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MQXF Prototype Development

MQXF Prototype Development. Giorgio Ambrosio. LARP Internal Project Review Fermilab June 10, 2013.

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MQXF Prototype Development

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  1. MQXF Prototype Development Giorgio Ambrosio LARP Internal Project Review Fermilab June 10, 2013 The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404 Work supported by the US LHC Accelerator Research Program (LARP) through US Department of Energy contracts DE-AC02-07CH11359, DE-AC02-98CH10886, DE-AC02-05CH11231, and DE-AC02-76SF00515

  2. GOAL CERN nomenclature for the Nb3Sn Low Beta quadrupoles with 150 mm aperture G. Ambrosio • The goal of the MQXF prototype development is to demonstrate readiness for the MQXF production • Solid magnet design and fabrication process  Successful prototypes • Proven fabrication plan  Two successful production lines

  3. LARP-CERN Integrated Plan G. Ambrosio LARP and CERN are working closely together for developing and demonstrating the MQXF design: • Requirements from Hi-Lumi LHC WP3 • With strong LARP participation • Shared work for the design (single design) • Working groups with representatives from 4 labs • Shared effort for the 1stshort model (SQXF1) • CERN will focus on successive short models (SQXF) • LARP will focus on full-length (4 m) prototypes (LQXF)

  4. SQXF Plan (LARP & CERN) G. Ambrosio • Coils: • 6 coils by LARP (RRP) • 12 coils by CERN (RRP and PIT) • Support structure: • 2 SQXF structuresfabricated and qualified at CERN • One for CERN and one for LARP • Agreement to be finalized • Tests: • 2 single coil tests in mirror structure (LARP) • First test by end of 2014  Feedback to LQXF coil fabrication • Second test depending on results/issues • 4 SQXF tests (CERN, LARP ?): • First magnet test in early 2015 Feedback to LQXF assembly • Then SQXF1b (RRP), SQXF2 (PIT), SQXF2b (PIT)

  5. LQXF plan (LARP) G. Ambrosio • 16 coils (for 3 generations) • 2 structures: • 1st structure (LQXF1/2): for demonstrating main features • Aperture, length, tolerances, main MQXF requirements • 2nd structure (LQXF3): MQXF prototype • MQXF requirements to be defined by Technical Design Report (2015) • Feedback from LQXF1 • 5 tests: 3 with new coils; 2 re-assemblies • Design criteria: • Coils, tooling design, and structure developed with SQXF

  6. LQXF Fabrication Plans G. Ambrosio Fabrication plan at startis based on LQ and LHQ plans at the end demonstrates production readiness: • Strand procurement: BNL & LBNLBNL • Cabling: LBNL LBNL • Cable insulation: NEWTNEWT • Coil W&C: FNAL BNL & FNAL • Coil R&I: BNL & FNALBNL & FNAL • Structure assembly & QA: LBNLLBNL • Cold mass assembly: LBNL BNL & FNAL / LBNL • Test: FNAL or BNL(see next slide)

  7. Test Facility for LQXF G. Ambrosio • Presently there is no facility in the US for LQXF • Two options: • Upgrade of FNAL horizontal test facility • used for present LHC low beta quads • Upgrade of BNL vertical test facility • used for LARP Long Racetrack • In the present schedule and budget we have the horizontal test facility • Most expensive upgrade • We are planning a review by the end of FY13

  8. Schedule 2013 | 2014 | 2015 | 2016 | 2017 | SQXF coil in mirror SQXF1 SQXF1b SQXF2 SQXF2b LQXF1 LQXF1b LQXF2 LQXF3 & 3b G. Ambrosio and P. Ferracin

  9. Schedule Milestones G. Ambrosio • SQXF practice winding: 10/13 • SQXF coil fabrication start: 02/14 • SQXF mirror test: 12/14 • SQXF1 test: 04/15 • SQXF1b test: 10/15 • LQXF coil fabrication start: 01/15 • LQXF1 test: 02/16 • LQXF1b test: 09/16 • LQXF2 test: 04/17 • LQXF3 test: 08/17

  10. “What … if …” Analysis G. Ambrosio • Issue during 1st mirror test • Issue during SQXF1 test • Issue during LQXF1 test

  11. 2014 | 2015 | 2016 | 2017 | • - Make changes and test in 2nd mirror • - SQXF1b delayed by 1 Quarter • - LQXF1 coils may use “old” design if not too bad • or try the new design • - LQXF2 coils will use new design demonstrated by 2nd mirror SQXF coil in mirror SQXF coil in mirror LQXF1 SQXF1 LQXF1b SQXF1b SQXF2 SQXF2b LQXF2 LQXF3 & 3b G. Ambrosio and P. Ferracin

  12. “What … if …” Analysis G. Ambrosio • Issue during 1st mirror test • Issue during SQXF1 test • Issue during LQXF1 test

  13. If due to structure/assembly: - Use spare or 2nd set of SQXF coils for SQXF1b - Delay LQXF1 by 1 quarter If due to coil weakness: - 2nd SQXF mirror - LQXF2 coils will use new design demonstrated by 2nd mirror 2014 | 2015 | 2016 | 2017 | SQXF coil in mirror SQXF1 SQXF1b SQXF2 SQXF2b SQXF coil in mirror LQXF1 LQXF1b LQXF2 LQXF3 & 3b G. Ambrosio and P. Ferracin

  14. “What … if …” Analysis G. Ambrosio • Issue during 1st mirror test • Issue during SQXF1 test • Issue during LQXF1 test

  15. 2014 | 2015 | 2016 | 2017 | If due to structure/assembly or protection issue: - Make changes and use spear coil for LQXF1b or LQXF2 coils for new LQXF If due to coil weakness: - Make changes in LQXF3 coils (NOTE: this is late, we are testing LHQ coils to prevent it) SQXF coil in mirror LQXF1 SQXF1 LQXF1b SQXF1b SQXF2 SQXF2b LQXF2 LQXF3 & 3b G. Ambrosio and P. Ferracin

  16. Prototype Budget (k$) • Notes: • No escalation (it is introduced in Marc’s summary) • There is contingency in the budget only for the horizontal test facility ($900k) • Contingency for all other tasks is scope: • $290k without an LQXF test • $3.4M without an LQXF coil generation (5 coils) • $940k without the 2nd LQXF structure G. Ambrosio

  17. Risk Analysis (in progress) G. Ambrosio

  18. Summary G. Ambrosio • The Short and Long QXF prototypes are going to demonstrate readiness for MQXF production • SQXF: 18 coils, 2 mirrors, 4 magnet tests • LQXF: 16 coils, 5 magnet tests • Note: other CERN work not included in this plan • The plan is sufficiently robust to accommodate the most probable issues

  19. EXTRA G. Ambrosio and P. Ferracin

  20. SQXF statusCable R&D G. Ambrosio and P. Ferracin • Target criteria established • Mechanical stability during winding • Stability current Is≥ 3*Iop • RRR after cabling > 150 • No shear planes in micrograph images • First iteration completed in 03/2013 • Winding tests, cross-section images, extracted strand meas. • No cable reached all targets • Second iteration has started • Cabling, winding tests, micrograph images in 04/2013 • Extracted strand measurements in 05/2013 • Cable parameters for first set of coils by end of 05/2013 • Cable R&D will continue (PIT strand, improved parameters…)

  21. SQXF statusInsulation R&D G. Ambrosio and P. Ferracin • First ten-stack measurements in 03/12 • Either too thin (LARP) or too thick (CERN) • Thickness optimization in progress • Target 125-150 micron

  22. SQXF statusCoil design and magnetic design G. Ambrosio and P. Ferracin • First iteration completed • 2D magnetic analysis • Coil cross-section and yoke design • Magnetic shimming • 3D magnetic analysis (OPERA and Roxie) • Peak field • 3D Field quality • 3D CAD model • Coil (turns and blocks) • End spacers (Roxie and BEND)

  23. SQXF statusCoil fabrication tooling G. Ambrosio and P. Ferracin First iteration of pole and end-shoes design completed Design of W&C and R&I started in 03/2013

  24. SQXF statusSupport structure G. Ambrosio and P. Ferracin • 2D optimization completed • Update of the structure (alignment assembly features) • Alignment key • Dimensions of the components • LHe vessel mechanical analysis • Effect of coil deformation on field quality • 3D analysis started • 3D CAD modelling in progress • Integration, LHe vessel containment, length • Two options (CERN, BNL) under study

  25. SQXF Plan and Schedule G. Ambrosio • Finalize 1st coil design in 07/2013 • Coil tooling • Design completed in 07/2013 • Procurement • Long lead item procurement already in progress • Parallel coil fabrication LARP-CERN • CERN: 1 Wind&Curing + 1 React&impreg • LARP: 1 Wind&Curing + 2 React&impreg • Winding & curing starts in 10/2013 • Full coil fabrication starts in 02/2014 • both at CERN and in the US  First long coil wound in 01/15

  26. SQXF plan and schedule G. Ambrosio and P. Ferracin

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