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11 T Dipole Integration & Plans M. Karppinen

11 T Dipole Integration & Plans M. Karppinen. From short models to the series. 11 T Nb 3 Sn Dipole Project. Short model program Magnetic and mechanica l design validation Conductor development Magnet protection Material choices Fabrication process validation Scale-up

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11 T Dipole Integration & Plans M. Karppinen

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  1. 11 T Dipole Integration & PlansM. Karppinen From short models to the series

  2. 11 T Nb3Sn Dipole Project • Short model program • Magnetic and mechanical design validation • Conductor development • Magnet protection • Material choices • Fabrication process validation • Scale-up • Coil fabrication (winding, curing, reaction, impregnation) • Handling • Cold mass integration (collaring, yoke assembly) • Cold mass integration • Cold bore tube • Bus-bar routing • Interconnects • Spool correctors • Heat exchanger • Instrumentation • Alignment • Cryo-assembly (5.5 m) • Cold-test in SM18 • Collimator integration • Collimator dimensions • Interfaces (powering, instrumentation, vacuum, cryogenics, ...) • Cryostat design • QC and testing • Transport & handling M. Karppinen CERN TE-MSC

  3. 11T Dipole Coldmass (5.3 m) 5´911 • To reduce the length by 0.2 m the B0 shall be 11.66 T, which requires additional ~530 A (wp 81% => 85%) • TF correction requires -300 A, so a bi-polar 600 A trim PC could do the job. 5´772 5´546 6´257 (Ltotal) 5´772 (LCM) 242.5 242.5 M. Karppinen CERN TE-MSC

  4. FNAL 1-in-1 Model Magnet (1m) & CERN Coils Courtesy of D. Mitchell, FNAL 22 May 2013 M. Karppinen CERN TE-MSC

  5. CERN Construction Status • Coil fabrication tooling: • Winding, curing, and reaction fully operational • Vacuum impregnation system now commissioned • Practice coil fabrication • PC-#1-2 (Cu-cable) reacted, being impregnated • PC #3 Nb3Sn (low-Jc WST strand) scrapped • Nb3Sn (RRP-54-61) reacted, to impregnate • Magnet R&D: • Cable insulation (braided S2-glass & Mica) • ODS (oxide dispersion strengthened) wedges • Selective laser sintering (SLS) end spacers • Coil pre-loading concept (“pole-loading”) • Magnet protection (inter-layer heater) Coil reaction Coil impregnation Reacted Nb3Sn (RRP-54/61) coil M. Karppinen CERN TE-MSC

  6. CERN 11 T Dipole Coil Loading plate 2 mm 316LN SLS End Spacers with “springy legs” ODS Cu-alloy Wedges Braided 11-TEX S2-glass on “open-C” Mica sleeve Courtesy of D. Mitchell, FNAL M. Karppinen CERN TE-MSC

  7. CERN Short (2 m) Model Program • Assemble and test the RRP-54/61 coil (reacted) as single coil assembly (MBHSS101) using existing collars, yoke, welded outer shell, and end plates • Two RRP-108/127 coils to assemble and test the 1st 1-in-1 model (MBHSP101) • Two RRP-132/169 coils to assemble and test the 2nd 1-in-1 model (MBHSP102) • Collared coils from MBHSP101 & 102 to assemble and test the 1st 2-in-1 model (MBHDP101) • Idem for PIT-cable: 2 x 1-in-1 model (MBHSP103-4) to have tested collared coils for the 2nd 2-in-1 model (MBHDP102). • Will be conflicting with MQXF and other magnet projects in terms of human resources and infrastructure M. Karppinen CERN TE-MSC

  8. CERN Single Coil Assembly Courtesy of C. Kokkinos & T. Lyon CERN TE-MCS Aftrer assembly at 293 K At 1,9 K, 11.02 T, 14.1 kA Azimuthal coil stress (Mpa) Azimuthal coil stress (Mpa) M. Karppinen CERN TE-MSC

  9. CERN Short Model Schedule Oct-Nov -13 Jan-Feb -14 Apr-May -14 1-in-1 #1 Test Nov -14 – Jan -15 Feb-Mar -15 1-in-1 #2 Test Apr-Jun -15 2-in-1 #1 Test 1-in-1 #3 Test 1-in-1 #4 Test 2-in-1 #2 Test M. Karppinen CERN TE-MSC

  10. CERN Prototype (5.5 m) Schedule • Start with winding trials using Cu-cable: • simplified trials • coil with bare cable • first practice coil with insulated Cu-cable to react and pot (PC-1). • First Nb3Sn practice coil with possibly low-performance (cheaper) cable (PC-2) • First “real” coil (PC-3) to cold test as a single coil (mirror?) • Four (or eventually more..) more coils for 2 collared coils to construct the full-scale proto and test it in Mid-2016. • the 5.5 m schedule is compatible with the present LMF plans including the major procurements • Additional coil production lines will be required for series magnets • It is also vital to get the industry on board during the prototype construction to be ready for the series units M. Karppinen CERN TE-MSC

  11. CERN 5.5 m Prototype Schedule May-June 2015 July-August 2016 Single coil Qualification Test 5.5-m-long 2-in-1 Prototype Test M. Karppinen CERN TE-MSC

  12. Series production (First impression) • LS2: • Ions: Install 2 x units (4 X 5.5 m CM) in IR2 + 1 spare • Protons: Install 4 x units (8 X 5.5 m CM) in IR7+ 1 spare Deliver 6-10 fully tested 5.5-m-long 11 T Dipole cold masses Integrate 2-4 fully tested 15.6-m-long cryo-assemblies in the LHC • Coil production: • 12-20 off 5.5-m-long coils to deliver • 1 Production line/2 production lines • 1/2 coil in 12 w, 2/4 coils in 17 w • All coils: 26-43 months / 13-22 months • Cold mass integration: • Two collared coils 8 months / 5 months • Cold mass assembly 1 month • Cryostat assembly 1 month • Cold test 2 months • 6-10 CM X 11 / 9 months = 48-84 / 34-54 months • Cryo-assembly: • Cold mass integration: 2 months • Cold test: 2 months • 2 complete units min. 28 months M. Karppinen CERN TE-MSC

  13. Cold mass vs. coil production lines M. Karppinen CERN TE-MSC

  14. 2 Off Cryo-Assemblies for IR2 M. Karppinen CERN TE-MSC

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