LARP LQX and MQX Cold Mass Testing at Fermilab Overview and Required Test Stand Upgrades Cosmore D. Sylvester

QXF Cold Mass Test Program To satisfy the Functional Requirements our plan is to: – Implement required upgrades (Cryo, Mech, Power & DAQ) – Test Prototype LQXF cold masses (4.8 m) on the Upgraded Test Stand (starting in Nov. 2015) – Test Production MQXF cold masses (20 total) on the Upgraded Stand (starting in Nov. 2018) – Complete the Production testing by “early 2021”

Overview of Existing Test Stand Magnet Support Stand outfitted with utilities (compressed air, LCW, cryogens, turbo pump, etc.) 30kA DC Power Supply (30V) 3 ea 15kA Vapor cooled Power Leads ASME Code Stamped Feedbox with helium vessel with interconnect features for LHC IR Quad Magnet Interfaces at the Lead and Return End Return End Can with additional Strain Gage Instrumentation readouts Warm Finger (60mm OD and 45mm ID) and Quench Antenna array Magnetic Meas. Probes (43mm OD) Translation and Drive Systems Rotating Probes for Integral and z-scan Measurements of the Cold mass Interfaces for SSW Measurements

Existing Test Stand (for LHC IR Quads) After a magnet is installed on the test stand and aligned to the Feedbox: Solder Power connections and insulate Connect Instrumentation Connect Piping and Perform Leak check of piping connections Insulate interconnects, add shield section and its insulation Close up interconnects and evacuate cryostat Perform pre-cooldown electrical checkout Cooldown Test Warm up and disassemble

Mechanical Upgrade Items Replace existing 15kA power leads with 30kA Lead assembly and LTS section; if final plan is to test two cold masses in a single cryostat – 3 leads are required Design and build a Warm Finger (WF) assembly with embedded Quench Antenna (QA) System and other Instrumentation (RTDs, Heaters) Design and build Magnetic Measurement Probe for 150 mm aperture magnet; preliminary sizing indicate a probe diameter of 100mm Modify the Return End (RE) Can to facilitate 150 mm aperture WF Assembly Refurbish and commission the Magnetic Measurement Table with Probe Translation System Design and fabricate miscellaneous tooling and fixtures Purchase and Install Vacuum Pump Cart for Insulating Vacuum Pumpdown Design and build an Adapter Box to accommodate the interfaces between the existing Feedbox and the LQXF/MQXF magnets.

Feedbox Lambda Plate Instrumentation Differential Pressure transducers LTS Bus feedthrough Liquid Level Sensors Potted Instrumentation feedthrough Instrumentation Connector Terminations Current Limiting Resistors Check Valves Lambda Plate tie-down rods

WF and Imbedded QA Assembly for LHC IR Quads Design and purchase multipole winding patterns on Kapton substrate Install QA windings at preferred/optimized locations (center and ends) plus heaters and RTDs Terminate above elements to room temperature connectors Design and build the WF assembly

Return End Can Disassemble and machine larger penetration to accommodate the WF and 100mm diameter measurement probe Reassemble unit and helium Leak check

Re-Usable Cryostat The plan is to use a re-usable cryostat to test all cold masses – Design and build a re-usable cryostats with: Vacuum Vessel LN2 cooled Thermal shield and multilayer insulation (MLI) Heat exchanger assembly Magnet supports/suspension – May need to purchase 2 cryostats to satisfy the magnet throughput

Power and Data Acquisition System Power System – 30kAmps vapor cooled leads – 1500 MCM cables – Stabilized LTS power bus Data Acquisition System – Plan to use existing system which was used to test the IR quads with updated electronics and Instrumentation Current Receivers Isolation Amplifiers Quench Management System Slow Scan System Replace, Repair, Calibrate Instrumentation Cabling and Connectors

Conceptual Layout for the Double Cold Mass w/WF and Probe Insertion from the RE For a long cryostat option will need to insert probe and warm finger from RE This is to avoid making modifications to the ASME Code Stamped vessel in the Feedbox Stop the probe shaft in the Interconnect region at Lead end Insert probe driveshaft for Feedbox end connect shaft sections at the lead end interconnect.

Cryogenics by Roger Rabehl

Test Stand Upgrade Cost (Labor plus M&S) Description Engineer (m-wks) Designer (m-wks) Technician (m-wks)M&S ($K) Project12 Cryogenic System $99 Feed Can $161 Magnetic Meas. System $68 Power System2.51.5$11 Quench Protection, DAQ upgrades1535$134 Vacuum System$21 Acceptance Test $8 Grand Total Fully Loaded, no contingency ($)$1,854,540

Operations Cost - Prototypes DescriptionEngineer (p-wks)Labor (p-wks)M&S ($K) Prototype (single cold mass)532$60 Fully loaded, no contingency ($)$230,768 Prototype (double cold mass)948$120 Fully loaded, no contingency ($)$338,886

Operations Cost - Single MQX Cold Mass DescriptionEngineer (p-wks)Labor (p-wks)M&S ($K) Single cold mass option unit test st production3.824$45 2nd production3.120$37.5 Production $540 TOTAL single cold mass (20 tests) $622.5 Fully Loaded, no contingency ($)$2,394,218

Operations Cost – Double MQX Cold Mass DescriptionEngineer (p-wks)Labor (p-wks)M&S ($K) Double cold mass option unit test4.524$60 1st production6.836$90 2nd production5.630$75 Production $480 TOTAL doble cold mass (10 tests) $645 Fully Loaded, no contingency ($)$2,104,506

Fixed and Operating (Variable) Cost DescriptionSingle Cold MassDouble Cold Mass Fixed CostQTY Test Stand Upgrade$1,854,540 Re-Usable Cryostat1$986,297$1,086,535 Total Fixed Cost$2,840,837$2,941,075 Operating Cost Cryostating Prototype4$578,854$TBD Prototype Test 4$923,072$TBD Cryostating Production20$2,894,27210$1,915,328 Production Test 20$2,394,21810$2,104,506 Total Operating Cost$6,790,416$4,741,786 GRAND TOTAL$9,631,253$7,682,866

Schedule to Prepare Test Stand

Schedule for LQXF (prototypes) Testing

Schedule for MQXF Testing

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