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11 T Dipole Status May 2012 M. Karppinen CERN TE-MSC On behalf of CERN-FNAL collaboration.

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Presentation on theme: "11 T Dipole Status May 2012 M. Karppinen CERN TE-MSC On behalf of CERN-FNAL collaboration."— Presentation transcript:

1 11 T Dipole Status May 2012 M. Karppinen CERN TE-MSC On behalf of CERN-FNAL collaboration

2 11 T Nb 3 Sn DS Upgrade  Create space for additional (cryo) collimators by replacing 8.33 T MB with 11 T Nb 3 Sn dipoles compatible with LHC lattice and main systems. M. Karppinen CERN TE-MSC 2 MB.B8R/L MB.B11R/L 5.5 m Nb 3 Sn 3 m Collim. 5.5 m Nb 3 Sn 3 m Collim  Joint development program between CERN and FNAL underway since Oct- 2010 to demonstrate the feasibility of Nb 3 Sn technology for this upgrade by 2014. 15,66 m (IC to IC plane)  LS2 2018: IR-2  LS3 2022: IR-1,5, Point-3,7 24/05/2012

3 11 T Dipole & Collimator Cryo-Assembly options M. Karppinen CERN TE-MSC 3 15,66 m (IC to IC plane) 10,6 m (L mag ) 3 m (collimator) 11,48 m (L CM ) beam tubes Line X (H.exch.) Line M (B.Bar line) 5,3 m (L mag ) 3 m (collimator) 5,3 m (L mag ) 2,27 m (collimator) 5,3 m (L mag ) 6,18 m (L CM ) 12 m (L CM ) 6,18 m (L CM ) 24/05/2012

4 11 T Design Challenges  Iron saturation effects  Transfer function matching with MB  Coil magnetization effects o Conductor development o Cable development  Quench protection o Heater development o QPS  Mechanical structure o Forces almost 2 X MB  Coil fabrication technique o Reproducibility o Handling  Thermal o Resin impregnated coils  Integration o Optics o Cold-mass o Collimator o Machine systems M. Karppinen CERN TE-MSC 4 24/05/2012

5 o Large aspect ratio, low compaction. Presently 20 µm additional compaction o FNAL roll the cable in two stages with an intermediate anneal o CERN use single pass process Strand & Cable 24/05/2012 5 M. Karppinen CERN TE-MSC Cable samples made with and without SS core show I c -degradation well within the initial goal of 10 %. Cored cable with RRP 151/169 being developed at FNAL.

6 11 T Dipole Coil Design M. Karppinen CERN TE-MSC 6  Coil optimization o >11 T at 11.85 kA with 20% margin at 1.9 K o Field errors below the 10 -4 level  6-block design, 56 turns (IL 22, OL 34) o 14.85-mm-wide 40-strand Rutherford cable, no internal splice o Several X-sections were analyzed with and without core o Coil ends optimized for low field harmonics and minimum strain in the cable B 0 (11.85 kA) = 11.21 T B 0 (11.85 kA) = 10.86 T 24/05/2012

7 Iron Saturation M. Karppinen CERN TE-MSC 7  Yoke design o The cut-outs on top of the aperture reduce the b 3 variation by 4.7 units as compared to a circular shape. o The holes in the yoke reduce the b 3 variation by 2.4 units. o The two holes in the yoke insert reduce the b 2 variation from 16 to 12 units. Relative permeabilityRelative FQ (units) 24/05/2012

8 Transfer Function M. Karppinen CERN TE-MSC 8  TF of 11 T dipole is different from MB: o More turns than MB (56 vs. 40)  11 T dipole is stronger at low field. o More saturation  reduction of transfer function at high field. Courtesy of H. Thiessen MB 11 T 300 A Monopolar Trim PC 2.4 Tm 24/05/2012

9 Coil Magnetization M. Karppinen CERN TE-MSC 9 MB (NbTi) 11 T Dipole Nb3Sn Mid-Plane Inner Layer Mid-plane Outer layer Inner Layer Pole Outer Layer Pole >10 X 24/05/2012

10 11 T Dipole Model Program 10 M. Karppinen CERN TE-MSC24/05/2012

11 11 T Model Dipole Parameters 11M. Karppinen CERN TE-MSC  FNAL 1-in-1 demonstrator based on existing HFD components. Coils with integrated poles.  CERN 1-in-1 model based on CTF (MB). Coils with non- integrated poles (pole-loading concept).  2 m long 2-in-1 magnets of both concepts. 24/05/2012

12 Titanium Poles with stress-relive slot Phosphor Bronze Key CS-Bump controls Inner Yoke Gap AL Clamp controls Outer Yoke Gap Uniform MP Shims Stainless Steel Skin Aluminum Clamp Iron Yoke Nb 3 Sn Coil Stainless Steel Collars Coil mechanical support is provided by stainless collars, vertically split iron yoke, aluminium clamp and welded stainless steel skin. Strong collars and iron yoke create the “rigidity belt” around Nb 3 Sn coil for conductor protection. Coil mid-plane and radial shims generate initial coil azimuthal pre-stress at collaring stage. Skin and clamp tensions deform the iron and produce the desired coil compression. The collar also acts as gap-controller. Collar-yoke-clamp-skin interfaces are tuned to sustain the horizontal EM force component. 1-in-1 Demonstrator Mechanical Concept 24/05/2012 12 M. Karppinen CERN TE-MSC Shims I. Novitski FNAL

13  Two alternative design concepts 2-in-1 Demonstrator Design 24/05/2012 13 M. Karppinen CERN TE-MSC Pole loading designIntegrated pole design

14 Pole Loading Concept 24/05/2012 14 M. Karppinen CERN TE-MSC Pole wedge Loading plateShim Filler wedge

15 CERN 2-in-1 Model 24/05/2012 15 M. Karppinen CERN TE-MSC

16  2 coils completed and fully instrumented with strain gauges and V-taps. CMM revealed dimensional distortions the origin of which is yet to be fully understood. All three coils made so far appear to be similar.  Spare coil wound from CERN supplied cable has been reacted and is ready for epoxy impregnation.  Mechanical model of the straight part (about 500 mm) was assembled and used for determining the initial shimming for the Demonstrator.  Cold mass assembly completed. Electrical connections (splice, instrumentation, heaters) underway  Magnet test expected as of 4 June. FNAL 1-in-1 Demonstrator Status 24/05/2012M. Karppinen CERN TE-MSC 16

17 Coil Fabrication WindReaction Epoxy impregnationInstrumentation Cure 24/05/2012M. Karppinen CERN TE-MSC 17

18 MBH03 900 mm from RE 1 box =.004” MBH02 900 mm from RE 1 box =.004” PC01 908 mm from RE  Reasons for dimensional distortions being investigated.  All 3 coils appear similar.  Different from previous coils made at FNAL.  Post-assembly measurement show smaller (approx. 50 µm) distortions. Coil Dimensions 24/05/2012M. Karppinen CERN TE-MSC 18

19  Mechanical model based on Nb3Sn practice coil (PC-0) instrumented with strain gauges  Assembly parameters were explored with 5 different sets of shims  Validation of the assembly tooling and procedure  Coil and collared coil dimensional control before and after the assembly Mechanical model 1 24/05/2012M. Karppinen CERN TE-MSC 19

20 552 mm from RE 652 mm from RE 1260 mm from RE 1160 mm from RE MM Measurement Locations (4)

21 455 mm from RE 705 mm from RE 552 mm from RE 652 mm from RE Before MMAfter MM

22  Measured signals from the strain gauges in line with the mechanical model. Demonstrator Collaring 24/05/2012M. Karppinen CERN TE-MSC 22

23 Demonstrator Cold-mass Assembly 24/05/2012M. Karppinen CERN TE-MSC 23

24  Demo test in June  2 lengths of cored RRP 151/169 cable available for 1 m coils.  Cabling trials in progress to validate single pass process (like CERN).  Design of 5.5 m long coil fabrication tooling in progress.  Infrastructure for 5.5 m long coils exists (winding, curing, reaction, impregnation, coil assy, collaring). FNAL Activities 24/05/2012M. Karppinen CERN TE-MSC 24

25  1-in-1 Demonstrator test Jun-12  1 m model(cored RRP-151/169) o Coil fabrication Jun..Aug-12 o Cold mass assemblyNov-12 o TestDec-12  2-in-1 Demonstrator (2 m) o Coils for aperture-1Aug..Oct-12 o 1-in-1 assembly and testFeb-13 o Coils for aperture-2Nov..Feb-13 o 1-in-1 assembly and testQ2-13 o 2-in-1 assembly and test (@cern)Q3-13  5.5 m prototype magnet o Practice coil (Cu)Q2-13 o Practice coil (Nb3Sn)Q4-13 o Coils for aperture-1 & mirror testsQ2-14 o Collared coilQ3-14 FNAL Milestones 24/05/2012M. Karppinen CERN TE-MSC 25

26  1-in-1 (2 m) magnet assembly and fabrication drawings being completed.  2-in-1 (2 m) magnet assembly in progress.  Design of 5.5 m long tooling has begun.  Collaring tooling design complete.  Conceptual design of coil handling and assembly tooling complete. Fabrication design in progress. CERN Design Effort 24/05/2012M. Karppinen CERN TE-MSC 26

27  Collar laminations for the mechanical model were delivered and inspected in CERN metrology lab. The order for collars for the aperture #1 was raised. Invitation to tender for the supply of collar laminations for aperture #2 to #5 being launched.  1-in-1 yoke laminations ordered.  Order for the outer shells to raise.  ODS copper alloy based wedges (Discup C3/30 material) expected in July.  Winding tooling completed and commissioned.  Curing tooling delivered.  Reaction tooling delivered at CERN. Dimensional control underway.  Reaction furnace commissioning planned for late July.  Vacuum impregnation tooling order placed (lead-time 18 w)  Vacuum impregnation tank expected in August. Procurement 24/05/2012M. Karppinen CERN TE-MSC 27

28  Practice coils (2 m) o Practice coils #1-#2 (Cu) Jun..Aug-12 o Practice coil #3 (ITER Nb 3 Sn) Aug..Sep-12 o Practice coil #4 (LARP RRP 54/61) Oct..Nov-12 o Mirror test at FNALJan-12  2-in-1 Demonstrator (2 m) o Coils for aperture-1 (RRP 108/127)Jan..Mar-13 o 1-in-1 assembly and testQ2-13 o Coils for aperture-2 (PIT)Apr..Jun-13 o 1-in-1 assembly and testQ3-13 o 2-in-1 assembly and testQ4-13  5.5 m prototype magnet o Practice coil (Cu)Q1-14 o Practice coil (Nb 3 Sn)Q2-14 o Coils for aperture-1 & mirror testsQ4-14 o Collared coilQ1-15 o 2-in-1 cold-mass and cryo-magnetQ2-15 o Cold testQ3-15 CERN Milestones 24/05/2012M. Karppinen CERN TE-MSC 28

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