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HO Correctors prototypes

This article discusses the design, electromagnetic properties, and mechanical studies of the high order corrector magnets prototypes for the HL-LHC. It also presents the construction process and the results obtained.

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HO Correctors prototypes

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  1. HO Correctors prototypes Marco Statera on behalf of the LASA team INFN Milano - LASA International Review on the High Order Correctors and the D2 OrbitCorrectordipole for the HL-LHC CERN – December 18th 2018

  2. OUTLINE • Scope: the High Order correctorsmagnets • Design • Electromagnetic • Design iteration • Mechanical • Coils studies • The prototypes: construction and results • Conclusions M. Statera CERN 18 Dec 2018

  3. SCOPE - High Order Correctors • The INFN-LASA follows the design, construction and test of the 5 prototypes of the High Order (HO) corrector magnets for the HL interaction regions of HL-LHC. KE2291 • This activity is funded by INFN (Magix “activity”), and with an agreement CERN contributes for about 50% • The INFN-LASA will follow the series production of the HO corrector magnets for the HL interaction regions of HL-LHC. KE3085 M. Statera CERN 18 Dec 2018

  4. THE LOW BETA SECTIONand the High Order Correctors by P. Fessia b3 b4 b6 b5 73.6 m a5 a6 a3 a4 IP M. Statera CERN 18 Dec 2018 a2

  5. HO CORRECTORSSPECS M. Statera CERN 18 Dec 2018

  6. OUTLINE • Scope: the High Order correctorsmagnets • Design • Electromagnetic • Design iteration • Mechanical • Coils studies • The prototypes: construction and results • Conclusions M. Statera CERN 18 Dec 2018

  7. SUPERFERRIC DESIGN • Longitudinaldimension • Quenchprotection • Small dimension: 84kN series production (5 magnets) NbTisuperconding coils • Racetrack • Insulationby S2 glassreinforcedmaterial Superferricdesign • Compact and modular • Strong contribution of the ironpoles • Field qualityinfluencedby the shape of the poles constraints • Existingpowersupplies • Nominalcurrentlimited to 105 A • Exceptthe quadrupole (182 A) • Quenchprotection • No energyextraction (but 4P) • 60% margin @ 1.9 K M. Statera CERN 18 Dec 2018

  8. THE SUPERCONDUCTINGWIRE • Small diameter: lowoperatingcurrent • Easy to handle, • Insulationshouldnot reduce toomuch the Je • High Cu content • Lowoperatingcurrent • Protectionw/o energyextraction • Easy to be produced ~ off the shelf • Small filaments for –Iop to +Iopoperation Bruker – EAS Nb-Ti for fusion application Cu:NbTi ~ 2.3 RRR > 100 typical 160 N. of filaments 3282 Wire (filamentdiameter) 0.5 mm (5 mm) 0.7 mm (7 mm) S2 glassinsulation 8 km + 8 km for prototypes 77 km + 36 km for series Report by M. CrouvizierEN/MMEEDMS1554721 M. Statera CERN 18 Dec 2018

  9. HO CORRECTOR MAGNETS ZOO MCSXFP1 MCOXFP1 OD460 OD320 a2 a3 b3 a4 b4 Tested 2016 Tested 2017 Assembly ongoing MCQSXFP1 a6 b6 a5 b5 Tested 2018 Tested 2018 MCDXFP1 MCTXFP1 M. Statera CERN 18 Dec 2018

  10. QUENCHPROTECTION • LASA QuenchProtection • ENERGY EXTRACTION by dumpresistor • Threshold 200 mV • Validation time 20 ms • protectionin LHC – no energyextraction (except the quadrupole) • measuringcurrent • time range 60-180 ms • maxcurrent: ultimate current (114 A) • testsatLASA – Rdump = 0 • quechinduced by heater (and AlNinsert) • increasevalidationtime 150 msat ultimate current by S. Yammine R = 0 W M. Statera CERN 18 Dec 2018

  11. DESIGN ITERATION 2017Nominalcurrentlowered from134 A to 105 A (quadrupole notaffected) • The sextupole wasalreadybuilt, design and drawingshavebeenupdated 2017Heatexchangersposition • Quadrupole cross sectionchanged 2018Changeof allintegratedgradients(exceptdodecapoles) due to betterestimates of Nb3Sn quadrupolesfieldquality • Design prototypes and series production magnetsupdated • 6P, 8P and 10P built and testedbefore the change • Quadrupole prototypehas the updated design, evenif the contract for constructionwasalreadysigned Builtat LASA constructiondrawingschangeaccepted by Saes Rial Vacuum (SRV) fine tuningperformed M. Statera CERN 18 Dec 2018

  12. MECHANICS coils pole shape maximum area n > 3 modifedideal n= 2; 3 idealshape ARMCO iron non magnetic wedges pole fluxreturnplates M. Statera CERN 18 Dec 2018

  13. FORCE MANAGEMENT Longitudinalprestress on iron • Avoidlaminationmovementsduringtranspotation or installation • 1D model • Twostepprestress (pole and full magnet) prestress on coils • Longitudinal • 1D model • Wedgesprestress • Avoidcoils movements/falling • 1D model 3D modelling of the coils for stress managenment M. Statera CERN 18 Dec 2018

  14. ASSEMBLY • Procedure developedat LASA • 6P, 8P, 10P assembledatLASA • 12P and 4P assembled in industry • Pole laminations • Inner CuBerods’ load • Coils centeringand fixing • Connections • Finallaminations • Outer CuBerods’ load alignment frame coil upper PCB PCBs fixing lamination lower PCB CuBerods wedge M. Statera CERN 18 Dec 2018 bridge

  15. COILS STUDIES 8 coils duratron • Radiationrequirement: 15 MGy • ValidatedMaterials (for coils) • Duratron • BTS2 by Arisawa • Hybrid BTS2/Duratron 5 coils BTS2 5 coils hybrid developmentat LASA Onetechnology for all HO correctors coils: 7or 8partsBTS2 for differentdimensions, formfactors, forces M. Statera CERN 18 Dec 2018

  16. FINAL DESIGN • Onetechnology for all HO correctors coils • 7-8 parts BTS2 (up to 12 in the previousversion) Machined from bulk 0.15 mm sheet 1.0 mm sheet M. Statera CERN 18 Dec 2018 In & out

  17. ASSESSMENT Procedures, measurements and reports ready for series production Coil • Wirelength, turns • Resistance(short magnets) • HVgroundinsulation (2,5 kV) • Magnet • Laminations’ profiles and slits • Alignmentof the assembly • HVgroundinsulation of the magnet (up to 2 KV) M. Statera CERN 18 Dec 2018

  18. GROUND INSULATION IEEE Standard 95-177 Room Temperature test Vtest=(2 x Vmx + 500) x2 • maximum voltageduringoperation • maximum voltage test @RT quenchprotectioncalculations by S. Mariotto • quadrupole requiresenergyextraction • ground connection in the middle of the 1.5 W M. Statera CERN 18 Dec 2018

  19. HV GROUND INSULATION 6P 8P 10P reached for 8P-10P notdefinedwhen 6P wasdesigned 12P 4P reached for 12P M. Statera CERN 18 Dec 2018

  20. OUTLINE • Scope: the High Order correctorsmagnets • Design • Electromagnetic • Design iteration • Mechanical • Coils studies • The prototypes: construction and results • Conclusions M. Statera CERN 18 Dec 2018

  21. HO CORRECTOR MAGNETS ZOO MCSXFP1 MCOXFP1 OD460 OD320 a2 a3 b3 a4 b4 Tested 2016 Tested 2017 Assembly ongoing MCQSXFP1 a6 b6 a5 b5 Tested 2018 Tested 2018 MCDXFP1 MCTXFP1 M. Statera CERN 18 Dec 2018

  22. MAGNETQUALIFICATION request: 1h@108% in HeII 1h@108% + 1h@150% Inom short magnets @2.17 K (HeII) 1h@ 150% In qualification 1h@ 108% In long magnets @4.2 K (HeI) Typicalcycle M. Statera CERN 18 Dec 2018

  23. RESULTS • Aa M. Statera CERN 18 Dec 2018

  24. MCSXFP1 241 A 97% of s.s.limit @4.2 K • Inom = 134 A • G10 insulated coils • 0.5 mm thickcopper coil to coil connections Consolidationof mechanical and electricalassemblyprocedure Tested in Feb 2016 Cu plates frame spacers longitudinalsetting duratronrings M. Statera CERN 18 Dec 2018

  25. MCOXFP1 • DURATRON coils • Aluminumnitridedisk: improvedprovokedquenchpropagation • Electricalconnection redesigned • Printedcircuitboards • Reducednumber of parts • Improved (coil to coil) quenchpropagation some training goodstability Tested in 2017 electricalconnections on PCBs M. Statera CERN 18 Dec 2018

  26. MCDXFP1 Consolidationof coils technology • Coils • Full BTS2 • HybridBTS2/DURATRON • ImprovedPCB suppots BTS2 Tested in 2017 reachedSSL DURATRON M. Statera CERN 18 Dec 2018

  27. MCTXPF1 AND MCQSXFP1 • Dodecapoleand quadrupole are more than 500 mm long • The coils can’t be produced in LASA winding machine MCTXPF1 and MCQSXFP1 produced in industry • Know how transfer • Proceduresand QA for series production At LASA • New 4.2 K cryostatcommissioned • MCTXPF1 and MCQSXFP1 testedat 4.2 K • Series magnetstestedat 4.2 K MCTXFP1 M. Statera CERN 18 Dec 2018

  28. MCTXFP1 • Construction in industryconsolidated (procedures, QA, NC, MIPs, etc) • HVgroundinsulation design proved Inom = 105 A NO energyextraction COILS • BTS2 Arisawa design • 432 windings • F 0.5 mm NbTi • 440 m • improvedelectrical connection design (HV) 575 mm OD320 Tested in Sept 2018 tested up to 150% Inom for mechanicalreasons 150% Inom FIRST HO Correctorprototypebuilt in INDUSTRY M. Statera CERN 18 Dec 2018

  29. QUENCH ANALYSIS Iultafterfew minutes maybe a precursor • Mechanicalvibration • Coil’smovement • Fluxjump Va Vb B1 B2 - B3 B4 - B5 B6 - B7 B8 - B9 B10 - B11 B12 M. Statera CERN 18 Dec 2018

  30. PRODUCTION IN INDUSTRY first HL-LHC HO coil produced in industry M. Statera CERN 18 Dec 2018

  31. MCQSXFP1 538 mm OD 460 mm • Iop= 182 A • Energy extraxtion 1.5 Wdump – ground in the middle • COILS • BTS2 Arisawa design • 754 windings • 815 m of F0.7 mm NbTi First PCB having double connections (F. RodriguesMateos) M. Statera CERN 18 Dec 2018

  32. MCQSXFP1 CONSTRUSCTION • Mechanicsmachined • Assembly ongoing • Winding test in industryperformed • Coils’ fabricationongoing • G10 insulated Test coil • BTS2 insulated coils (4 out of 6) pole assembled first coil produced cross section of the test coil M. Statera CERN 18 Dec 2018

  33. MAGNETIC FIELD MEASUREMENTS • Magneticfieldmeasurements for the prototypes are performedat CERN • A new systemwill be designed by CERN and installedat LASA 6P fieldqualitymeasurement goodagreement with simulations (<15 U) below the 100 U requirement 6P 8P 10P measured goodagreement with simulations by L. Fiscarelli M. Statera CERN 18 Dec 2018

  34. CONCLUSIONS • Electromagnetic design of the HO correctorshasbeencompleted • Twoiterations in current and gradient • Three prototypesweremanufacturedat LASA and succesfullytestedat 4.5 K • Sextupole, octupole, decapole • Allrequirementsreached • Solid design able to reach 50% currentmargin • Dodecapolemanufacturedat SRV • Transfer of technology, succesful test • Quadrupole constructionongoing M. Statera CERN 18 Dec 2018

  35. THANK YOU LASA team F. Alessandria, G. Bellomo, F. Broggi, S. Mariotto, A. Paccalini, A. Pasini, D. Pedrini, A. Leone, M. Quadrio, M. Prioli, M. Sorbi, M. Statera, M. Todero, C. Uva CERNA. Musso, E. Todesco M. Statera CERN 18 Dec 2018

  36. SPARES M. Statera CERN 18 Dec 2018

  37. LOADLINES • aa M. Statera CERN 18 Dec 2018

  38. ROUND COIL SUPERCONDUCTINGMAGNET Fe f 380 • multipolar MgB2magnet • inner bore f 150 mm • single MgB2 coil • bare diameter 1 mm • electromagnetic design • workingpoint 133 A @4.2 K • margin 48 % on the load line • adiabatic hot spot temperature < 90 K coil demonstrator 100 mm G. Volpini et al. EletromagneticStudy of a Round Coil SuperferricMagnet,IEEETr. App. Sup, 26, 4 (2016) coil tested in Mar 2018 Fe M. Statera CERN 18 Dec 2018

  39. RCSM Single Coil Test Conicalsprings Hall probe MgB2winding BTS2 • no quench training • the Coil isstableat the Ultimate Current (108% Iop) • maximum value of the currentreached: 73% of the Short Sample Limit PCB BUS BAR Straingages M. Statera CERN 18 Dec 2018 soldering

  40. PRODUCTION IN INDUSTRY • long prototypesproduced in industry • new winding machine • new custom vacuum oven M. Statera CERN 18 Dec 2018

  41. INTEGRATION H. Prin • integration in the cold mass ongoing • position • lengths • disetances - magneticcoupling • alignment • cabling • fixthreadsby resin (CTD 101K) and anti vibrationwashers • position and diameter for the HeatExchanger (MCQSXF) • connection box and cabling • integration in the powergridand electricaltests • allmagnetsbut quadrupole no energyextraction (simulation and test) • definingquenchprotectionparameters (thresholds, Dt, resistance and protectioncircuit) • definingvoltagetests (focus on series production) • powerconnections • Documentation SeeA. Musso talk F. RodriguesMateos M. Statera CERN 18 Dec 2018

  42. IEEE Standard 95-177 Room Temperature test Vtest=(2 x Vmx + 500) x2 • aaa updatedquenchprotectioncalculations by S. Mariotto • quadrupole requiresenergyextraction • ground connection in the middle of the 1.5 W M. Statera CERN 18 Dec 2018

  43. coil CuBerods M. Statera CERN 18 Dec 2018

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