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Status and prospects of PS magnets programs consolidation program

with contributions by D.Bodart, A.Newborough, T.Zickler. Status and prospects of PS magnets programs consolidation program. Consolidation program of the PS main units : description status of Phase I consolidation findings proposed next steps Documentation

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Status and prospects of PS magnets programs consolidation program

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  1. with contributions by D.Bodart, A.Newborough, T.Zickler Status and prospects of PS magnets programs consolidation program • Consolidation program of the PS main units : • description • status of Phase I consolidation • findings • proposed next steps • Documentation • Overview of the spare magnet situation for the LHC first injectors chain • Conclusions Davide Tommasini

  2. http://indico.cern.ch/conferenceDisplay.py?confId=52221 Supporting Recent Documentation

  3. Original cost estimate : Phase I PS Main Magnet Consolidation W. Kalbreier, T. Zickler AT-MEL AC Meeting 26-6-2003

  4. PS Main Magnet Consolidation W. Kalbreier, T. Zickler AT-MEL AC Meeting 26-6-2003 Original cost estimate : Phase II

  5. 51 installed units + 4 spare units refurbished Status of Phase I consolidation Completed • we have 1 spare magnet + one set of components per magnet type • three consecutive failure on each magnet type can be covered

  6. 100 + 1 main magnets operating since 1959 : 50 years ! Description / 1 Figure of 8 windings 4 types of Pole Face Windings

  7. loose laminations since 1970  fasteners + spacers added in ‘77-’79 • damaged fastener during the shutdown 2002/2003 on MU 31 • coil insulation to ground damaged on most units but still effective • first coil insulation failure in 1999 in MU7 (short circuit to thermal interlock copper plate) • HV test in 2002/2003 shutdown two failures : in MU6 and in MU19 • same 2002/2003 shutdown a water leak provoked a short circuit on MU 20 bus bar • severe degradation (aging) of PFW cables and of their internal contacts • repair loose laminations with LHC cycle not effective but with shims to Fo8 (to be confirmed) Findings in 50 years of operation MU1 Loose laminations MU6 MU31 Loose laminations PFW connection MU19 Ground insulation

  8. insulation between main coil turns : never failed • failure of insulation to ground of main coils : it happened three times • in general dielectric insulation coils-to-ground appears very reliable this was equally true before and after Phase I Findings : in summary • degradation of PFW insulation and connections (though few failures) • problem of loose laminations still affects several units • recent failure Fo8 connection : bad tightening of a refurbished unit • shutdown preventive (in particular thermal and audio-visual inspections) maintenance limits problems during runs In 50 years of operation failures on PS main units, excluding water leaks, can be counted on the fingers of a single person

  9. Considering that : • the PS shall operate for 10 more years • we have 1 spare magnet + one set of components per magnet type • three consecutive failure on each magnet type can be covered • failures have been rare episodes so far • the most critical magnets have already been treated in phase I • replacing a magnet requires few days • any “typical” fault is repairable EXCEPT the PFW • the machine without PFW does not work (are we sure?) • time to manufacture new PFW is long • We propose to : • launch the manufacture of 50 sets of PFW (~ 3 MCHF, 2 years) • carefully monitor magnet performance with LHC cycles • continue annual inspections (on Main Coils, F8W, PFW, Yoke, Leaks) • be ready to reconsider the strategy at any time Proposed actions on PS main units

  10. Inventory • Accelerators PX, SPS and LHC • Spares • Components • Documentation • Recovering of the paper archives • Identification and scanning • Activities procedures • Web Tools • Wiki http://normawiki.web.cern.ch/normawiki/ • Database Documentation / 1

  11. Pilote work for naming and labeling old & new magnets • Total of 1993 magnet found • 1880 correctly identified and 113 under investigation • Total of 1463 magnets installed and 530 spares • 212 different equipment design codes • 1542 magnets created in the MTF (80% of the total) • 1751 magnets physically labelled (91% of the total) Documentation / 2 we are coordinating a PS Complex Equipment Catalogue very large consensus and interest for a CERN wide strategy

  12. Documentation / 3

  13. The PS complex

  14. LINAC type I to X Quadrupoles • Type I, II, IV, V, VII - spares are available (not tested). • Type III – LINAC 2 spares being used in 3 MeV test stand (tested 2007 AJN). • Type IX – LINAC 3 spare being used in 3 MeV test stand – other spare failed • Under 5 Hz testing for 3 MeV test stand (Detailed in EDMS Document: 466793 ). • Problem occurs when LINAC 4 goes into operation, NO SPARES! Current policy is that 3 MeV test stand quads can be taken if needed for LINAC 2, When LINAC 4 becomes operational LINAC 2 quads become spares. • Produce spare magnets • Type III – Desirable • Type IX – Recommended

  15. Multipoles 11 ONO/XNO/QSK (Type I) 4 ONO/XNO/QNO (Type II) 1 OSK/XSK/QNO (Type III B) 4 ONO/OSK/XNO/XSK (Type A) 4 OSK/XSK/DVT/DHZ (Type B) Booster Multi-pole correctors PS Booster No or few spares, however : cannibalization possible retuning possible Antony Newborough TE/MSC - MNC

  16. Bending magnet TBH (PXMBHFBWWP) • Only one unit in the Booster Transfer line • (BT.BHZ.10) • 0 Spares – essential for LHC operation. Bends to either PS or ISOLDE. Spare coils used in 1997, forced into yoke with 7 tone concrete block! • Laminated machined yoke due to tapered aperture (CERN 1975) • Water leak discovered Friday 13th February 2008 (Bust Water Hose) • Absolute minimum fabricate spare coils • Fabrication of new spare magnet recommended • In parallel search for alternative solutions

  17. Bending magnets 205 in the PS Proposed actions on PS main units Frequent failures of cooling channels/brazed joints 10 magnets installed, one old spare available !

  18. IONS : LINAC 3 LINAC 3 ATC/ABOC Days, January 08 - T. Zickler

  19. LEAR + TL ~ 10 magnet types with no spares IONS : TL and LEIR For main quadrupoles cannibalization may work These tables are not fully correct : situation of spares still to be assessed

  20. PS consolidation : • with the exception of PFW, everything is repairable in a short time • we may not need phase II if the machine has to be operated for just 10 more years • Other machines on the injection way to the LHC • consolidate the status of spares (storage and certification) • spare situation for Booster TL, Linac 3, Ion Beam TL, LEIR needs to be improved • We propose to • purchase 50 sets of PFW ( ~ 3 MCHF, 2 y) • produce 2 spare type IX quadrupoles for LINAC 3 (~ 30 kCHF, 12 m) • manufacture a TBH magnet + spare coils OR find alternative optics ( ~ 200 kCHF, 2 y) • manufacture spare coils for six LINAC 3 magnet types ( ~ 300 kCHF, 18 m) • manufacture a spare coil set for the LEIR main bending magnets (~150 kCHF,18 m) • LEIR TL : perform a more detailed review of status of spares before taking decisions • manufacture 2 sets of spare coils for the 205 pulsed dipole (~ 35 kCHF,12 m) except if the ones on the extraction line will be no longer used (thanks to MTE) Conclusions

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