1 / 33

Long Quadrupole Giorgio Ambrosio

Long Quadrupole Giorgio Ambrosio. BNL - FNAL - LBNL - SLAC. DOE Review ‘09 July 13-14, 2009 FNAL. OUTLINE: Status Coil, Instrum & QP, Structure, Test Prep. Plans Schedule and budget. 1. Long Quadrupole. Main Features: Aperture: 90 mm magnet length: 3.6 m Target:

iona-daugherty
Download Presentation

Long Quadrupole Giorgio Ambrosio

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Long QuadrupoleGiorgio Ambrosio BNL - FNAL - LBNL - SLAC DOE Review ‘09 July 13-14, 2009 FNAL • OUTLINE: • Status • Coil, Instrum & QP, Structure, Test Prep. • Plans • Schedule and budget 1 G. Ambrosio - Long Quadrupole

  2. Long Quadrupole Main Features: Aperture: 90 mm magnet length: 3.6 m Target: Gradient: 200+ T/m Goal: Demonstrate Nb3Sn magnet scale up Timeframe: 1st Long Quad test by the end of 2009 2nd Long Quad test in Spring 2010 LQ Design Report available online at: https://plone4.fnal.gov/P1/USLARP/MagnetRD/longquad/LQ_DR.pdf G. Ambrosio - Long Quadrupole

  3. LQ WBS Coils are being fabricated at FNAL and BNL F. Nobrega (FNAL), and J. Schmalzle (BNL) Quench protection and instr. design & proc. at LBNL H. Felice Shell structure: design, procur. & assembly at LBNL  P. Ferracin Collar structure: procurement at FNAL (STOPPED)  F. Nobrega All LQ models to be tested at FNAL  G. Chlachidze 3 G. Ambrosio - Long Quadrupole

  4. Status Summary • 4 coils ~ready for LQS01 assembly • Shell-structure is ready • Pre-assembly practice in progress • Readiness review: ~July 27 • Test prep ~completed • Readiness review TBD • LQS01 test in October G. Ambrosio - Long Quadrupole

  5. COILS G. Ambrosio - Long Quadrupole

  6. Coil Fabrication • Coil fabrication is a labor intense work, using a lot of different tooling • Wind & Cure: 3 weeks • Reaction: ~5 weeks • Impregnation: 4 weeks • Instrumentation: 2 weeks • Shipment(s): 2 weeks each • Found and fixed several “bumps on the road” • See next slides • Long coil fabrication technology is improving • Last FY we fixed the HT, this FY the impregnation G. Ambrosio - Long Quadrupole

  7. DR's LQ06 LQ07 LQ08 LQ09 LQ10 LQ11 Total minor 7 2 3 1 1 1 15 moderate 1 4 2 2 0 2 11 severe 0 0 0 0 0 0 0 Total DR's 8 6 5 3 1 3 26 Discrepancy Reports We are implementing Discrepancy Reporting, formal (FNAL) and/or verbal (BNL, FNAL) minor DR: parts are missing or don't fit properly, revisions to drawings or traveler moderate DR: no permanent damage to the coil, change in process and/or part required severeDR: damage or irregularity to coil Discrepancy reports during winding & curing: Discrepancy reports during reaction: Moderate/severe :1 (coil #7) Discrepancy reports during impregnation: Severe :2 (coils #6 and #9) G. Ambrosio - Long Quadrupole

  8. Coil Fabrication Status – I Found tension on conductor after coil #3 heat treatment Performed analysis† Developed solution for LQS01 coils (gaps) Further analysis by Toohig fellow and core programs Coils 4 and 5 will be used for practice assembly Coils 6 to 9 will be used for LQS01 SOLVED †G. Ambrosio, et alt., “Development and Coil Fabrication for the LARP 3.7-m Long Nb3Sn Quadrupole”, ASC08 – To be Published in IEEE Trans. on App. Supercond. 8

  9. Coil Fabrication Status – II • Coil #4: non effective mold-release • In use for practice assembly; Mold-release tested on coil #3 parts • Coil #5: leakage during impregnation  incomplete impregnation • Used for QP heater tests; for practicing with 2nd impregnation; in use for practice assembly • Coil #6: incomplete impregnation • Fixed by 2nd impregnation; added soak time under pressure after impregnation • Coil #7: Power outage during HT stopped argon flow • Witness samples are OK; removed valves • Coil #8: No problem • Coil #9: Midplane insulation stuck to impregnation fixture • Repaired with room-temperature epoxy • Coil #10 & #11 in progress Practice coils Next coils should show that debugging is over! G. Ambrosio - Long Quadrupole

  10. Instrumentation Completed plan LBNL: trace design, procur., ID instr. BNL & FNAL: trace installation, OD instr. Revisions to traces and procedures Based on practice coils and first production coils Added trace QC tests Additional insulation over ends Decided and implemented qualification tests for production coils Data shared on LARP plone Test of protection heaters at LN on practice coil #5 Successfully passed with large margin Modification required based on coils #4 and #5 feedback implemented in coil #8 and subsequent coils Test of coil#5 protection heaters at LN 10 G. Ambrosio - Long Quadrupole

  11. Coil Readiness Review G. Ambrosio - Long Quadrupole

  12. STRUCTURE G. Ambrosio - Long Quadrupole

  13. Yoke rod tension: 330 MPa Compressive force: 760 kN Structure Assembly • LQS structure has been fully assembled LQSD = LQS with Al dummy coils G. Ambrosio - Long Quadrupole

  14. Short Model Test at LN • 1 section (850 mm) was assembled with aluminum coils, pre-loaded and tested at LN Comparison: measurements and target values after cool-down • Dummy coil stress during cool-down to 77 K • Axial • Azimuthal G. Ambrosio - Long Quadrupole

  15. LQSD = LQ with Al Dummy Coil • Assembled and tested with many strain gauges: • Structure: 10 stations at the center of each shell segment • Coils: 6 stations • Each station with y and z gauges with temperature compensators

  16. 1.9K top head Handling & pivoting fixture LQSD Shipping fixture w shock absorbers Dedicated container on dedicated truck pedestal LQ Shipping & Test prep. • LQSD (LQ w dummy coils) gave us an opportunity to check handling and transportation (LBNL  FNAL) OK to go! G. Ambrosio - Long Quadrupole

  17. Note: LQSD has AL coils with higher module than TQS coils LQSD LN Test Results • Measured values close to targets • Stress variations in shell smaller than in TQS02 • Shell roundness is better than in TQS02 • Stress variations in coils larger than in TQS02 • Due to shell ID variation (+/- 5 mil) from section to section *TQS shell 22 mm thick, LQS shell 20 mm thick **TQS coils with Ti poles ***TQS rods made of aluminum G. Ambrosio - Long Quadrupole

  18. Shell Readiness Reviews • LQS Structure Readiness Review • Hold at LBNL before CM12 (April 7, 09) • Recommendations: PASSED • Action items: • Compute with FEM analysis the coil stress variation due to longitudinal ID variations • +/- 15 MPa • Next step: LQS01 pre-assembly review • Possibly the week of July 27 G. Ambrosio - Long Quadrupole

  19. Collar-based Structure • The test of a Long Quadrupole with Collar-based structure was in the plan approved by the LQ Support Structure Review (Nov. 07) • In the FY09 budget we planned to complete LQC procurement as back-up ($190k) • Based on recent DOE guidelines we decided to stop any LQC work. At this point: • Skin and yoke parts have been procured • Assembly tooling has been designed • Collars and tooling have not been procured (~$90k) G. Ambrosio - Long Quadrupole

  20. TEST PREPARATION G. Ambrosio - Long Quadrupole

  21. Done Done In progr. Done Test Preparation • Quench Detection System with Adaptive Thresholds • To allow using low threshold at high current avoiding trips due to voltage spikes at low current • Both DQD and AQD • Symmetric Coil Grounding • To reduce peak coil-ground voltage • LQ needs larger dump resistance than TQ magnets (60 vs 30 mOhm) • Active Ground Fault Monitoring System (Proposal) • Reconfiguration of the Magnet Protection System • Additional Heater-Firing-Units for all LQ heaters (16) • Modified Strain Gauge Readout System • To reduce noise and sampling time G. Ambrosio - Long Quadrupole

  22. T (K) ~ 30 hrs To 200 K ΔT=50 K 15 hrs ΔT=150 K 24 hrs LQSD Test Experience LQSD (Long Quad w dummy coils) test at LN was very useful and successful for: • Practice LQS handling and connection to VMTF • Cooldown with limited temperature gradient (top-bottom) • 48 hrs of cool down will be necessary for LQS01 to reach 4.5 K if temperature constraint is ΔT<150 K: • Total of 4 days including overnight idling • It will take ~4 times longer if ΔT< 50 K • Strain Gauge readout systems • Comparison VMTF and portable LBNL systems:  very good agreement Next: Test Readiness Review G. Ambrosio - Long Quadrupole

  23. SCHEDULE BUDGET PLANS G. Ambrosio - Long Quadrupole

  24. LQS01 Schedule LQS01 pre-assembly Readiness Review: ~July 27 Start LQS01 test: October Spare/LQS02 coils in progress 24 G. Ambrosio - Long Quadrupole

  25. Latest FY09 Budget Original FY09 budget + carry forward: 2,487 733 1,116 638 +41% increase LQ coil cost: • Estimates with no contingency • FY09 budget while plan was not defined • $5M max for magnet R&D 25 G. Ambrosio - Long Quadrupole

  26. “Project” monitoring Estimated with linear spending in sub-tasks FNAL LQ coil Labor expenses Actual expenses Estimated with all spending at the end of each sub-task 26 G. Ambrosio - Long Quadrupole • Weekly LQ Task Leader meetings (video/phone) • Status, progress, issues • All documents on LARP plone https://plone4.fnal.gov/P1/USLARP/MagnetRD/longquad/ • Expenses monitoring • Based on LARP finance status reports (irregular at year start)

  27. FY10 Plans • Complete LQS01 test, analysis and disassembly • Estimate: $168k (counting on FY09 carry-forward) • LQS01b/02 assembly, test, disassembly & analysis • LQS01b = LQS01 changing one/two coils • If LQS01 will show limited performance (G < 200 T/m) • LQS02 = LQS with a new set of coils • Goal: demonstrate performance reproducibility • Estimate: $482k • Complete coils #12 & #13; make two new coils • Estimate: $686k Meetings, reports, Reviews; • Estimate: $90k I would like to count on contingency money for a possible 3rd LQ test TOTAL FY10 Budget: $1,426k G. Ambrosio - Long Quadrupole

  28. LQ FY10 Schedule Start LQS01b/02 assembly: January 2010 Start LQS01b/02 test: April 2010 Two spare coils after LQS01 test feedback Q1 Q2 Q3 28 G. Ambrosio - Long Quadrupole

  29. Conclusions • Four coils the and shell-structure are ready for the assembly of LQS01 • The test facility upgrade is almost complete  LQS01 test planned in October 09 Most feedback after the test; nonetheless presently we can say that: • Long coil design and fabrication technology significantly improved • Long shell-structure was successfully assembled and tested at LN G. Ambrosio - Long Quadrupole

  30. Appendix G. Ambrosio - Long Quadrupole

  31. LQS01 Readiness Reviews PASSED PASSED 31 G. Ambrosio - Long Quadrupole • GOAL: Assess readiness for LQS01 assembly (by evaluating: choice of coils, structure, target pre-stress and assembly procedure) and test (test facility and test plan) • #1: “LQS structure and target pre-stress” • April 7, LBNL • #2: “LQ coil design and fabrication” • June 17, FNAL • #3: “LQS01 pre-assembly” • end of July at LBNL • #4: “Test readiness and test plan”  Introduction – G. Ambrosio LQS01 Readiness Review #1 – LBNL, Apr. 7, 2009

  32. Pre-load scenarios and comparison with TQS02 (scaled) cases Paolo Ferracin 32 04/07/2009

  33. LQS01 target pre-stressScenario 2: pre-load for 230 T/m (13.2 kA) Paolo Ferracin 33 • Shell • Strain • From 386 to 1714 µε • Stress • From 29 to 152 MPa • Coil pole • Strain • From -295 to -701 µε • Stress • From -42 to -112 MPa • Coil peak stress: 160 MPa 04/07/2009

More Related