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11 T Dipole Project CERN Status M. Karppinen 11 T Management meeting 1 July 2013.

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Presentation on theme: "11 T Dipole Project CERN Status M. Karppinen 11 T Management meeting 1 July 2013."— Presentation transcript:

1 11 T Dipole Project CERN Status M. Karppinen 11 T Management meeting 1 July 2013

2  Optimisation of Case #1 (CERN coil & CM) and #2 (FNAL coil & CERN CM) completed Structural Analysis Status 1 July 2013 Case #1 design features: 1. Pole shim 2. Mid-Plane Shim 3. Collar/yoke shim 4. Pole adjustment shim 5. Gap closing @ room temperature remaining closed to 12 T. 6. Stainless-steel shell 1. 3.3. 4.4. 5. 6. 2.2. Case #2 design features: 1. Mid-Plane Shim 2. Collar/yoke shim 3. Gap closing @ room temperature remaining closed to 12 T. 4. Stainless-steel shell 5. Coil/Collar Radial Shim 2.2. 3.3. 4.4. 1.1. 5.5. M. Karppinen CERN TE-MSC 2

3 CoilWedgesPoleCollarYoke Central Yoke Shell Stage Case 1 Case 2 Case 1 Case 2 Case 1 Case 2 Case 1 Case 2 Case 1 Case 2 Case 1 Case 2 Case 1 Case 2 Under Press 94113 15012947747312821146------ Collared Coil 7469 1197939833912451037------ Welding 131149 168181685109778110652423801852718978 Cold Mass 131153 17219568410648271082228371215266301312 Cool Down 139135 199177539767967939186269537464520528 B=11.22T 130156 181189150169838847220318562503530536 B=12T 144165 18020196153813835230325571513532538 Maximum Von Mises stress (MPa) on main components 1 July 2013M. Karppinen CERN TE-MSC 3

4 Acceptable solution with both configurations The maximum coil stress is lower with CERN coils Yoke gap with CERN coils is closed at RT with all parameter sets, while in the FNAL coil & CERN cold mass scenario, it’s quite challenging. The FNAL coil in CERN cold mass requires radial shimming in the Collar/Coil interface, the mid-plane shim is not required. FEA: Case #1 & # Summary 1 July 2013M. Karppinen CERN TE-MSC 4

5 CERN FNAL Mechanical Design Concepts 1 July 2013 Pole loading designIntegrated pole design M. Karppinen CERN TE-MSC 5

6  Coil fabrication tooling fully operational  Practice coil fabrication o PC-#1-2 (Cu-cable) impregnated, in CMM o PC #3 Nb 3 Sn (low-Jc WST strand) scrapped, sliced o Nb 3 Sn (RRP-54-61) reacted, to splice and impregnate  MBHSP101, first 1-in-1 model magnet: o First coil (MBH-101) wound and cured o 2 nd coil (MBH-102) wound, OL curing today. o 3 rd unit length of RRP-108/127 cabling this week o Winding of 3 rd coil (MBH-103) early August o Collar packs made for AP-1, 1-in-1 yoke to stack o Shell welding trial successfully completed CERN Construction Status 1 July 2013 Coil reaction Coil impregnation Reacted Nb 3 Sn (RRP-54/61) coil M. Karppinen CERN TE-MSC 6

7 Courtesy of M. Guinchard CERN-EN-MME Welding Trial 1 July 2013M. Karppinen CERN TE-MSC 7

8  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 1 st 1-in-1 model (MBHSP101)  Two RRP-132/169 coils to assemble and test the 2 nd 1-in-1 model (MBHSP102)  Collared coils from MBHSP101 & 102 to assemble and test the 1 st 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 CERN Short (2 m) Model Program 1 July 2013M. Karppinen CERN TE-MSC 8

9 CERN Single Coil Assembly 1 July 2013 After assembly at 293 K At 1,9 K, 11.02 T, 14.1 kA Azimuthal coil stress (Mpa) Courtesy of C. Kokkinos & T. Lyon CERN TE-MCS M. Karppinen CERN TE-MSC 9

10 CERN 1 st 2-in-1 Short Model Schedule 1 July 2013 Nov-Dec -13 Sep-Oct -13 Single Coil Test 1-in-1 #1 Test May-Jun -14 Feb-Mar -14 2-in-1 #1 Test 1-in-1 #2 Test M. Karppinen CERN TE-MSC 10

11 CERN Short Model Schedule 1 July 2013 Nov-Dec -13 1-in-1 #3 Test Jan-Feb -15 May-Jun -14 1-in-1 #4 Test Mar -15 Feb-Mar -14 2-in-1 #2 Test May-Jun -15 1-in-1 #1 Test 2-in-1 #1 Test 1-in-1 #2 Test M. Karppinen CERN TE-MSC 11

12  Start with winding trials using Cu-cable: o simplified trials o coil with bare cable o first practice coil with insulated Cu-cable to react and pot (PC-1).  First Nb 3 Sn 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 CERN Prototype (5.5 m) Schedule 1 July 2013M. Karppinen CERN TE-MSC 12

13 CERN 5.5 m Prototype Schedule 1 July 2013 May-June 2015 5.5-m-long 2-in-1 Prototype Test July-August 2016 Single coil Qualification Test M. Karppinen CERN TE-MSC 13

14  We are yet to demonstrate the target quench performance  Reasons for coil degradation are yet to be understood: o Both coils of MBHSP01 o Coil #7 of MBHSP02 o Several changes implemented/planned for coils #8..#10 o Cable stability is an issue  FNAL is completing 1 m Mirror structure. Could this be extended to 2 m to test CERN coils?  First model with pole loading concept expected by End-13  Protection studies are in progress. Inter-layer heaters would help the safe operation of 11 T dipoles in the LHC. FNAL participation in IL-heater development?  Both labs shall continue with the present short model program. The coil technology is the main topic and requires close collaboration and exchange of information.  We shall demonstrate solid 2 m coils before starting the scale-up to 5.5 m. CERN-FNAL Short Model Program 1 July 2013M. Karppinen CERN TE-MSC 14

15  Both labs working on the 5.5 m coil fabrication tooling  FNAL has the main infrastructure in place and would be operational with additional $400k investment. The main limitation is the available manpower.  CERN long tooling procurement plan is compatible with the prototype magnet schedule. Full impact of the LS1 and the industrial contracts (manpower) is yet to be seen.  CERN could provide the conductor and the coil parts.  The prototype is expected on the 2 nd half of 2016, assuming CERN only activity. This could (TBC) be advanced if the first coils were coming from FNAL.  Cold mass assembly and cold testing at CERN. CERN-FNAL 5.5 m Prototype Program 1 July 2013M. Karppinen CERN TE-MSC 15

16  LS2: o Ions: Install 2 x units (4 X 5.5 m CM) in IR2 + 1 spare o 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: o 12-20 off 5.5-m-long coils to deliver o 1 Production line/2 production lines o 1/2 coil in 12 w, 2/4 coils in 17 w o All coils: 26-43 months / 13-22 months  Cold mass integration: o Two collared coils 8 months / 5 months o Cold mass assembly 1 month o Cryostat assembly 1 month o Cold test 2 months o 6-10 CM X 11 / 9 months = 48-84 / 34-54 months  Cryo-assembly: o Cold mass integration: 2 months o Cold test: 2 months  2 complete units min. 28 months Series production (First impression) 1 July 2013M. Karppinen CERN TE-MSC 16

17 Cold mass vs. coil production lines 1 July 2013M. Karppinen CERN TE-MSC 17

18 2 Off Cryo-Assemblies for IR2 1 July 2013M. Karppinen CERN TE-MSC 18

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