1. Progress in D1 (since last collaboration meeting…) Michinaka SUGANO, Tatsushi NAKAMOTO KEK July 1, 2014 1

2. 2 19 13 8 4 44 turns Option C: LL75% Recall: Design Parameters of D1 Bore diameter150 mm # of turns44 (4 + 8 +13 +19) Nominal field (dipole)5.59 T Magnetic length * 6.3 m Operating current 12 kA Injection current~ 0.77 kA Field homogeneity<0.01% (R ref =50 mm) Peak field in the coil (SS) 6.45 T Peak field in the coil (end)6.75 T Load line ratio (SS)75% @ 1.9 K Inductance (low / nominal field ) 5.7 / 5.1 mH/m Stored energy340 kJ/m Peak field/central field1.15 Lorenz force X/Y (1 st quadrant)1.5/0.6 MN/m Iron Yoke ID222 mm Iron yoke OD550 mm (same as MB) Cold mass OD570 mm (same as MB) Cryostat OD914 mm (same as MB) Superconducting cableLHC MB Outer (NbTi) Strand diameter0.825 mm Cu/Non-Cu ratio1.95 Cable dimension / insulation 15.1* 1.48mm 2 / 0.155 mm (radial) 0.135 (azimuthal) No. of strands36 Keystone angle0.9 ° Superconductor current density 1832 A/mm 2 Total length of the cable 583 m (Coil length ~6.6 m)

3. Design Studies 3

4. 4 Geometric error during coil assembling r direction  (position angle) direction  (inclination angle) direction   d: assumed displacement, r: coil aperture, w: cable width   r w Bellesia et al, Proc. EPAC 2006, 2601 D1 with ID 150 mm Coil block displacement in 3 degrees of freedom was considered. rr

5. 5 Random geometric error Displacement, d (  m) Stand. dev. of b3 (unit) 1002.067 501.033 250.516 100.206 Tolerance ~ 25  m is required for b3 < 1unit D1 with ID 150 mm

6. HX hole diameter  50  60  70 Const. HX hole design:  50, R185   60, R190 Increase of b3 by 2 unit 6 HX  60HX  70 Position of HX hole R190R195 Main field (T) 5.57745.5721  b3 (unit) 2.0414.032  b5 (unit) 0.1830.373  b7 (unit) -0.005-0.010  b9 (unit) -0.0026-0.0056  b11 (unit) 0.00006 R185 R190 R195

7. 7 Optimization of coil block arrangement 1 2 3 4 HX50 (Optimized) 22 22 HX  60HX  70 Main field (T)5.57675.5705 b3-0.0512-0.0427 b5-0.0917-0.0706 b7-0.0991-0.0823 b90.2630.214 b110.3370.270 After optimization of coil block arrangement for HX  60 and HX  70 HX  50 (Optimized)HX  60 (Optimized)HX  70 (Optimized) 11 1.021 o 1.036 o 1.054 o 22 28.86 o 27.88 o 27.95 o 33 50.32 o 50.33 o 50.37 o 44 70.67 o 70.73 o 22 26.00 o 25.50 o 33 52.43 o 52.42 o 52.27 o 44 68.00 o 67.50 o Position of coil blocks after optimization Field error due to change in HX hole design can be improved without significant coil block re-arrangement

8. Shape of cryostat Elliptical (t=12)Elliptical (t=15) Main field (T) 5.57585.5816  b3 (unit) -2.049-0.369  b5 (unit) -0.1030.040  b7 (unit) 0.0150.014  b9 (unit) 0.00560.0036  b11 (unit) 0.00068E-05 ID 890x1112, t=12 ID  890, t=12 - Elliptical cryostat with t=12 mm   b3 ~ -2 unit - Increase in cryostat thickness can reduce field error 8 Cylindrical Elliptical Cold mass was centered for both cases

9. Coil deformation during yoking A B A B C Displacement of ref. points in yoke and collar Unit: mm in table m in Figure ABC UXUYUXUYUXUY Yoke0-1.167-0.055-1.188-- Collar-0.009-1.168-0.005-1.167-0.054-1.180 -0.009+0.032-0.005+0.033-0.054+0.020 Collar Iron yoke KeyKey Coil Gap between top yoke and mid-plane: 1.2 mm (inner) & 1.35 mm (outer) 0.5 unit thickness for each layer x y 9 -Deformation of iron yoke and collar during yoking was calculated with ANSYS -Deviation from ideal displacement in collar (UX=0, UY=-1.2 mm ) was estimated   UX<-50  m,  Uy<+30  m (Oval deformation due to bending)  UX,  Uy in collar

10. Field error due to yoking -Assumption: Coil deformation follows that of collar -Displacement of coil blocks was estimated with linear approximation Block 1 Block 2 Block 3 Block 4 Ref. points in each coil block P1 P2 P3 P4 Coil block No.  x (mm)  y (mm) 1P1-0.04630.0225 2P2-0.03900.0269 3P3-0.02730.0298 4P4-0.01410.0314 -Displacement of coil blocks: -14 ~ -46  m in x-direction 23 ~ 31  m in y-direction -Field quality was checked for model considering coil deformation Main field (T) 5.5826  b3 (unit) -0.989  b5 (unit) -0.311  b7 (unit) -0.121  b9 (unit) -0.0534  b11 (unit) -0.0391 Deformation during yoking  Increase of b3 by 1unit 10 Displacement of ref. points in each coil block

11. Quench Protection w/ R dump =75 m  Conditions of calculation – Rdump = 75 mohm Neglect coil resistance during quench -> Decay time constant is determined by only Rdump and Inductance – Quench detection threshold: 0.1V, 10ms Current decay Quench Shut down and start to decay Voltage Threshold Current Coil Resistive voltage Tim e Time Threshold Detection time Total MIITs = MIITs during detection + MIITs during current decay Time constant of Current decay = 30 mH / 75 mohm = ~0.4 sec

12. Quench Protection: Evaluation of detection time Worst case: Quench around lead – Bfield : almost zero Detection time (sec) = 0.01 + (0.1 - MPZ × R × I) / (Velo × 2 × R × I) MPZ : Minimum Propagation Zone R: Resistance of cable per meter @ 0 T, 10 K (ohm/m) -> 1.05e-5 (ohm/m) I: Current (A) Velo: Quench propagation velocity @ 0 T (m/s) MPZ and Quench propagation velocity @ 0 T Detection time and MIITs during detection @ 0 T

13. Quench Protection: Current vs Peak Temperature Peak temperature : Temperature rise @ Bpeak during quench Quench start around 0T region R dump = 75 m , I max =13 kA Already implemented for the MB circuit in the LHC.  is determined by only R dump and Inductance: ~ 0.4 sec Quench detection threshold: 0.1V, 10ms >> Peak Temperature: 305K Further study will be made with 3D field map soon. But, can we omit the QPH in the D1?

14. 2-m Long Model Magnet 14

15. 2m-long Model Magnet - Overview 15 Shell: SUS304L Horizontal split iron yoke: low-carbon steel (EFE by JFE steel) Collaring keys  60 mm HX hole Notches and  34 mm holes for iron saturation effects Same outer-interface for J-PARC SCFM jigs 4 split stainless steel spacer collars: NSSC130S NbTi SC cable (LHC MB outer) + Apical insulation Radiation resistant GFRP (S2 glass + BT resin) wedges Brass shoes Single-layer coil, 4-split spacer collars, collared yoke by keying HeII cooling channel

16. SC Cable Supply & Schedule 16 Delivery DateObjectiveRequirementRemark Feb. 2013 10 stack meas. (a piece length > 0.3 m) ~50 m w/ MB type insulation Both MB inner and outer cables w/ MB type insulation Jan. 2014 May 2014 2 practice coils * + 2 real coils for the 1st 2-m long model 220 m ** x 4LHC MB outer cables w/ MB type Apical insulation Jan. 2015 (possibly) 2 practice coils + 2 real coils for the 2nd 2-m long model 220 m x 4LHC MB outer cables w/ MB type Apical insulation JFY2016 (prospect) 6 or 7 full-scale magnets + 4 practice/spare coils 600-640 m x 18LHC MB outer cables w/ MB type Apical insulation Done!! NbTi LHC MB outer cable supplied by CERN for the new D1. Done!!

17. Cable Size Meas. 17 Hypothesis Max. experienced stress: 100 MPa Design stress: 80 MPa 38.55 mm for 22 cable stack Courtesy of R. Iwasaki Design cable size @ 80MPa: 1.7545 mm w/ insulation Azimuthal Insulation0.135 mm Radial Insulation0.155 mm E modulus 5.5 Gpa - 17.5 GPa Reference data for ROXIE, ANSYS Coil oversize for pre-stress

18. 2m-long Model Magnet: Practice Coil Winding 18 W/o curing Spacers, wedges made by 3D printer – quick adjustment wrt the actual coil shape New tooling, jigs Dry run for winding procedure Inclined cable turn and large gap >> Need modification

19. 2m-long Model Magnet: Coil end 19 Block NoBoverA 12.18 22.15 32.18 42.46 52.28 61.78 Block NoBoverA 161.3 171.3 181.3 191.3 201.3 211.3 Block NoBoverA 162.19 172.20 182.09 191.97 202.11 211.90 1 2 3 4 5 6 Horder=2.3 J-PARC-SCFM (173.4mm) D1-Rev5C (150mm)D1-Rev6 (150mm) 2.3<Horder<2.41 16 17 18 19 20 21 16 17 18 19 20 21 Test coil (July 2014) 1st Model (Dec. 2014) *after adjustment to the actual (inclined) coil. **upright cable turn (63° < beta < 85°)

20. GFRP End Spacers, Wedges GFRP: BT2160/2170 + S2 glass by ARISAWA – Radiation resistance beyond 50 MGy – similar modulus as G10: 29 MPa – But 30 % higher mechanical strength End-spacers: manufactured in-house – Design by ROXIE – Modeling with NX, Drawing with Solid Edge – CAD/CAM CATIA V5 Wedges 20

21. Coil Size Measurement System for the D1 Based on the same system for MQXC. (Thanks to G. Kirby) A new 50 ton hydraulic press. Coil size under compressive load. – L100mm x 2 sides of a single layer coil up 150 MPa. Assembly completed. Instrumentation of stain gages on the press-bars is being prepared. 21

22. Ground Insulation, QPH 22 Ground Insulation: same concept as MQXA – 4 layer of 0.125 mm thick Polyimide insulation (Upilex-RN) – Large shrinkage of the coil during the assembly should be taken into account. Brass shoes to intervene laminated collar sheets and the insulated coil. Quench Protection Heater: 0.25 mm think – Searching for manufacturer in Japan – Necessity?? Spot heater will be implemented in the model magnet for the quench protection study. – higher field at the straight section – lowest field at the coil end (probably at lead-out)

23. Collars, Yokes 23 A collared yoke structure (Originated at RHIC-dipole, followed by LHC MQXA) – Vertically split iron yoke locked by keys. – 4-split stainless steel collars: 2 for coil fixing at poles, 2 for floating spacers. Mechanical short model study: Demonstration of mechanical structure – Collars and Yokes: EDM – Concept of 4-split collars – Coil pre-stress measurement at assembly and cool-down to LN2 temperature Model magnet development: – Semi-mass-production of collars and yokes: Fine-Blanking technology to be adopted. Tooling and die for the D1 will be delivered by Dec. 2014. Then holes on the yoke sheet will be machined for the model magnets. – Increase of thickness difference (5.6mm & 6.0mm): help for yoke stacks assembly. assembly of top and bottom yoke stacks for J-PARC SCFM

24. Modification for Cooling Performance 24 Radial gap of 4 % for HeII up to 2 x  60 HX holes (suggestion by Rob van Weelderen) New HX holes:  60 @R=190 (old:  50 @R=185) Collar lamination w/ 0.1mm gap by emboss Longitudinal grooves on collar: d2 x w20, both sides of triangle notch. Yoke packing factor of 98 % Yoke 98% Collar 96% Heat Exchanger

25. Procurement of Materials 25 Low carbon steel: EFE by JFE steel – 15 tons of EFE sheets (5.6mm & 6mm thick) delivered for the model magnet. – Another 30 tons will be procured within this year. – Y.S.: > 240 MPa. Magnetic property: OK. Stainless steel: NSSC 130S (same as YUS130S) – 12 tons of NSSC-130S sheets (2.3mm & 2.6mm thick) delivered. This can cover the model magnet development and >30% of the 7-m long full-scale magnets production. – Specification, once set for the LHC MB, is fulfilled. Very low permeability of 1.002 confirmed at RT/4.2K. Radiation resistant GFRP – BT2160/2170 + S2 glass by ARISAWA – 4 Pipes (  150 x 900, end spacers & wedges), 2 plates (500 x 500 x 30, ramp box & covers) were delivered for the model magnet.

26. Presses, Jigs 26 3.6 m long hydraulic press for coil curing and yoking is ready. Yoking jig (J-PARC SCFM) Forming block 3500 tons hydraulic press Collaring press (MQXA) Horizontal collaring facility is designed in the mean time.

27. Preparatory Work for Cold Tests Modification and procurement of the cryostat for “12 kA, 150 mm aperture” D1 magnet. – Current Spec: 7.5kA, 70 mm aperture – New top flange w/ larger warm bore and 15 kA CL. Procurement of 15 kA CL >> March 2015 Consolidation of PC and bus lines. (7.5 kA >> 15 kA). – New 15kA-DCCT will be calibrated at CERN. New DAQ systems 27 Cold test of LHC-MQXA New 15kA-DCCT New flanges, plate, warm bore Modified 15kA Bus lines

28. Plan [Model magnet development] Practice coil winding (w/o curing): ~ June 2014 Test coil winding (w/ curing): ~ End of July 2014 Coil size measurement:Aug. 2014 Mechanical short model assembly (20 cm long):Oct. 2014 1st model coil winding:Dec. 2014 Collaring:Feb. 2015 Yoking, splice work, shell welding:~April 2015 [Test station] Delivery of new top flange:Aug. 2014 Delivery of 15 kA CL:Mar. 2015 Inspection by local government:May 2015 Commissioning:June 2015 Cold test of 1st model:July 2015? 28