1. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Status and prospects of PS magnets programs consolidation program Davide Tommasini  Consolidation program of the PS main units :  description  status of Phase I consolidation  findings  proposed next steps  Documentation  Overview of the spare magnet situation for the LHC first injectors chain  Conclusions with contributions by D.Bodart, A.Newborough, T.Zickler

2. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Supporting Recent Documentation http://indico.cern.ch/conferenceDisplay.py?confId=52221

3. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Price breakdown for Phase I of the consolidation of the first half of the PS Main magnets 2003-2006: KCHF Aluminium conductor for coils 650 Coil fabrication 3,676 Pole Face Windings 3,480 Bus-bars506 Magnet workshop 426 PS Inflector (to allow ISOLDE operation in 2005) 200 Engineer for magnet design & fabrication for AT-MEL (consultant) 200 Industrial Support for magnet refurbishment for AT-MEL 400 Industrial Support for magnet transport PS  workshop for ST-HM 150 Industrial Support, new chambers & autom. Welding machine for AT-VAC 593 Survey90 Contingency50 Overall Estimate 10,341 PS Main Magnet Consolidation W. Kalbreier, T. Zickler AT-MEL AC Meeting 26-6-2003 Original cost estimate : Phase I

4. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 PS Main Magnet Consolidation W. Kalbreier, T. Zickler AT-MEL AC Meeting 26-6-2003 Price breakdown for Phase II of the consolidation of the second half of the PS Main magnets 2006-2013: KCHF Aluminium conductor for coils 650 Coil fabrication 3,676 Pole Face Windings 3,480 Bus-bars386 Magnet workshop 0 PS Inflector (to allow ISOLDE operation in 2005) 0 Engineer for magnet design & fabrication for AT-MEL (consultant) 0 Industrial Support for magnet refurbishment for AT-MEL 400 Industrial Support for magnet transport PS  workshop for ST-HM 150 Industrial Support, new chambers etc for AT-VAC 443 Survey90 Contingency50 Overall Estimate 9,325 Original cost estimate : Phase II

5. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Status of Phase I consolidation  we have 1 spare magnet + one set of components per magnet type  three consecutive failure on each magnet type can be covered 51 installed units + 4 spare units refurbished

6. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Description / 1 100 + 1 main magnets operating since 1959 : 50 years ! Magnet TypeCoil TypeDescriptionN° Installed RABCDReturn yoke outside D-F35 SABCDReturn yoke outside F-D15 TEFGHReturn yoke inside D-F35 UEFGHReturn yoke inside D-F15 4 types of Pole Face Windings Figure of 8 windings

7. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Findings in 50 years of operation  loose laminations since 1970  fasteners + spacers added in ‘77-’79  damaged fastener during the shutdown 2002/2003 on MU 31  coil insulation to ground damaged on most units but still effective  first coil insulation failure in 1999 in MU7 ( short circuit to thermal interlock copper plate )  HV test in 2002/2003 shutdown two failures : in MU6 and in MU19  same 2002/2003 shutdown a water leak provoked a short circuit on MU 20 bus bar  severe degradation (aging) of PFW cables and of their internal contacts  repair loose laminations with LHC cycle not effective but with shims to Fo8 (to be confirmed) MU6 MU19 MU31 MU1 Loose laminations Ground insulation PFW connection

8. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Findings : in summary  insulation between main coil turns : never failed  failure of insulation to ground of main coils : it happened three times  in general dielectric insulation coils-to-ground appears very reliable this was equally true before and after Phase I  degradation of PFW insulation and connections (though few failures)  problem of loose laminations still affects several units  recent failure Fo8 connection : bad tightening of a refurbished unit  shutdown preventive (in particular thermal and audio-visual inspections) maintenance limits problems during runs In 50 years of operation failures on PS main units, excluding water leaks, can be counted on the fingers of a single person

9. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Proposed actions on PS main units Considering that :  the PS shall operate for 10 more years  we have 1 spare magnet + one set of components per magnet type  three consecutive failure on each magnet type can be covered  failures have been rare episodes so far  the most critical magnets have already been treated in phase I  replacing a magnet requires few days  any “typical” fault is repairable EXCEPT the PFW  the machine without PFW does not work (are we sure?)  time to manufacture new PFW is long We propose to :  launch the manufacture of 50 sets of PFW (~ 3 MCHF, 2 years)  carefully monitor magnet performance with LHC cycles  continue annual inspections (on Main Coils, F8W, PFW, Yoke, Leaks)  be ready to reconsider the strategy at any time

10. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Documentation / 1 - Inventory - Accelerators PX, SPS and LHC - Spares - Components - Documentation - Recovering of the paper archives - Identification and scanning - Activities procedures - Web Tools - Wiki http://normawiki.web.cern.ch/normawiki/http://normawiki.web.cern.ch/normawiki/ - Database

11. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Documentation / 2 Pilote work for naming and labeling old & new magnets we are coordinating a PS Complex Equipment Catalogue very large consensus and interest for a CERN wide strategy  Total of 1993 magnet found  1880 correctly identified and 113 under investigation  Total of 1463 magnets installed and 530 spares  212 different equipment design codes  1542 magnets created in the MTF (80% of the total)  1751 magnets physically labelled (91% of the total)

12. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 MachineTotal MagnetsCreated in MTFLabelled PS Main Ring245244240 LINAC 2524651 LINAC 330029 BOOSTER264252264 BOOSTER TL96 77 East Hall625958 Ion Beam Lines474647 AD196183186 CTF 3371333351 LEIR44242 TT25655 146313161400 Documentation / 3

13. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 The PS complex

14. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Type I, II, IV, V, VII - spares are available (not tested). Type III – LINAC 2 spares being used in 3 MeV test stand (tested 2007 AJN). Type IX – LINAC 3 spare being used in 3 MeV test stand – other spare failed Under 5 Hz testing for 3 MeV test stand (Detailed in EDMS Document: 466793 ). Problem occurs when LINAC 4 goes into operation, NO SPARES! Current policy is that 3 MeV test stand quads can be taken if needed for LINAC 2, When LINAC 4 becomes operational LINAC 2 quads become spares. Produce spare magnets Type III – Desirable Type IX – Recommended LINAC type I to X Quadrupoles

15. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Antony Newborough TE/MSC - MNC Multipoles 11 ONO/XNO/QSK (Type I) 4 ONO/XNO/QNO (Type II) 1 OSK/XSK/QNO (Type III B) 4 ONO/OSK/XNO/XSK (Type A) 4 OSK/XSK/DVT/DHZ (Type B) Booster Multi-pole correctors No or few spares, however : cannibalization possible retuning possible PS Booster

16. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Bending magnet TBH (PXMBHFBWWP) Only one unit in the Booster Transfer line (BT.BHZ.10) 0 Spares – essential for LHC operation. Bends to either PS or ISOLDE. Spare coils used in 1997, forced into yoke with 7 tone concrete block! Laminated machined yoke due to tapered aperture (CERN 1975) Water leak discovered Friday 13 th February 2008 (Bust Water Hose) Absolute minimum fabricate spare coils Fabrication of new spare magnet recommended In parallel search for alternative solutions

17. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Frequent failures of cooling channels/brazed joints 10 magnets installed, one old spare available ! Proposed actions on PS main units Bending magnets 205 in the PS

18. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 IONS : LINAC 3 LINAC 3 ATC/ABOC Days, January 08 - T. Zickler Medium RiskSolenoid (2) Bruker quads (4) Spectrometer (2) Doublet B (2) Triplet (3) Bending 106º (2) Proposed Mitigation Produce spare coils Costs [kCHF] 352540254050 Manpower [FTE*y] 0.2 0.3 Delay [months] 12 18

19. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 IONS : TL and LEIR LEAR + TL ~ 10 magnet types with no spares These tables are not fully correct : situation of spares still to be assessed For main quadrupoles cannibalization may work

20. Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4 th – 6 th 2009 Conclusions  PS consolidation :  with the exception of PFW, everything is repairable in a short time  we may not need phase II if the machine has to be operated for just 10 more years  Other machines on the injection way to the LHC  consolidate the status of spares (storage and certification)  spare situation for Booster TL, Linac 3, Ion Beam TL, LEIR needs to be improved We propose to  purchase 50 sets of PFW ( ~ 3 MCHF, 2 y)  produce 2 spare type IX quadrupoles for LINAC 3 (~ 30 kCHF, 12 m)  manufacture a TBH magnet + spare coils OR find alternative optics ( ~ 200 kCHF, 2 y)  manufacture spare coils for six LINAC 3 magnet types ( ~ 300 kCHF, 18 m)  manufacture a spare coil set for the LEIR main bending magnets (~150 kCHF,18 m)  LEIR TL : perform a more detailed review of status of spares before taking decisions  manufacture 2 sets of spare coils for the 205 pulsed dipole (~ 35 kCHF,12 m) except if the ones on the extraction line will be no longer used (thanks to MTE)