1. FCC 16T dipoles Analysis of magnet assembly cost drivers update 25/04/2017

2. FCC 16 T dipole 4578 dipoles + 5 % spares : 4807 dipole magnets
16T nominal field; 14.3 m long
7.5 years production
Training and pre-series phases : 18 months
Start up phase : 12 months
Series fabrication : 5 years
means
962 magnets/year over 5 years full rate production
20 magnets/week
4 companies  5 magnets/week, 1 magnet/day, but for cost model we will consider as if one single company had to produce all the magnets

3. FCC 16 T dipole – design options
To be updated
For all configurations
2 double layer coils / pole
8 double layer coils / magnet
Cosintheta configuration
Several wedges
Coil dimensions (v 16T-22b-37-optd7f8) :
110 x 55 mm²
170 x 85 mm²
Block configuration
Few wedges (in the ends)
Need for High Field splices
Coil dimensions (v19ar):
135 x 70 mm²

4. Assembly steps x nb operations/magnet
Coil Winding x 8
Coil Heat-treatment x 8
Internal HF splices (only block graded coils) x 16
Transfert from reaction fixture to impregnation mold x 8
Splices preparation x 2 x 8
Coil Instrumentation x 8
Coil Impregnation x 8
Control measurements x 8
Coil pack assembly x 2
Structure assembly (+ Splices) x 2
Cold mass assembly x 1

5. Coil winding It covers:
Winding preparation (cable, tools, coil parts, ..)
Winding itself. Each coil is made of two layers , wound the one after the other, with no internal splices
Positioning and closing of the reaction fixture (including cable ends supports) around the winding
Cosinetheta vs block : 3 times longer winding
Curing of binder : 1 day per layer
Min 2 weeks for one coil
MQXF : 3 weeks for one coil
LHC dipoles : For one layer : 2 shifts, 1 week + curing
For one coil (2 layers) : 4 shifts, 1 week
 we will consider 2 weeks, 1 shifts for full rate production

6. Coil winding - tools Winding machine Beam + Mandrel
Winding reels 1 and 2
Lathe for cable preparation
Guiding tools
Handling tools
Estimated cost for a winding machine, 15 m long : 300 kCHF

7. Coil Heat Treatment Typical Heat Treatment lasts 2 weeks It covers :
Positioning of reaction fixture(s) into furnace
Furnace preparation, pumping, « rinsing », filling with inert gaz
Reaction cycle
RRP FRESCA2 cable : 7 days + cooldown from 650°C
PIT FRESCA2 cable : 10 days + cooldown from 650°C
Longer heat treatments for IT strands
Reaction fixture(s) extraction from furnace
20 magnets/week
8 double layer coils per magnet
160 coils heat treated/week

8. Coil Heat Treatment - Tools
Reaction fixtures (nb equal to 2 x nb of coils/furnace)
Handling tool
Furnace(s)
Tool for Insertion into furnace

9. Coil Heat Treatment – Furnace 1/2
160 coils/week
2 weeks Heat Treatment
If one coil = 1 furnace  320 furnaces are needed
If 1 furnace : 1 MCHF
 320 MCHF/4807 magnets  67 kCHF/magnet
Or big furnaces, with more than one coil heat treated at the same time
Température homogeneity should not be an issue
Heating parts could be uniformely distributed inside the furnace
4 coils/HT  80 furnaces, 1.5 MCHF each  25 kCHF/magnet
up to 20 coils /HT, 5MCHF furnace ?  17 kCHF/magnet
Risk analysis needed : 4 coils vs 2 ?
20 coils vs 4 ?

10. Coil Heat Treatment – Furnace 2/2
Inert Gaz furnace vs Vacuum furnace : 4 times cheaper
The possibility of using cheaper nitrogen gaz instead of argon should be considered, even if Nitrogen is less inert than Argon.

11. Heat Treatment  Impregnation
Time for transfert from reaction fixture to impregnation mold should not be neglected :
Remove all the screws / open reaction fixture (hundreds of screws !)
Replace upper part of reaction fixture with upper part of impregnation mold
Fix the two parts together
Rotate
Remove all the screws
Replace lower part of reaction fixture by lower part impregnation mold
11 T : 3 weeks (with splices and instrumentation)
Tools needed to handle, rotate, tilt, close/unclose fixtures:
Tables
Rotation tool
Handling tool

12. Splices High Field Splices
Needed only for block configuration, graded coils
Nb3Sn/Nb3Sn splices between high field and low field regions
Thermal diffusion splices or classical SnAg solder splices
Nb3Sn / NbTi splices
For all coil configurations, at each end of the cable
It covers :
Reaction parts replacement impregnation
Half a day for one splice
NbTi / NbTi external splices
Assembly of coils in a pole
Assembly of poles in apertures (after structure assembly)
It can be done once the assembly done in a parallel line (not on critical path)

13. Coil instrumentation
During transfert from reaction to impregnation fixtures
In // to Nb3Sn / NbTi splices
11 T : 3 weeks (with transfert and splices)
MQXF : 1 week
We will consider 2 weeks for
Coil transfert from reaction to impregnation fixtures
Nb3Sn/NbTi splices (+ HF splices if needed)
Coil instrumentation

14. Coil impregnation It covers:
Mold preparation (mold closing, sealing, impregnation circuit preparation, ..) : 1 day
Pumping, degazing at around 100°C : from 2 to 5 days (cfd Oxford)
Filling with resine : 1 day
Resin curing cycle : 2 days
Mold opening, coil extraction
Coil finishing
It lasts 1 to 2 weeks for one coil
CERN:
Building 180 (8 m long coils) : 3 weeks
Building 927 (short models) : 1.5 weeks
we will consider 1 full week, 1 shift with no need for operators during pumping phase (week-end…)

15. Coil impregnation - resin
FRESCA2, EuCARD2 reference : CTD-101-K
1 Kit 5 gallons, 35 kg cost is 2kCHF, but there are cost savings for increased volumes
The resin has a shelf life of 1 year from date of manufacture
Resin density around 1 g/cc
Needed resin in a coil is quite small but for one impregnation, up to 4 times more should be prepared and injected in the impregnation circuit to allow to put pressure (3-4 bars) inside the mold
MQXF, 11T : 1.5 kg needed inside a coil but 6 kg prepared for each imp.

16. Coil impregnation - tools
Impregnation mold
Impregnation circuit
Heating system
Autoclave or Vacuum chamber ?
At CERN:
Vaccum chamber building 180 : 1M€
Vacuum chamber « standard » : k€

17. Coil controls Coil mechanical measurements
150 mm steps, 15 m  100 measuremens /coil !
Electrical tests
Insulation to ground
Quench heaters
Coil dimensional measurements ?
MQXF, 11T : 1 week

18. Magnet assembly It covers: Coil pack assembly
8 Coils assembly  4 poles, 2 apertures
Assembly of the structure around the coil pack
Insertion of the coil pack inside the structure modules
Bladder & keys insertion
Structure modulus (laminations, Al shells) pre-assembled 1 m long modules
NbTi splices
Splices between coils
Warm field measurements needed at each steps
Aperture
Magnet
We will consider 2 weeks, 1 shift for full rate production

19. Magnet assembly - tools
Assembly tables
Coil dimensional measurement tools, Fuji paper, ..
Bladders
Warm field measurements bench

20. Cold mass assembly It covers:
Precise positioning of the two halves of the helium vessel
Longitudinal welding of the two halves
Assembly of end coves
Orbital welding of covers
Busbars
Spool pieces
Cold mass finishing
Leak tests
Warm field measurements on cold mass
We will consider 4 weeks, 2 shifts, 2 people/operation
Industrial best offer for welding the two halves :
5 magnet/week, 2 shifts, 1 press

21. Cold mass assembly - tools
Laser tracker
Welding press
Walding posts
Leak tests bench
Warm field measurements bench

22. Man power 1/2 Technical man power
Working in 2 shifts seems reasonable in term of costs
3 shifts is well more expensive
Process step
Shifts
Time needed (WEEKS)
Nb of
Operators
Work Hours
Qualification
Operations/magnet
Tot hours/magnet
Coil Winding 1 2
160
Mechanical/Winding 8
1280
Coil Heat treatment 3
0.1 24
Non skilled worker
192
Internal Splices (HF, if any) 2/coil
Mechanical
Transfert, Coil instrumentation, end splices
Mechanical/Electrical
Coil Impregnation 80
Mechanical/chemist
640
Coil tests 40
Electrical/Mechanical
320
Coil pack Assembly
120
240
Structure assembly
Cold mass assembly and finishing 4
14 weeks
1344
4712
3.5 months

23. Man power 2/2
Production engineering : around 4/company; 1 every 50 workers
Foreman : 1 every 10 workers
1 Engineers for Components inspection
2 Engineers for Quality Assurance
1 Administrative
Estimations (max 2 shifts)
70€/hour Technicien
110 €/hour Engineers
48 weeks/year
40 hours a week

24. Next steps Consolidate assembly steps/man power table
Estimate tools cost
Contact Rosario Principe for production flow charts exemples
Edit a first furnace specification; Friedrich Lackner could discuss with GERO or other firms to evaluate feasability and cost of a large furnace