Thoughts about the MQXF development plan P. Fessia Thanks to discussions within the MDT section (P. Ferracin, J. C. Perez, E. Todesco, P. Ferracin), L. Bottura, L. Rossi, F. Savary.

Summary Objectives of the wider aperture ( mm) quadrupole model program LARP proposed plan Proposal of plan and milestones of a possible CERN- LARP integrated model program LARP and CERN contributions to the model program and CERN resource status Prototypes: objectives, CERN short term contribution, CERN medium term contribution for development Open issues

Objectives of the wider quadrupole model program Demonstrate that the technologies and techniques used for the 120 mm aperture can be successfully adopted for the mm aperture Extend the applicability of the LHQ result to mm aperture to open directly the path to full length prototype (8 meter) Demonstrate that the coil fabrication technology is well mastered allowing – To use all the produced coils for magnet assembly (choosing and even sorting for the 8 meter long unit is not an option so the coils shall meet specification or the specification shall be revised) – Demonstrate that RRP and PIT conductors can be efficiently and successfully managed in the frame of the same production Tests as many as possible of the long magnet features (in particular iron yoke design) if it does not delay the test plan

MQXF MODEL

US LARP proposed plan not resource loaded The model program to be discussed in the following pages

CERN-LARP proposed integrated model program

Main features in the program Coils: – 12 poles produced (2 with tooling set 1, 10 with all the 4 sets of tooling necessary to fulfil the plan) – 6 coils with RRP, 6 coils with PIT Models: – 2 models for each assembly line out of 6 poles – Two options for the structure design Option A: all accelerator features are known in May We introduce all of them and we perform in one go the procurement of twice the same structure (probably by LARP). Option B: we have 2 structures just slightly different (as more complex option it is this, the one assumed in the plan) – Model V1 (to be assembled by LARP): 1 st package of accelerator features as known as 01/05/2013 – Model V2 (to be assembled by CERN): 2 nd package of accelerator features as known as 01/11/2013

Main milestones in the plan Milestones n. descriptionDate [completion date] 1Fixing final cable dimensions for tooling30/11/2012 2Completion engineering coil and coil tooling03/05/2014 3Delivery coil tooling set 118/10/2014 4Engineering mech. structure and procurement structure LARP version 04/07/2014 5Engineering mech. structure and procurement structure CERN version 03/10/2014 6Copper coil1/12/2013 -> 21/02/2014 7Practice coil n. 120/01/2013->19/05/2014 8Delivery tool set 2,3,4 after modifications from copper coil experience 11/07/2014 9Completion 1 st 4 coils including 2 practices20/12/ Assembly MQXF0L13/01/2015->06/04/2015 (start test) 11Assembly MQXF1C06/05/2015->25/08/2015 (start test) 12Assembly MQXF2L03/08/2015->23/10/2015 (start test) 13Assembly MQXF3C28/10/2015->26/01/2016 (start test)

Superposition of the US LARP proposed plan with tests

LARP and CERN integration for MQXF model program, a 1 st proposal TASKLARPCERN Cable parameter definition RRP X Verification parameter PITXX Conceptual designX (protection and mechanical analysis) X (magnetic analysis and mechanics) Engineering coil and toolingX Engineering mech. structureX Procurement LARP version mech. structure X (translation in US format of drawings) Procurement CERN version mech. structure X Coil productionX Assembly and test of 2 modelsXX

MQXF PROTOTYPE

Prototype phase A prototype is a magnet ready to go in the machine. The following developments are needed – Bus bar – Heat exchanger tube – Cold bore + shielding – Cold mass envelope – End covers – Cold support posts – Instrumentation + instrumentation feed through – Bellows The prototype shall be submitted to the following procedures to be developed – Alignment, extremity cartography, full geometry characterization – Magnetic measurement QA – Other QA (electrical measurements, pressure test, leak test, ) produced in technology suitable for mass production Components and tooling (i.e. mandrels, molds,.. )shall be produced in technology suitable for mass production, therefore production techniques and production methodology have to be completed revised respect to the short model Remind that we could, at CERN, decide to have the quads built in industry, in this case we need to demonstrate to company that the industrial risk is manageable. For this we shall produce at least 2-3 successful proto and have all the technologies in hand

CERN estimated prototype activity sequences and durations But we need the people to work on the preparation phases and these people will become fully available only at the LS1 end April-May LMF will TRY (see later) to leave a small group of people on surface to keep ongoing the projects preparation, but at a reduced speed not the one foreseen here above If we launch the procurement of the tooling after winding 1-2 SC coil test date of proto 1 would be April 2018 We need to advance the prototype construction independently from the cold test feed back of the model program or we will be too late. The connections between the 2 programs will be technical (availability of complete and possibly validated design from the model program)

Prototype What is starting now M.S. for the furnace is out. In few months green light to purchase 2 furnaces 1) 6.5 m long unit 11T dipole targeted (delivery June 2013) 2) 8+ m long unit MQXF targeted (delivery January 2014) Impregnation system. Targeting one system fulfilling 11T and MQXF project. We will need to go through MS and IT. Optimist expected delivery September 2013 Resources short term In LMF efforts being done to free some resources from LS1 (Fellow 40 %, Technician for tooling development 30%, Technician for development of manufacturing procedures 30% ), Just enough to Follow up the main infrastructure procurement and installation Participate in the model tooling development to extend the tooling to long length Resources medium term A very large task is the all the cold mass finishing and tunnel integration. For this task CERN is ready to take the lead, but the activity can only be fully staffed as mid 2014 (end LS1).

Technical connections between short and long model Participation to the tooling development The review of the tooling after coil 1-2 short coil production. Test of models will arrive 4 months after the start of production according to LARP proposed plan

FALL BACK “STRATEGIES”

Possible actions/consequences I EventDateReactionConsequenceDetails Impossibility to get consistent quality on long cable lengths (8 m coils) or too high cost End 2014Go back to half length units 9 months delayTooling re-procurement Systematic model failure: quench performance December 2015 Redesign magnet2 years delayNew 2 models, modification proto Modify operational gradient Revision of optics-> new layout with increased length Back to the 120 mm if aperture issue 1 year delayNo model, redesign of long tooling Systematic model failure: electrical integrity December 2015 Redesign insulation1 year delay short model (if no new coils are needed down to 6 months) 6 months delay long magnet 1 short model reassembly

Possible actions/consequences II EventDateReactionConsequenceDetails Systematic model failure: field quality February 2016 Coil modifications inside the coil envelope 1 year delay1 extra short model, procurement of new component for the long proto with financial impact Actions on the yoke or other structural components 6 months delayExtra cost, no model, delayed proto, new components with financial impact Change of strand?? Failure of the proto because of length End 2018Back to half length1.5 years extra from the moment of decision Design to be scaled down, short tooling but very large economical impact on component procurement of series that has already started (i.e. cryostats, bus bars, all long components) Modification of specification if possible Probable delay of 3-6 months Impact on machine performance

OPEN ISSUES

Open issues Model development: resource wise the critical phase are the next 1.5 years. For this phase we are lacking 1 engineer and 1 technical engineer. CERN top management has started to look for resources outside the group but the lack of this personnel will impact the plan. Cable and strand procurement: procurement plan to be assessed final cable dimensions :it is assumed that the dimensions are available as November 2012 and that they will be suitable also for PIT strands. Prototype phase. At the present status CERN cannot engage to place more resources on short term (before end LS1) on the prototype work. As consequence more detailed planning is premature