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Development of HL-LHC D1 Magnets and Preparation for Series Production

Development of HL-LHC D1 Magnets and Preparation for Series Production. Tatsushi NAKAMOTO (KEK) KEK On behalf of CERN-KEK Collaboration for D1 Development for HL-LHC. 13 th CERN-KEK Committee, CERN, Dec. 11, 2018. Japanese Contribution to HL-LHC: D1 magnets.

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Development of HL-LHC D1 Magnets and Preparation for Series Production

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  1. Development of HL-LHC D1 Magnetsand Preparation for Series Production Tatsushi NAKAMOTO (KEK) KEK On behalf of CERN-KEK Collaboration for D1 Development for HL-LHC 13th CERN-KEK Committee, CERN, Dec. 11, 2018

  2. Japanese Contribution to HL-LHC: D1 magnets • Beam separation dipole (D1) by KEK • Design study of D1 for HL-LHC within the framework of the CERN-KEK collaboration since 2011. • 150 mm single aperture, 35 Tm (5.6 T x 6.3 m), Nb-Ti technology. • Development 2-m long model magnets (3 units) at KEK • Deliverables for HL-LHC • 1 full-scale prototype cold mass (MBXFP) • 6 series cold masses (MBXF1-6) T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  3. Short summary of 2-m D1 models: MBXFS • MBXFS1: Previous cross section. Insufficient quench performance. • Cold test at April 2016 • MBXFS1b: Increased coil prestress to improve quench performance. • Cold test at Feb. 2017. • MBXFS2: New cross section, improvement on prestress, QPH… • Cold test at Oct. 2018. • MBXFS3: Reproducibility check. • Cold test foreseen at July 2019 T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  4. Design overview from MBXFS2 4 8 13 4 blocks 44 turns 19 Technical challenges ・Large aperture： Management of coil size and pre-stress. ・Radiation resistance：Radiation resistant material for coil parts. Cooling capability. ・Iron saturation：Good field quality from injection to nominal current T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  5. Performance of #1 and #1b: Training Quench • Training performance was significantly improved in the MBXFS1b. • Same or better coil prestress level (target: 115MPa) in MBXFS2. Development by 2017 T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  6. Design Parameters: 1st vs 2nd Models 4 8 13 4 blocks 44 turns 19 • Four HX holes instead of two in yoke: REQUEST from CERN. • Enhancement of mechanical support of coil blocks • Newly designed QPH for reducing MIITs (max T) T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  7. Curing Temp 190oC Coil pressure 30oC/h Total HT time: 15h10m 150oC 15oC/h 120oC 30oC/h Full-close Press w lower pressure Unload/reload Time 3h20m 4h 2h 4h 1h20m 30m • Curing condition for epoxy-blended cyanate ester: 120oC x 4h + 150oC x 4h • Self-fusing of polyimide insulation: 190oC x 0.5h • Coil pressure: lower at RT, while full-closing at 120oC T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  8. Magnet assembly QPH, ground insulation wrapping Top/bottom coil assembly Collaring End-ring welding Shell welding Yoking T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  9. Azimuthal coil pre-stress in straight section • Azimuthal coil pre-stress after yoking: 111 MPa(Target value = 115 MPa) T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  10. Training history MBXFS2 MBXFS1b Ultimate • 7 quenches to the nominal current (12.050 kA) • 11 quenched to the ultimate current (13.020 kA) • Quench current of MBXFS2 achieved acceptance criteria. Nominal MBXFS1 T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  11. Field integral(I=12.047kA) (): OPERA • Unallowed multipole components small enough. • Issue: large b3 of 18 unit at Straight Section. T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  12. MOU’s • MOU’s were signed on July 6, 2018 at MEXT, Tokyo, in presence of Dr. Isogai, Director General of Research Promotion Bureau, MEXT. T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  13. D1 Cold mass Design Pressure: 2.0MPa abs. Operating Temperature: 1.9 K Shell: SUS304L t10 Alignment markers (32) 2 HX pipes Cap for alignment hole End-cover Cold bore (Beam pipe) Support for post • Two halves shell (t10, SUS304L) • Structural design of the main body: KEK • Design of interface (extremities, end-cover, support): CERN (H. Prin) • Alignment feature on the shell: 8 x 4 holes for targets (like MQXA) T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  14. Compliance with CERN Safety Rules • Pressure vessel of the D1 cold mass (LMBXF) delivered from Japan MUST comply with safety requirements defined in 2014/68/EU Pressure Equipment Directive. • HL-LHC Project, CERN-HSE (as notified-body) and KEK have been establishing the agreement and the technical guideline. Final versions will be released soon. T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  15. Open-Tender for Prototype and Series Production • Finalization of Technical Specification: • Body text pp.66, • Appendices pp.113, • Drawings pp. 480. • Explanatory meeting of provisional technical specification: Dec. 14, 2018. • Hearing of opinions by Jan. 4, 2019. • Open-Tender: Jan. 16 - Mar. 11, 2019. • Opening of bids: Apr. 2, 2019 T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  16. Schedule Start of series production Contract signed Deadline of delivery KEK in-house ? Industrial manufacturer • Model magnetdevelopmentuntil 2019. • A contract of a full-scale 7-m long prototype magnet (MBXFP) willbegiven at April 2019. • Production of seriesmagnets (MBXF1-6) willstartafter the vertical test of the prototype. • Foreseenmilestones: delivery date of cold masses (presentbaseline) • MBXFP (for string test): Sep. 2020. • MBXF1-4 (for the HL-LHC machine): Dec. 2022. • MBXF1-6 (all): Dec. 2023. T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  17. Summary • Development of beam separation dipole (D1) for HL-LHC has been carried out by KEKwith a scope of Japanese in-kind contribution to the project. • Development of the 2nd model magnet (MBXFS2) has been carried out. • New cross section with 4 HX holes and several features implemented: enhanced coil pre-stress, improved coil end shape & wet-winding, new QPH, etc. • The 1st cycle of the cold test was done. Good training performance. Fairly good field quality except large b3 of 18 unit. • The 2nd cycle is currently underway. (Dec. 10 - 22) • The 3rd model development for reproducibility check will be started in Jan. 2019. • Significant efforts have been made by KEK with a support of CERN for preparation of a full-scale prototype and series production of D1 cold masses. • Finalizing the technical specification for open-tender. • Harmonization of the interface with respect to CERN’ s design and plan. • Compliance with CERN Safety Rule, in particular PED(2014/68/EU)ESRs. • Quality management in accordance with HL-LHC Quality Plan. T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  18. Link to Technical Reports of D1 (MBXF) • 8th HL-LHC Collaboration Meeting • https://indico.cern.ch/event/742082/overview • HL-LHC WP3 Meeting • https://indico.cern.ch/event/693219/ • https://indico.cern.ch/event/736308/ • https://indico.cern.ch/event/773207/ T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  19. T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

  20. Overview of Production of D1 Prototype and Series • In-house development of 2-m model magnets so far. • Drawings of magnet are available. Preparation for 7-m magnets have started. • Fine tuning of wedges and end-spacers only after MFM of the 2nd model. • Fine-blanking dies for collar and yoke are developed and are ready for production. • 50% of stainless steel (NSSC130S) for the whole project already procured. • Production of 7-m magnets (cold masses) by a manufacturer. Contract will be given at April 2019. • Involvement of industry already from model magnet development: smooth technical transfer, accurate (lower) cost estimate. • Most of tools will be prepared by the manufacturer. • Very tight time frame for the prototype cold mass: April 2019 to Dec. 2020. • Procurement of coil winding machine in 2018 • Raw materials procured by KEK: timely provision to the manufacturer. • Low cobalt iron and stainless steel, radiation resistant GFRP. • Supplies from CERN: insulated SC cables, laminates of QPH (to be paid), HX tubes, insulated beam tubes (to be paid), end-covers (under discussion). T. Nakamoto, Development of HL-LHC D1 Magnets and Preparation for Series Production

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