressing R&D issues - Remaining R&D effort should focus on accelerator integration and production-oriented processes Timely infrastructure upgrades will also be key to an efficient transition toward production CERN, EuCARD, KEK, US Laboratory core programs have strong expertise in many key areas requiring further work Need to closely coordinate R&D plans

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans LARP Plans as of 12/09 (pre-Chamonix) : complete technology demonstration LQ to address all length-related issues (& fully reproduce TQ results): : 2-3 additional tests using 54/61 coil series : Fabricate 4-6 additional coils using 108/ : ~2 tests with 108/127 coil series HQ to address field/energy limits and accelerator quality : Several tests with 1 m models Progressively push performance : Field quality characterization/optimization May require extension to m length : Prototype for “Phase 2” Technology Selection :IR quadrupole production for “Phase 2” upgrade

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Luminosity Task Force Analysis Established to re-evaluate commissioning, operation, consolidation & upgrade plans in light of the results of the Chamonix workshop: General considerations: (a) need to minimize the number of interventions and maximize the luminosity gain from each one (due to installation & ramp up time, radiation issues etc.); (b) global optimization is required involving new Quads, cryogenics, powering, correctors, collimators etc. Schedule considerations: (a) radiation lifetime limit of present IR will be reached around 2020; (b) spares policy should be decoupled from upgrade plans; Recommendations: (a) Delay the inner triplet replacement to a single HL-LHC upgrade around 2020; (b) technology decision NbTi vs. Nb 3 Sn is required in

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Updated LHC Schedule Further plan refinements following CERN Council and SLHC meetings in June Inner Triplet upgrade during 2020 shutdown

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Summary – Current Status & Perspective Despite significant changes in the overall LHC plan, the key technical milestones and target decision dates for LARP are essentially still valid The new LHC plan is giving Nb 3 Sn technology a prominent position as the leading candidate for the upgrade Following our technical success over the last several years we have a unique opportunity to make a critical contribution to the HEP program We now need to renew our effort to make the best use of this opportunity

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Next Goal: Technology Selection ( ) Good consensus within LARP and with CERN on the basic strategy:  Build on existing platforms (90 mm LQ & 120 mm HQ)  LQ for length effects, HQ for high field and accelerator quality CERN still plans to proceed with a series of 2m long NbTi models Direct performance comparison of NbTi and Nb 3 Sn models with same (120 mm) aperture will represent an important input to the technology selection Several critical questions need to be addressed:  Detailed accelerator quality/integration requirements (for TS)  HQ scale-up strategy: 1  2  6 m or 1  4  8 m  R&D plan coordination with CERN, EU, Japan programs Both US and CERN recognize that an official protocol is needed  Will guide some critical decisions and R&D priorities

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans R&D plan for 90 mm Long Quadrupoles Fully reproduce performance of the TQ short models  Higher gradient (220 T/m in TQS02, 240 T/m in TQS03)  Fast training (plateau in 5-10 quenches, no retraining) Systematic analysis of coil length effects  Detailed modeling of the reaction process  Understand/optimize coil strain state after reaction Design and process optimization for construction  Coil size control/reproducibility  Protection heater design, esp. for inner layer  One-side loading with 4 m keys/bladders  Cable insulation techniques for production

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans LQ Plan

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans R&D plan for 120 mm Quadrupoles (1/2) Present focus: address electrical insulation issues in HQ Good progress on results analysis and identification of root cause, other contributing factors and possible solutions Task leaders to summarize findings and action items in their respective areas Apply solutions and mitigating factors at the earliest opportunity Short model R&D:  Performance limits, training, pre-load optimization  Quench protection and thermal studies  Cored cables to control dynamic effects  Structure optimization for production and accelerator integration  Field quality characterization and optimization

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans R&D plan for 120 mm Quadrupoles (2/2) Length scale up: different strategies are being discussed A: 1  2  6 m  2 m models balance magnetic length (1 m) and cost/turnaround  2 m models provide a direct comparison with CERN models  6 m models approach full length while limiting infrastructure cost B: 1  4  8 m  4 m models can provide a convincing technology proof  8 m models can be seen as full scale prototypes for production Questions that need to be addressed to define the best strategy: Are 1 m models adequate for studies/demonstration of field quality What information will be required to start a construction project under US DOE rules (in addition to the technology selection requirements) What levels of funding can be provided in preparation for construction

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans HQ Plan

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Construction Schedule Considerations Define production line: complete set of winding, curing, reaction, potting infrastructure, tooling, crew 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 Ramp-up time will depend on availability of infrastructure and conductor: Preliminary cost estimate for infrastructure upgrades (at BNL): 2.8M$ for 6 m coil fabrication; 3.5M$ for 8 m coil fabrication Conductor procurements for prototypes and production start (long lead time, limited production volume) Consider for possible application of redirected APUL funding

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans FY10 Budget Details (initial allocation) Total October 1 st allocation: 5 M$ (3.8M$ labor, 1.2 M$ M&S)

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Mid-Year Contingency Allocations Model Quadrupoles - Increased funding for coil parts and coil fabrication at BNL/FNAL - Transferred 2 tests from FNAL to LBNL and CERN (due to resource availability) - Eliminated accelerator integration funding at FNAL/LBNL Long Quadrupoles- Updated/finalized plan for LQS02 and LQS03 (coil fabrication, assembly/test) Materials- Added significant conductor procurements (start to correct inventory shortage) Not funded- HQ mirror and length scale-up (due to budget limitations and technical readiness) - Conductor characterization (due budget limitations and resource availability)

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Financials as of June Close (HQ Test) - HQ01b test and insulation failure analysis/recovery not budgeted - Additional 30 k$ needed for large diameter measuring FNAL (Procurement)- Conductor FNAL, BNL for 150 kg each underway Comments:

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Preliminary Estimates for FY11 Baseline (HQ, LQ, Mat) plus contingency consistent with FY09 MS levels (~7M$) HQ scale-up: additional ~800k$

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Medium Term Budget Scenarios LARP MS constant at FY09 level No APUL funding for infrastructure, conductor LARP MS: +2.4M$ in FY11-12 (same integral) 9.5 M$ APUL funding for construction preparation Currently -700k$ (total LARP budget decreased by ~640k$; ~700k$ contingency still available) Cost estimate for first LHQ: 6.8 M$

DOE Review, 7/15/2010GianLuca SabbiMagnet Systems - Progress and Plans Summary Very good match between the new LHQ upgrade strategy and the LARP R&D progress and existing plans Systematic testing of LARP Nb 3 Sn models and CERN NbTi models with same specs will provide direct technology comparison and qualification The medium term Nb 3 Sn development plan is being adjusted to maximize readiness for a technology decision and construction initiation in Depending on detailed requirements, an increase in the LARP MS budget may be needed to meet the technology readiness milestone Significant and timely investments will be needed for full-scale model fabrication and construction project preparations The US is in a unique position to make a critical contribution to LHC and the overall HEP program, resulting from a combination of programmatic vision and technical success in developing a new generation of magnets Incorporation of Nb 3 Sn technology in the LHC luminosity upgrade will open the way to many other applications within and outside HEP