1. 11 T Dipole Integration & Plans M. Karppinen
From short models to the series

2. M. Karppinen CERN TE-MSC
11 T Nb3Sn Dipole Project
Short model program
Magnetic and mechanical design validation
Conductor development
Magnet protection
Material choices
Fabrication process validation
Scale-up
Coil fabrication (winding, curing, reaction, impregnation)
Handling
Cold mass integration (collaring, yoke assembly)
Cold mass integration
Cold bore tube
Bus-bar routing
Interconnects
Spool correctors
Heat exchanger
Instrumentation
Alignment
Cryo-assembly (5.5 m)
Cold-test in SM18
Collimator integration
Collimator dimensions
Interfaces (powering, instrumentation, vacuum, cryogenics, ...)
Cryostat design
QC and testing
Transport & handling
12 June 2013
M. Karppinen CERN TE-MSC

3. M. Karppinen CERN TE-MSC
11T Dipole Coldmass (5.3 m)
5´772
5´911
5´546
6´257 (Ltotal)
242.5
5´772 (LCM)
To reduce the length by 0.2 m the B0 shall be T, which requires additional ~530 A (wp 81% => 85%)
TF correction requires -300 A, so a bi-polar 600 A trim PC could do the job.
12 June 2013
M. Karppinen CERN TE-MSC

4. FNAL 1-in-1 Model Magnet (1m) & CERN Coils
Courtesy of D. Mitchell, FNAL
22 May 2013
M. Karppinen CERN TE-MSC

5. CERN Construction Status
Coil fabrication tooling:
Winding, curing, and reaction fully operational
Vacuum impregnation system now commissioned
Practice coil fabrication
PC-#1-2 (Cu-cable) reacted, being impregnated
PC #3 Nb3Sn (low-Jc WST strand) scrapped
Nb3Sn (RRP-54-61) reacted, to impregnate
Magnet R&D:
Cable insulation (braided S2-glass & Mica)
ODS (oxide dispersion strengthened) wedges
Selective laser sintering (SLS) end spacers
Coil pre-loading concept (“pole-loading”)
Magnet protection (inter-layer heater)
Coil reaction
Coil impregnation
Reacted Nb3Sn (RRP-54/61) coil
12 June 2013
M. Karppinen CERN TE-MSC

6. M. Karppinen CERN TE-MSC
CERN 11 T Dipole Coil
Loading plate
2 mm 316LN
SLS End Spacers
with “springy legs”
ODS Cu-alloy
Wedges
Braided 11-TEX S2-glass
on “open-C” Mica sleeve
Courtesy of D. Mitchell, FNAL
12 June 2013
M. Karppinen CERN TE-MSC

7. CERN Short (2 m) Model Program
Assemble and test the RRP-54/61 coil (reacted) as single coil assembly (MBHSS101) using existing collars, yoke, welded outer shell, and end plates
Two RRP-108/127 coils to assemble and test the 1st 1-in-1 model (MBHSP101)
Two RRP-132/169 coils to assemble and test the 2nd in-1 model (MBHSP102)
Collared coils from MBHSP101 & 102 to assemble and test the 1st 2-in-1 model (MBHDP101)
Idem for PIT-cable: 2 x 1-in-1 model (MBHSP103-4) to have tested collared coils for the 2nd 2-in-1 model (MBHDP102).
Will be conflicting with MQXF and other magnet projects in terms of human resources and infrastructure
12 June 2013
M. Karppinen CERN TE-MSC

8. CERN Single Coil Assembly
Courtesy of C. Kokkinos & T. Lyon CERN TE-MCS
Aftrer assembly at 293 K
At 1,9 K, T, 14.1 kA
Azimuthal coil stress (Mpa)
Azimuthal coil stress (Mpa)
12 June 2013
M. Karppinen CERN TE-MSC

9. CERN Short Model Schedule
Oct-Nov -13
Jan-Feb -14
Apr-May -14
1-in-1 #1 Test
Nov -14 – Jan -15
Feb-Mar -15
1-in-1 #2 Test
Apr-Jun -15
2-in-1 #1 Test
1-in-1 #3 Test
1-in-1 #4 Test
2-in-1 #2 Test
12 June 2013
M. Karppinen CERN TE-MSC

10. CERN Prototype (5.5 m) Schedule
Start with winding trials using Cu-cable:
simplified trials
coil with bare cable
first practice coil with insulated Cu-cable to react and pot (PC-1).
First Nb3Sn practice coil with possibly low-performance (cheaper) cable (PC-2)
First “real” coil (PC-3) to cold test as a single coil (mirror?)
Four (or eventually more..) more coils for 2 collared coils to construct the full-scale proto and test it in Mid-2016.
the 5.5 m schedule is compatible with the present LMF plans including the major procurements
Additional coil production lines will be required for series magnets
It is also vital to get the industry on board during the prototype construction to be ready for the series units
12 June 2013
M. Karppinen CERN TE-MSC

11. CERN 5.5 m Prototype Schedule
May-June 2015
July-August 2016
Single coil Qualification Test
5.5-m-long 2-in-1 Prototype Test
12 June 2013
M. Karppinen CERN TE-MSC

12. Series production (First impression)
LS2:
Ions: Install 2 x units (4 X 5.5 m CM) in IR2 + 1 spare
Protons: Install 4 x units (8 X 5.5 m CM) in IR7+ 1 spare
Deliver 6-10 fully tested 5.5-m-long 11 T Dipole cold masses
Integrate 2-4 fully tested 15.6-m-long cryo-assemblies in the LHC
Coil production:
12-20 off 5.5-m-long coils to deliver
1 Production line/2 production lines
1/2 coil in 12 w, 2/4 coils in 17 w
All coils: months / months
Cold mass integration:
Two collared coils 8 months / 5 months
Cold mass assembly 1 month
Cryostat assembly 1 month
Cold test 2 months
6-10 CM X 11 / 9 months = / months
Cryo-assembly:
Cold mass integration: 2 months
Cold test: 2 months
2 complete units min. 28 months
12 June 2013
M. Karppinen CERN TE-MSC

13. Cold mass vs. coil production lines
12 June 2013
M. Karppinen CERN TE-MSC

14. 2 Off Cryo-Assemblies for IR2
12 June 2013
M. Karppinen CERN TE-MSC