Long Racetrack (LR) strategy – G. Ambrosio 1 LARP DOE review - FNAL, June 12-14, 2006 BNL - FNAL -...

BNL - FNAL - LBNL - SLAC

OUTLINE:• LR R&D goals & plans• Long Racetrack design (overview)• LRS01 Readiness Review• Schedule and budget• Conclusions

Long Racetrack (LR) StrategyGiorgio Ambrosio

DOE review - FNAL June 12-14 2006

Long Racetrack (LR) strategy – G. Ambrosio 2LARP DOE review - FNAL, June 12-14, 2006

Length Scale-Up Plan

LENGTH SCALE-UP CHALLENGE: No Nb3Sn accelerator magnet longer than 1m has ever been builtLARP should make a successful 4m long quadrupole by end of 09

2006

2007

2008

2009

FNAL Long Mirrors

LARP Long Racetracks

LARP TQs

LARP LQ DS

LARP Long Quadrupoles

Diversity and Risk mitigation for the highest probability of success of the LQs:2 mechanical designs + 2 scale-ups + design studies


Long Racetrack - GOALS

1. The main goal is to develop long Nb3Sn coils fabrication technology (winding, curing, heat-treatment, impregnation, handling)

target is to reproduce performance of short coils focus is on coil (Iss) more than magnet performance (training)

2. Coils will be tested in an Al-shell-based supporting structure (preloaded using bladders and keys) in order to verify the use of this concept for long magnets

Coil layout: two flat double-layer racetrack coilsTechnology successfully developed at LBNL and successfully modified at FNAL

From 0.3 m to 3.6m

Performed at BNL

Developed at LBNL


Long Quadrupole issues I

• Cable and insulation – Fabricate long (~300 m) Nb3Sn cables– Insulate long Nb3Sn cables: sleeve/tape/braided-on-cable

• Coil winding and handling (in all phases) – Tooling and procedures

• Heat Treatment (Nb3Sn expansion – different CTE)– X-section: “azimuthal gap” as LARP TQ models

– Ends (free vs. confined)

– Pole gaps (how many? how much?)

– Wedges: segmented vs. single-piece

Ad

dres

sed

by

LR

Par

t. a

ddr.

by

LR

Ad

dres

s. b

y ot

her

LM

LM/DS


• Impregnation – Coil orientation: vertical vs. angle – Epoxy flow: slow impregnation vs. pot-life– Epoxy input: single vs. several ports– Coil-pole interface: bonding vs. sliding surface

• Instrumentation and Quench Protection– Quench protection of long Nb3Sn magnets– Long quench heaters

• Magnet assembly– Uniform pre-stress application by:

• (i) Bladder&key tech., • (ii) Collars+skin

– End support and pre-load

Long Quadrupole issues II

Ad

dres

sed

by

LR

Par

t. a

ddr.

by

LR

Ad

dres

s. b

y ot

her

LM

TQTQ

LM


Long Racetrack R&D - Plan• Short Racetrack (SRS01), to validate technology transfer to BNL

– Same as LBNL Small Racetrack series

• Long Racetrack (LRS01), 1st test of long coils, as simple as possible– Very similar to SRS01, except a few design modifications for long coils:

• Side rails instead of horse-shoe,

• Larger yoke OD, thicker shims and coil skins

• Short Racetrack (SRS02), to introduce TQ coils fabrication tech. – Same fabrication technology of LARP Technological Quads (TQ) coils

• Ceramic binder, curing under pressure, • heat treatment with tight coil dimension control (“horizontal” gap)

• Long Racetrack (LRS02), test of long coils with TQ fabric. techn.

Curing

Heat treatment


Supporting structure - plan

Al-shell-based supporting structure (preloaded by bladders-&-keys) have successfully been used in 1m-long magnets.

Long magnets require long shells.

PLAN:

- design, procure and assemble a supporting structure with long shell

- Test with a dummy coil package (at LBNL)- Pressure sensitive paper and strain gauges

- Optimize structure

- Test with a dummy coil package (at BNL)- Possibly using real coil parts and practice coil

- Use for LRS01 and LRS02


Technology transfer: LR LQ

GOAL: to maximize the transfer of technology, information and expertise from the Long Racetrack R&D to the Long Quadrupole R&D

• The lead engineer of the Long Quadrupole R&D (Fred Nobrega, FNAL) is involved in all steps of the Long Racetrack R&D (design, assembly, test and analysis), and will visit BNL during key operations (winding, impregnation, coil inspection …)

• The lead technician of the Long Quadrupole R&D (Marty Whitson, FNAL) will be at BNL during the major steps of the coil fabrication for LRS01 and LRS02

• The L2 coordinator of Supporting R&D (G. Ambrosio) is coordinating and over-viewing all LR activities

• Trips planned in July-Sept.: PC winding, impregnation and inspection


LRS01 Design Report

Corresponding author: Giorgio Ambrosio Fermi National Accelerator Laboratory

Technical Division Magnet System Department

Mail stop 315 P.O. Box 500

Batavia, Illinois 60510

LARP_note_2006_01 4/20/2006

DRAFT_Version 15

DESIGN OF THE FIRST LARP LONG RACETRACK MAGNET (LRS01)

G. Ambrosio1, M. Anerella2, E. Barzi1, D. Cheng3, D. Dietderich3, P. Ferracin3, A. Ghosh2, S. Gourlay3, R. Hafalia3, A Lietzke3, J. Muratore2, F. Nobrega1, G.L. Sabbi3, J. Schmalzle2,

P. Wanderer2, A.V. Zlobin1

1Fermi National Accelerator Laboratory, Batavia IL 60510, USA 2Brookhaven National Laboratory, Upton NY 11973, USA

3Lawrence Berkeley National Laboratory, Berkeley CA 94720, USA

Abstract:

The LHC Accelerator Research Program (LARP) is developing, Nb3Sn quadrupole magnet models for a luminosity upgrade of the Large Hadron Collider (LHC). A major milestone in this development is to assemble and test two 4m-long quadrupole cold masses by the summer of 2009.

These quadrupole magnets will be the first Nb3Sn accelerator magnet models significantly longer than 1m, approaching the length of real accelerator magnets. The design is based on the LARP Technological Quadrupoles (TQ), with gradient higher than 200 T/m and aperture of 90 mm, made of two layers without interlayer splice. The mechanical design will be chosen between two designs presently explored for the TQs: traditional collars and Al-shell based design (preloaded by bladders and keys).

The fabrication of the first long quadrupole model is expected to start in the last quarter of 2007. Before that 4m-long racetrack coils will be fabricated and tested in an Al-shell based supporting structure. They will allow a quick start in addressing several issues related with the fabrication of long Nb3Sn coils. The design of the first Long Racetrack magnet (LRS01), including

TABLE OF CONTENTS

1. INTRODUCTION

2. CONDUCTOR CHARACTERISTICS By A. Ghosh3. MAGNETIC DESIGN By P. Ferracin4. COIL FEATURES AND FABRICATION By J. Schmalzle, and D. Dietderich5. MECHANICAL DESIGN By P. Ferracin, D. Cheng, and R. Hafalia6. MAGNET ASSEMBLY By D. Cheng, R. Hafalia, P. Ferracin, and J. Schmalzle7. QUENCH PROTECTION By J. Muratore8. COIL INSTRUMENTATION By G. Ambrosio, and P. WandererReferences

https://dms.uslarp.org/MagnetRD/SupportingRD/LongMagnetDevelopment/LRS01_design_V18.doc


Long Racetrack - DesignParameter Unit

Cable type SM

N of double-layer coils 2

Number of turns per layer 21

Strand diameter mm 0.700

Number of strands 20

Cable width (bare) mm 7.793

Cable thickness (bare) mm 1.275

Insulation thickness mm 0.092

Cu/Sc ratio 0.90

Jc(12 T,4.2 K) A/mm2 2800

Bpeak(4.2 K) T 12.23

Iss (4.2 K) kA 10.80

Iss (4.2 K) per strand A 540

Inductance @ Iss (4.2 K) mH/m 1.5

Energy @ Iss (4.2 K) kJ/m 86

Fx per quadrant @ Iss kN/m +1903

Fy per quadrant @ Iss kN/m -9

Fz per quadrant @ Iss kN 20


2D mechanical design

“Low pre-stress & rigid boundary”

• Pre-stress provided by– Bladder and keys (293 K)– Aluminum shell thermal contraction (4.2 K)

• After cooldown– Peak coil stress: 35 MPa – Most of the force to the rails and pole

• At peak field– Current has opposite direction in coil A and B– Peak coil stress: 75 MPa

Aluminum

Iron

S. steel

Coil

A B


LR longitudinal design

• Aluminum shell– Single piece– Length: 3.6 m

• Iron yokes– 50 mm thick laminations

• Iron pads– Half length (1.8 m)

• Stainless steel skins– Full length (3.6 m)

• Bladders– Half length (1.8 m)

• Keys and shims– Half length (1.8 m)


LRS01 Readiness Review

“Given the upcoming results from SRS01, the fabrication and delivery of various parts and tooling, and the inspection and commissioning of those parts and tooling, the committee feels the program should keep proceeding.

April 24-25

• We do feel that several commissioning plans and detail designs should be more carefully documented.

• Extend the ‘what if’ analysis to include ‘success’ in the LRS01 test and how the program might be extended in this scenario.o For instance, a mirror race track configuration could test other regions

of the coils for degradation and coil prestress / end load effects”Possible back-up plan in FY08

Partially done, partially in progress


Long Racetrack Schedule

LRS01 test

SRS01 test

Support. Structure

SRS02 test

LRS02 test

Oven


Long Racetrack Long Quad

• Expertise and test results of the Long Racetrack R&D will be very valuable for the Long Quadrupole R&D LQ coil design review: Feb 9, 07 Feedback by:

• LR practice coil fabrication and inspection

• LRS01 coils fabrication

• LRS01 magnet test

LQx01 coil fabrication start: Nov 6, 07 Feedback to coil fabrication procedures by:

• All of the above + LRS02 coils fabrication and magnet test

LQ mechanical design selection: May 15, 07 Feedback by: • LR supporting structure tests at room temperature

• LRS01 magnet test


FY07 budget (in progress)

• Complete coil fabrication and assembly of LRS01• Coil fabrication and assembly of SRS02 and LRS02• Test of Supporting Structure• Test LRS01, SRS02 and LRS02

k$ BNL FNAL LBNL

Long Magnet Development

FY06 Racetrack coil fab & test Schmalzle 1515 1399 24 92

Racetrack supporting structure Ferracin 222 222

FY07 Racetrack coil fab & test Wanderer 850 594 36 220

Extra coil 132 132

Coordination through: • Weekly conference calls or video-meetings of LR working group (BNL, LBNL, FNAL)• Weekly reports by task leaders• Minutes, reports, drawings, pictures, … on the LARP web site


Conclusions

• The Long Racetrack R&D has almost completed the 1st phase (Technology Transfer & LR design)– SRS01 will be tested next week

– The design of LRS01 is almost complete

– Successfully passed LRS01 Readiness Review

• Despite some delays the Long Racetrack R&D is on track to give very valuable feedback to the LQ R&D Feedback to LQ coil tooling design Feedback to LQ coil fabrication procedures Feedback to LQ mechanical design selection

Long Racetrack (LR) strategy – G. Ambrosio 1 LARP DOE review - FNAL, June 12-14, 2006 BNL - FNAL -...

Documents

Transcript of Long Racetrack (LR) strategy – G. Ambrosio 1 LARP DOE review - FNAL, June 12-14, 2006 BNL - FNAL -...