Status and test plans of MBRDP1 prototype cold mass LMBRDP

1. Status and test plans of MBRDP1 prototypecold mass LMBRDP A.Foussat TE-MSC With contributions from H. Prin, Th. Sahner, OussamaId’Bahmane, Ph. Perret (EN-MME) 25 sept. 2018

2. LMBRDP design status • On going / next • Target CAD completion 10 Dec 2018 • Fabrication drawings for subcomponents: • Manufacture of End covers flanges • IFS system components drawings, next procurement • LV instrumentation pot prototype • Centring pieces for insertion of cold tube • Tube and flares joints drawings • Instrumentation pots components to be prototyped • Wires routing optimisation in Connection box • Next: • Qualification of longitudinal TIG/MIG welding • Specific supply line procurement • Assembly sequence, dedicated tooling • Pressure / test bench connections New 1.9K HEX Sept 2018 End flat Cover flange (QQS side) Orbital butt welding D2 Electrical bus connection side, Quench Protection and Mechanical Instrumentation • Connection Lines LD1, LD2 • D2 Electrical bus connection side, • Quench Protection VTs and Mechanical Instrumentation • Double wall extended CWT Support Pad SS Shells D2 correctors SS Shells D2 • Shells under procurement, TIG/MIG bevel details to be finalized • Two End flat covers designed, under procurement • Cryosupports complete under procurement, position approved • Cryostating interfaces definition pending • IFS design routing for prototype and series complete ( instrumentation amount envelop, final IFS location to be approved) • Prototype busbar fixed point load assembly tested up at 14kN ( no damage) • QQS connection integrated (CMI) • Connection lines to the CFB on going optimization (TF) • LV Instrumentation pots design done • QMOS of orbital TIG welding End flat Cover flange (NCS) Designcompleted by Octo 2018 D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

3. Components status Ordered/Delivered Components to be ordered, Shells: 2 for w46 (on critical path as interleaved with MQXF supply) End covers: from w 45 Supports: To be delivered and accepted Heat exchanger : shall be manufactured commissioned at CEA Grenoble Supply pipe: to be procured IFS flexible: Designed, prototype to be manufactured, long lead time Cold bore tube:nominal diameter to be changed, insulation thinner, production time 12 months, from W44 under discussionas issue with long pipe insertion clerance over 13 m IFS LV prototype components : to be procured, qualified (LMF) Flexible lines:  (SM18) Splice stabilization: design (LMF/MDT) Tooling Orbital welding machine to be upgraded, welder qualification, cross weld samples qualification, [10/2018 - 04/2019] Alignment bench: to be designed Rotation bench: to be designed, Lifting beam:  Welding press: longitudinal welding process still under development, Welding cradles:Under procurement, W06 Laser tracker:  Magnetic mole: To be developped Finishing bench tooling:To be designed, procured Pressure/test bench: Pending studies for connection D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

4. Integration layout D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

5. Cold mass layout dimensions September 2018 model reference D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

6. Instrumentation synopsis Optional location to be discussed, need vacuum evacuation line QQS LV IFS (baseline) HV/LV IFS HV IFS LV IFS (B) IFS capillary D2 CCT-2 CCT-1 IFS capillary 13kA LV signal (SG, TempS) * Quench heaters Cryo heaters Internal busbars Voltage taps 0.6kA * Inside insulation vacuum D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

7. Instrumentation budget on MBRDP, routing Wires, cable routing on going, integration from INFN model Work in progress To be confirmed with contract by 01/19 O. Id’ Bahmane D2 heat exchanger integration & D2 cryogenics meeting, Sept 2018 , A Foussat

8. MBRDP IFS location • Proposal to optimize IFS location to minimize on wires integration lengths Proposal only for prototype, check for evacuation line QQS Move on NCS D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

9. HEX integration position • All the HEX flanges dimensions fixed, dedicated assembly tooling to be designed by LMF, welding heads. Next to be decide about HEX prototype envelop into Pressure test chamber Dwg: LHCLMQ_T0114 D2 heatexchnagerintergation & D2 cryogenics meeting, A Foussat 2018

10. M3 bus extension, splices • The splices location of 13kA and 600 busbars to be designed in the external cryostat sleeve with voltages taps and supports – Nov 2018. D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

11. Cold tube integration • Lead production time of 316LN cold tubes is 12 months • Insulation thickness has been reduced to minimum 0.3 mm without discrete tube supports as per MQ magnet; • Tolerances on tubes and expected deformation of coils would reduce insertion gap to 0.7 mm, ( see sagging calculation over 4 m span) • New tube dimension under request: 98.5 mm to keep 1.6 mm insertion gap • As external manufacture contract of prototype and serie magnets about to be placed, need to keep opened integration options: • Baseline: insertion of 13 m long tube from sides / dummy tubes for Magnetic measurement to be procured, New cold tube OD of 98.5 mm • Optional: Coil collaring on tube at manufacturer (full length tube or short ones with need to develop sound tight butt welding by CERN) D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

12. MBRDP test interface to SM18 CFB • On going integration study by Ph. Perret of cryostated D2 prototype, MM anticryostat. Height adjustment - OK • Connection of HEX compatible with test cryostat • Next design of internal connection routing from CM exits lines to CFB M2, N, C’, E. • Pending flanges design from CM pressure test to SM18 CFB Courtesy P. Perret, reference presentation 29-06-2017 D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

13. Specific IFS in insulation vacuum • For large amount of LV signal wires, use of local evacuated pot with double D-Sub feedthroughs to route wire in insulation vaccum • Evacuation line to be added, min ID 10 mm to reach 10-4 mbar. • Seff = Q/Pend ; Pend=10-5mb, • Assuming a gas leak evolution of Q = 10-3 mb.l.s-1, Seff =100 l/s 210-D50-CF100-2 D-Sub Feedthrough, Weld Adapter to be selected Check for leak rate at cold, < 10-9 mb.l.-1 at 1.9K Tightness under 2.5 Mpa to be checked Ref catalog Allectra D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

14. Structural analysis of D2 CM model under gravity FEM structural analysis of D2 cold mass under gravity shows 0.6 mm maximum deformation, VM stress less than 200 Mpa. Local analysis on existing cold support to be done D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

15. Prototype Test plan • MBRDP shall follow standard NbTi magnet test campaign program • with in addition some dedicated tests: • Horizontal Magnetic measurement in anticryostat, magnetic cross talk study • Efficiency of D2 heat source power transfer through 1.9K HEX cooling • Mutual influence of D2 and correctors • Quench Pressure characterization… D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

16. Schedule • D2 prototype cold mass assembly scheduled from 10/2019 with lead time of 5.5 months. • Large procurement by LMF of critical components to be managed in parallel with coil manufacture, procedures trouble shooting at coil supplier. • The cold mass construction of D2, CCTs magnets involve new tooling and manufacture procedures to be validated through prototype. • Prototype assembly scenario is under study, options for minimizing production time under progress • Procurement time for Magnetic measurement to be included to check mid plan tilt shall be used, possible axis positioning through feed down in control of mechanical alignment. D2 heatexchangerintegration & D2 cryogenics meeting, Sept 2018 , A Foussat

17. Summary • Cold mass CAD model is complete, focus ot complete component drawings by end 2018 • Qualification of welding processes or component prototypes to be launched [03.2018- 06.2019] • Main procurement of final CM components started, several other auxiliaries series items to be procured when drawings completed [04.2018 – 09.2019] • The sequence and procedure writing of CM assembly to be designed in detail to procure dedicated jigs [ 12.2018 – 08.2019] • Test program of D2 magnet prototype to be integrated with all system test requirements, by Mar. 2019. D2 heat exchanger integration & D2 cryogenics meeting, Sept 2018 , A Foussat

18. Common design for end plate, cold supports for D2 and MQXF Universal 30t lifting tool commissioned for D2 and MQXF Orbital automatic TIG QMOS welding Next longitudinal WPS, QMOS, cross weld, UT inspection procedure

19. Thank you for your attention