Dogleg Review Dogleg Upgrade Tommy Hiatt Magnet Modifications

Dogleg Review Outline Requirements Design Approach Mechanical Design Modeling Performance Schedule Summary

Dogleg Review Modification Requirements Design modifications to dipoles so that the dogleg dipoles meet the specified BL requirements Constraints –Use same type of power supply for each string –Modifications compatible with existing stands –Magnet deinstallation-modification-measurement- reinstallation must fit within UIM down (summer 2014) Dipoles affected –Dog3 – 1 BX dipole –Dog4 – 1 BX dipole and 2 BW dipoles

Dogleg Review Design Approach Use similar approach as the 12 GeV dipoles –Minimize Cost –Reuse existing magnet cores –Limit temperature rise in LCW to be consistent with 12 GeV Upgrade (<40C dT) –Use lengthening shims or field shaping shims if needed on modified magnets Repurpose or procure steel to increase core length Minimize additional LCW consumption Remove / touch as few magnets as possible

Dogleg Review Mechanical Design Dogleg dipoles have published field maps on a 300 A loop –Dog1 will operate within that range at 167 A All other dipoles will be pushed to higher currents –Some will meet the BL requirements by just pushing the current Dog2 – 318 A Dog5 – 365 A Dog6 – 389 A Dog7 – 414 A Dog8 – 396 A Dog9 – 413 A –Others will need mechanical modification to achieve BL Dog3 BX – new coils Dog4 – new coils and more steel

Dogleg Review Mechanical Design Modify Dog3 BX –Use larger cross section coil (BZ conductor) –No coil pocket mods necessary –No lengthening steel added Modify Dog4 BWs –Use larger cross section coil (BZ conductor) –Modify coil pocket (remove steel) –Add face shim to make up for part of the coil pocket mod. –Add ~30 cm of lengthening steel Modify Dog4 BX –Use larger cross section coil (BZ conductor) –No coil pocket mods necessary –Add ~60 cm of additional steel

Dogleg Review Mechanical Design BX Modifications (1 in Dog3 and 1 in Dog4) –Use larger cross section coils –Dog3 – no lengthening steel –Dog4 – ~60cm of additional steel Dog 4 BX Modifications

Dogleg Review Mechanical Design BW Modification (2 in Dog4) –Use larger cross section coils –Modify coil pocket –Use face shim to make up for part of the coil pocket modification Dog 3 BW Modifications

Dogleg Review Mechanical Design Mechanical changes result in –3 modified coil designs 2 for BX (with and without steel addition) 1 for BW –31 ft 3 of additional steel required Lengthen 3 dipoles –Decision point on steel acquisition options Option 1 – Obtain permission to use excess 12 GeV spare steel –Billets were purchased as back up steel for catastrophic machining or handling of S/R and arc dipoles. 2 – 3m steel billets on hand Dogleg upgrade will consume 2 billets 6 – 1m steel billets on hand Dogleg upgrade will consume 2 billets Option 2 – Purchase the steel billets that we need (similar to 12 GeV) and machine (~$65k) Option 3 – Design for 1 plate laminates (something readily procure-able) and purchase plate

Dogleg Review Modeling Linear extrapolations were done to calculate preliminary BL Tosca models were used to –confirm saturation effects for Dog3 and Dog4 –dial in exact lengths of additional steel for Dog4

Dogleg Review Modeling Use TOSCA to confirm B 0 at high currents Dog3 BX at A, B 0 = 8421G (1/4 symmetry, vert. and hor.) Dog 4 BW at A, B 0 = 7390 G (1/2 symmetry, horizontal only) Scale is ,000 GScale is 10, ,000 G Scale is ,000 GScale is 10, ,000 G

Dogleg Review Performance DogCurrent B 0 (linear) Total Voltage Total Flow LCW Max dT (A)(G)(V)(gpm)(C) – BY 7189 – BZ – BY 7656 – BZ – BY 8148 – BZ – BY 7794 – BZ – BY 8127 – BZ 58621

Dogleg Review Performance BL without modifications DogDipoleCurrent Tosca B 0 dLBL Required BL - -(A)(G)(cm)(G-cm) 3 BX ,098837,196 4 BW ,145588,806 4 BX ,8991,177,612

Dogleg Review Performance BL with modifications DogDipoleCurrent Tosca B 0 dLBL Required BL - -(A)(G)(cm)(G-cm) 3 BX ,098837,196 4 BW ,849588,806 4 BX ,177,6911,177,612

Dogleg Review Schedule Coils –~12 month lead time –Complete detailed design and drawings by March 2013 (drop dead) –PO finalized by end of April 2013 (drop dead) –Ready for magnet assembly by May 2014 Steel –Decision of option path by Feb. 22, 2013 (drop dead) –Complete detailed design drawings in next 12 months –Ready for magnet assembly by May 2014

Dogleg Review Summary Most dogleg dipoles meet BL requirements with current increase only Some dipoles will require lengthening steel and new coils Will need to purchase 3 families of coils Will need 30.6 ft 3 of steel This work is understood and similar to recent work done for 12 GeV

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Dogleg Review backup

Dogleg Review backup

Dogleg Review backup Machine Shop work –2 machinist at 1 week per dipole half 2 BW, 1 BX = 6 dipole halves 2 x 6 = 12 man-weeks (12*40*$55 = $26.4k) Refurb work –2 MT at 1 week per dipole 2 BW, 2 BX = 4 dipoles (4 * 2 * 1 * $1.3k = $10.4k) Installation –Tooling Design 1 MD for 5 weeks = (1 * 5 * $1.3k = $6.5k) –Tooling cost - $5k –Ripout – 6 MT at 2 weeks each side (6 * 2 * 2 * $1.3 = $31.2k) –Install – 6 MT at 4 weeks each side (6 * 4 * 2 * $1.3 = $62.4k) –Vacuum – half of Install estimate = $31.2k –Alignment – 2 MT for 2 week (2 * 2 * $1.3 = $5.2k) –My estimate (above = $141k) Neils estimate 209 man days = $95k