Inner triplet phase i corrector design status
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Inner Triplet Phase I Corrector Design Status:. Corrector Package. Q3. ~5..7 m. M C S (T) X. D1. MCBXV. MCBXH. M Q S X. MQXC. B PM. A2. A1. B1. B3/(B6?). M. Karppinen AT/MCS 24/07/08. To IP . Outline. Corrector requirements and constraints

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Inner triplet phase i corrector design status

Inner Triplet Phase I Corrector Design Status:

Corrector Package

Q3

~5..7 m

M

C

S

(T)

X

D1

MCBXV

MCBXH

M

Q

S

X

MQXC

B

PM

A2

A1

B1

B3/(B6?)

M. Karppinen AT/MCS 24/07/08

To IP 


Outline
Outline

  • Corrector requirements and constraints

  • Some corrector specific fabrication aspects

  • Design status:

    • MCBX (CERN)

    • MQSX (STFC/RAL & CERN)

    • MCSX (CIEMAT & CERN)

  • Summary

M. Karppinen AT/MCS


Requirements constraints
Requirements & Constraints

  • Fit all correctors in dedicated cryo-assembly within 5..7 m between Q3 and D1

  • Aperture ø120 mm (TBC!)

  • Operating temperature 1.9 K or 4.5 K (TBC!)

  • (Try to) Use existing:

    • Power converter

    • Bus-bars

    • Current leads

    • Quench detection & protection systems

M. Karppinen AT/MCS


Requirements cont
Requirements.. (cont)

  • MCBX

    • correct for a triplet misalignment of 1mm

    • 1-1.5 Tm for generation of X-angle, parallel separation, and transverse adjustment of the IP

    • 6 Tm in H- and V-plane (presently 3 x 1.51/1.56 Tm)

  • MQSX

    • Compensate for triplet roll of 4 mrad

    • 20 Tm/m or 40 T/mx 0.5 m

  • MCSX

    • correct for b3 (6 units) of D1 (29 Tm)

    • 25 T/m2x 0.5 m

  • MCTX

    • MQX systematic b6 (1 unit) correction

    • 0.02 Tm @R40mm (may be suppressed)

  • MCSOX

    • Not yet clear if required…

M. Karppinen AT/MCS


Fabrication aspects
Fabrication Aspects

  • Flat cable

    • Purpose built machine to bond 2-25 enamel insulated wires together

    • Tolerance +0.02/-0.01 mm, unit length up to 160 m

    • Wires are connected in series on connection plate

    • Sometimes problems with cable splitting during winding

  • Coil winding

    • Dipole coils with standard winding machine

    • Counter-winding technique used for single winding block coils

    • All coils epoxy impregnated in vacuum or by wet-laying

  • Assembly

    • Epoxy-glass around the coils by vacuum impregnation or pre-preg

    • Pre-stress from shrink-fitted Alu/St.steel cylinders or collars

    • Off-center laminations

M. Karppinen AT/MCS


Superconducting wire

Nb47%Ti

PVA insulation

RRR >100

Filament diameter 6-7 micrometer.

Limited quantity available for model magnets

Superconducting wire

M. Karppinen AT/MCS


Coil winding
Coil winding

Counter-winding (MQSX)

Dipole winding (MCBM)

M. Karppinen AT/MCS


Coil assembly
Coil assembly

M. Karppinen AT/MCS




Electrial connections
Electrial connections

M. Karppinen AT/MCS


Mcbx for phase i
MCBX for Phase I

  • From 3 nested to 2 separate H/V-orbit correctors

  • Central field: 3 T => ~3.5 T

  • Total length: 0.7 m => ~2 m/unit

  • Aperture: ø90 mm => ø120 mm

  • Stored energy: 44kJ => ~150 kJ

  • Field quality < 1unit @30 mm

  • Quench protection: none => active protection

  • Collar based structure as an alternative for the present mechanical concept

  • First design iteration for Inom<600 A

    • Wire #4, Wire #3, New larger X-section

  • Alternative compact high current design based on MQY cable

M. Karppinen AT/MCS


Parameters 600 a design
Parameters: 600 A design

M. Karppinen AT/MCS


Cable design 4 5k
Cable design, 4.5K

  • Based on MQY Inner Cable

  • Fabrication easier than 600 A design

  • All harmonics < 1 unit @30 mm

  • db3 ≈ 20 units (can be reduced)

  • Probably requires heaters and/or Rdump

M. Karppinen AT/MCS


600 a design
600 A Design

wp = ~60 % on the LL

8-way cable

PVA insulated wire

Potted coils

Each coil consists of 8 electrical circuits in series with a quench stopper in between

Quench stopper between the coils

Existing power converters

Std. LHC QP system

M. Karppinen AT/MCS


Mcbx quench analysis
MCBX: Quench analysis

  • Four cases analysed at this point

    • Wire #4, 1.9 K, no dump resistor

    • Wire #4, 1.9 K, with dump resistor

    • Wire #4, 4.5 K, with dump resistor

    • Wire #3, 1.9 K, with dump resistor

      Additional case to look into

    • New Larger Wire, no/with dump resistor

    • Cable version, with heaters/dump resistor

M. Karppinen AT/MCS


Ver1 wire 4 1 9 k no r dump
Ver1: Wire#4, 1.9 K, no Rdump

M. Karppinen AT/MCS


Ver1 wire 4 1 9 k no r dump1
Ver1: Wire#4, 1.9 K, no Rdump

Tmax = 220 K

Ugnd = 500 V

UR= 1500 V

=> Probably OK (?)

Tmax

M. Karppinen AT/MCS


Lhc 600 a circuit
LHC 600 A circuit

Courtesy of Gert-Jan Coelingh (AT-MEI)

Design for Rd=0.7 Ω with 2 x mass available

Ugnd ≤ 420 V

Present Rd tested with 113 kJ (+115°C)

Breaker designed for 750 A

3 spare systems available

M. Karppinen AT/MCS


Ver1 wire 4 1 9 k with r dump
Ver1: Wire#4, 1.9 K, with Rdump

M. Karppinen AT/MCS


Ver1 wire 4 1 9 k with r dump1
Ver1: Wire#4, 1.9 K, with Rdump

Rd = 0.7 Ω (14.6 ms)

Tmax = 140 K

Ugnd = 400 V

UR= 1100 V

=>SAFE

Tmax

Quench origin

M. Karppinen AT/MCS


Ver1 wire 4 4 5 k with r dump
Ver1: Wire#4, 4.5 K, with Rdump

Rd = 0.7 Ω (14.6 ms)

Tmax = 110 K

Ugnd = 350 V

UR = 870 V

=>SAFE

Ver2: Wire#3, 1,9 K, with Rdump

Rd = 0.9 Ω (14.6 ms)

Tmax= 250 K

Ugnd = 1000 V

UR = 3100 V

=>RISKY

M. Karppinen AT/MCS


Mechanical design collars
Mechanical design: collars

  • Hor. Split yoke

  • St. steel/Al. collars

  • Welded st.steel skin

  • FEA underway

Courtesy of Thomas Sahner (TS-MME)

M. Karppinen AT/MCS


Mcbx plans
MCBX plans

  • Magnetic design

    • X-sections for 600 A

    • Software development/testing

  • Quench analysis

    • No protection

    • Active protection

  • Design optimization

    • Mechanical design

    • 2D&3D magnetic design

  • Model magnet (Aug -09)

  • Model Test (Sep -09)

  • Prototype Design & Construction

Underway

Next step

M. Karppinen AT/MCS


Mcbx summary
MCBX Summary

  • 600 A design based on wire #4 seems the most attractive alternative and would allow re-using the existing powering and protection systems

  • 1.9 K operation:

    • More compact coils, shorter overall length

    • Savings in material and tooling cost

    • Reduced risk of fabrication failure

    • 1.9 K Cooling available in the area

  • Cable design most compact, but requires significant investment in powering and protection. Coil fabrication much easier.

  • URGENT decisions required (aperture, Inom, operating T) to start the detailed design and to meet the tight milestones for the project.

M. Karppinen AT/MCS


Mqsx for phase i
MQSX for Phase I

  • Gradient: 80 T/m => 40 T/m

  • Total length: 0.3 m => 0.8 m

  • Aperture: ø70 mm => ø120 mm

  • Stored energy: 4.2 kJ => ~10 kJ

  • Field quality < 1unit @30 mm (Main challenge)

  • Quench protection: none => probably none (TBC)

  • Mechanical design based on the present concept

  • First design iteration for Inom<600 A

    • Wire #3

M. Karppinen AT/MCS


Mqsx present design
MQSX: Present design

M. Karppinen AT/MCS


Mqsx parameters
MQSX: Parameters

M. Karppinen AT/MCS


Field quality requirement
Field quality requirement

  • Scale measured mean MQXB to 30 mm

  • Scale with ß (12.5 km/4.5 km)n/2

  • MQSX strength 0.004 of MQXB

  • To stay in the shadow allow <10 %

M. Karppinen AT/MCS


Phase i mqsx
Phase I MQSX

M. Karppinen AT/MCS


Next steps

  • Moving forward with the baseline 6 wire 2 block configuration, there are a number of issues to be addressed.

  • Magnetically

    • Quench protection-should not be a problem, same ampere turns as single block model, but needs to be confirmed

    • Effect of manufacturing tolerances on harmonic structure

    • 3d models

      • end effects

      • spacer optimisation

  • Mechanically

    • PeterLoveridge has started looking at mechanical design issues

    • Doing some hand calcs to check any future modelling.

    • Now we have a baseline. He will do an FEA model .

  • Baseline definition

    • key components

    • Preliminary drawings

    • Manufacturing costs

James Rochford - STFC


Project resources

  • How to deliver the project within budget?

  • At the moment we are trying to better understand of the design and manufacturing costs involved, these are not same at for the existing magnet

    • 2 end spacers not 1 e.t.c

  • We need to define what RAL can do within the scope of the present budget.

    • What we will need assistance with

  • Goal in next week or so is answer these questions

James Rochford - STFC


To summarise

  • We have

  • Shown the requirements for MQSX

  • Presented 2d optimisation study

    • Defined a baseline configuration capable of meeting the requirements for MQSX

  • Started the mechanical definition of the magnet

  • Started to look at resource scheduling needed to deliver this magnet

James Rochford - STFC


Mcsx for phase i
MCSX for Phase I

Courtesy of Fernando Toral (CIEMAT)

M. Karppinen AT/MCS


Mcsx parameters draft 1
MCSX: Parameters (Draft 1)

Courtesy of Fernando Toral (CIEMAT)

M. Karppinen AT/MCS


Summary
Summary

  • MCBX can meet the Phase I requirements

  • 600 A design based on wire #4 with active protection is the most promising option

  • 1.9 K operation preferred for MCBX

  • MQSX can meet the Phase I requirements

  • Field quality spec is very tight and will translate into extremely tight mechanical tolerances

  • Super-ferric MCSX expected straight forward

  • Decision on aperture, operating current, and cooling URGENT

M. Karppinen AT/MCS


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