Giovanni Volpini, CdS Milano 8 luglio 2014

HL-LHC
Corrector Magnet
Design & Construction
Activity Status
Giovanni Volpini
on behalf of the LASA team
presented by Sorbi Massimo
Milano, CdS July 8th, 2014
MAGIX &
INFN participation to HL-LHC
CERN-INFN Collaboration Agreement
MAGIX
Design, construction and test of
WP1
CORRAL
the
five
prototypes
of
the
corrector magnets for the HL
interaction regions of HiLUMI
WP2
PADS
2D & 3D engineering design of
the D2 magnets
Development of HTS coil for
WP3
Approved by the INFN Board of Directors on
June 2014. Soon to be signed by the INFN
President and by CERN.
CERN endorses MAGIX WP1 & WP2
deliverables and milestones, contributing
with 527 k€
SCOW-2G
application to detectors and
1
accelerators
Low-loss SC development for
WP4
SAFFO
application to AC magnets
MAGIX is a INFN-funded research project,
(GrV, «Call») whose goal is to develop
superconducting technologies for application
to future accelerator magnets.
It includes four WP’s, two of which are
relevant to HL-LHC
2014-2017, 1 M€ + personnel funds
Giovanni Volpini, CdS Milano 8 luglio 2014
2
INFN already involved in FP7HiLumi (UE-HILUMI, GrV)
WP2 beam dynamics, LNF
WP3 magnets, MI-LASA
2
WP6 cold powering, MI-LASA
Weigth
Stored energy
Yoke outer radius
Wire diameter
Magnetic length
Int strenght at radius
= 50 mm
Aperture
Order
Name
Orientation
magnet characteristics
-
mm
Tm
m
mm
mm
kJ
kg
Quadrupole
S
2
150
1.00
0.807
0.7
230.0
24.6
1000
Sextupole
N/S
3
150
0.060
0.111
0.5
160.0
1.3
80
Octupole
N/S
4
150
0.040
0.087
0.5
160.0
1.4
70
Decapole
N/S
5
150
0.030
0.095
0.5
160.0
1.4
75
Dodecapole
N
6
150
0.086
0.430
0.5
160.0
4.3
250
Dodecapole
S
6
150
0.017
0.089
0.5
160.0
1.0
75
Giovanni Volpini, CdS Milano 8 luglio 2014
3
Quadrupole
891
460
coil
yoke
bore
Giovanni Volpini, CdS Milano 8 luglio 2014
4
Quadrupole 2D cross section
Yoke radius = 230 mm
Jeng (overall)
~ 300 A/mm²
Bpeak coil = 2.97 T
High Precision Zone
for harmonics
computation
boundary
bore
coil
iron
yoke
pole
HX hole
outer
air
HX bore D 60 mm @ r = 185 mm
Giovanni Volpini, CdS Milano 8 luglio 2014
5
Iron yoke total length 800 mm
HX hole D60 @
r = 185 mm
round bore flux
return plate
Symmetric
flux return plate
Sextupole
320
Yoke laminations machined
by laser cut
followed by EDM (final
accuracy 1/100 mm) on
the relevant surfaces:
poles, coil slots, alignment
slots.
123
5.8 mm thick iron
laminations
Giovanni Volpini, CdS Milano 8 luglio 2014
7
NbTi SC wires
- Small wire (low operating current), but not too small (must be easy to handle, insulation should not reduce too
much the Je);
- High Cu content (again, low operating current, protection (4-pole));
- From the shelf product (season sale?): small amount required (tens of kg);
- Small filament: not a strict requirement, but these magnets are designed to operate in the whole range 0 A to
Imax;
Bruker-EAS
NbTi for Fusion application
Fine filaments PF wires
Wire type 2
Cu:NbTi ≈ 2.30
Number of filaments 3282
Filament diameter ≈ 8 μm @ 0.73 mm
Two wire diameters: 0.5 and 0.7 mm
S2-glass insulation 0.14 mm thick (on diameter)
Jc (NbTi only) 3,000 A/mm² @ 4.2 K, 5 T
An order for 8 km (0.5 mm) + 8 km (0.7 mm) has been placed
in Feb 2014. Delivery in July 2014.
Luvata Pori
OK3900
Cu:NbTi ≈ 2.00
Number of filaments 3900
wire diameter 0.575 mm
Filament diameter ≈ 5.3 μm
Bare wire
An order for 20 km has been issued
Giovanni Volpini, CdS Milano 8 luglio 2014
8
winding and insulation
Winding machine:
-Commercial winding machine
-Home-developed braking system, controlling
the wire tensioning between 0.5 and 20 kg ;
Insulation scheme:
-wire w/ S2 glass 0.14 mm thick (on dia)
-ground insulation applied after removing the coil
from the winding tool w/ two crossed, 50%
overlapped, 0.13 mm thick S-2 glass tape (total
0.52 mm)
Use of polyimide-insulated wires discarded since:
-neither European company is able to provide
kapton insulated wire, at least for such small
supplies;
-could not identify an external supplier for dip
coating, but only tape coating;
-doubtful behaviour during impregnation w.r.t.
fiberglass: is polyimide porous enough and does it
stick well to the resin?
Giovanni Volpini, CdS Milano 8 luglio 2014
9
Impregnation mould
Giovanni Volpini, CdS Milano 8 luglio 2014
10
Oven & impregnation
CTD-101K resin
Temperature monitored with a PT100 on the mould,
in agreement within +/- 1°C wrt the set
temperature (in stationary conditions)
Giovanni Volpini, CdS Milano 8 luglio 2014
11
Cross section
outer side
inner side
Far from perfect, but this was a first test for the whole system!
Giovanni Volpini, CdS Milano 8 luglio 2014
12
«Coil 1»
under the
optical
measuring
machine
Giovanni CERN,
Volpini, CdS
Milano2014
8 lulgio 2014
Giovanni Volpini
1 July
13
Coil assessment
Test protocol
- Coil resistance @ RT
- Ground insulation test @ 5 kV (different techniques) > 8 Gohm
- Dimensional measurements;
w/ gauge, w/ optical measuring apparatus
-> mould parts misaligned, tolerances of +/- hundredths seem
feasible
- Thermal shock @ LN on coil and on resin sample -> some crack in
the coil, near bubbles, but not only. No crack in resin sample
- Repeat resistance & ground insulation test -> OK
TBD
- Inductance measurement
- Cut & cross sections
Giovanni Volpini, CdS Milano 8 luglio 2014
14
Test cryostat
2700
A new cryostat, to be fit inside the DISCORAP vertical
cryostat, has been designed. This allows to use the exsisting
services (current, LHe feed and GHe recovery, signals, etc.)
ID 510
Giovanni
Volpini,
Milano
8 luglio
Giovanni
Volpini, CdS
CdS Milano
8 lulgio
2014 2014
15
procurement and activity
status @ LASA
221/II
•
•
•
•
NbTi wire (8 km 0.5 mm dia + 8 km 0.7 mm dia, for all the corrector magnets)
to be supplied by B-EAS, already insulated. Delivery scheduled in July;
S-2 tape, 0.13 mm thick, delivered at LASA;
Duratron plates delivered at LASA;
1st CTD-101K resin batch delivered (CERN order);
4 iron plates (580x3975 mm2) ex-LHC to be delivered from CERN to LASA for the
sextupole manufacture;
108/I
•
•
•
•
•
•
Impregnation mould teflon coated at an external company;
First impregnation test performed in June;
Curing oven refurbished and tested with the CTD-101K resin;
Winding machine being upgraded with a new wire tensioning system;
1 year contract, HiLumi funded, for a physicist, Luca Somaschini, to follow
corrector magnets manufacture QA and room temperature and cryogenic tests,
started on May 5th, in addition to the established technical staff (~3 FTE) .
Giovanni Volpini, CdS Milano 8 luglio 2014
16
principali obiettivi per il 2015
Costruzione (M1.2) e collaudo del sestupolo
aprile 2015
è importante per validare tutte le soluzioni tecnologiche e costruttive
Progetto preliminare di 4-polo, 8-polo, 10-polo e 12-polo (D1.1)
Progetto esecutivo di 4-polo, 8-polo, 10-polo e 12-polo (D1.2)
il 6-polo segue infatti una corsia preferenziale
marzo 2015
ottobre 2015
Affidamento contratto per la realizzazione del criostato verticale
indispensabile solo nella fase finale per il collaudo di 4-polo e 12-polo (più
lunghi degli altri)
Affidamento contratto per la fornitura di ferro magnetico per i gioghi
prodotto speciale (è il medesimo ferro dei gioghi di LHC)
Progetto preliminare del magnete in MgB2
(M1.3) settembre 2015
dimostratore di questa tecnologia (per il quadrupolo)
Giovanni Volpini, CdS Milano 8 luglio 2014
17
INFN-CERN Agreement approved by INFN
board of directors in June ‘14,
to be signed by INFN President
HiLumi-MAGIX schedule
2014
v. February 2014
2
3
4
5
6
7
2015
8
9 10 11 12 1
2
3
4
5
6
7
8
9 10 11 12 1
2
Project Management
WP0
M 0.1
Feb 2014
Kick-off meeting with specification transfer
M 0.2
Dec 2014
1st year activity monitoring
M 0.3
Dec 2015
2nd year activity monitoring
M 0.4
Dec 2016
3rd year activity monitoring
M 0.5
Jun 2017
4th year activity monitoring
M 1.1
M 1.2
D 1.3
D 1.4
Jul 2014
Dec 2014
Mar 2014
Mar 2015
Oct 2016
Dec 2015
Mar 2016
Jul 2016
Oct 2016
Apr 2015
July 2016
Feb 2017
Mar 2017
June 2017
M 2.1
D 2.1
June 2015
M 2.2
D 2.2
WP1
CORRAL
D 1.1a
D 1.1b
D 1.2
M 1.3
M 1.4a
M 1.4b
M 1.5
M 1.6a
M 1.6b
M 1.6c
WP2
*
*
**
***
***
****
****
****
Sextupol engineering design.
Sextupol construction.
Preliminary 2D design of the five magnet types
Preliminary 3D design of the five magnet types
Executive design of the five magnet types
MgB2 quadrupole design.
Octupole and decapole construction
Quadrupole and dodecapole construction
MgB2 quadrupole construction
Test of the sextupole
Test of the octupole and decapole
Test of the dodecapole and quadrupole
Corrector magnet test report
Corrector magnets final check, packing and transport to CERN
PADS
2D magnetic design to minimize the cross talk between the two dipoles.
Dec 2015
2D mechanical design.
M 2.3
Feb 2016
3D magnetic design including the coil ends.
M 2.4
Apr 2016
Quench preliminary analysis.
M 2.5
Jun 2016
3D mechanical design with the axial pre-load study.
Dec 2016
Final Engineering design.
M 2.6
Notes
*
**
***
****
1
D 2.3
These two deliverables are grouped in one in the MAGIX project
Note the change of scope wrt to the MAGIX project
These two milestones are grouped in one in the MAGIX project
These two milestones are grouped in one in the MAGIX project
Explanation
Activity
Milestone
Deliverable
18
3
4
5
Richieste 2015
Missioni
Riunioni di collaborazione, visite presso ditte, visite CERN
10
Consumo
Ferro x gioghi 5,000 kg x 6€/kg
30
Altri metallici: SS CuBe Ti
8
Altri non metallici: Resine
3
Lavorazioni esterne
28
Qualifiche e collaudi
8
Attrezzature costruzione
19
Elettronica (sensoristica, acquisizione)
17
Manutenzione
5
Criogenia (altri
materiali di consumo)
Inventariabile
15
Criostato D500 x 2600
70
DCCT
12
Impiantistica
14
Altra strumentazione
10
TOTALE
249
Giovanni Volpini, CdS Milano 8 luglio 2014
19
Persone Coinvolte
Alessandria, Franco
Bellomo, Giovanni
P. Ass.
40%
Sorbi, Massimo
Ric
20%
Volpini, Giovanni
1 Ric
40%
Leone, Augusto
CTER
50%
Paccalini, Antonio
CTER
50%
Pedrini, Danilo
CTER
50%
Quadrio, Mauro
CTER
20%
Todero, Maurizio
CTER
50%
Somaschini, Luca
1.0 FTE
2.2 FTE
100% art. 2222 sui fondi di HiLumi
+ supporto officina meccanica 40%
Giovanni Volpini, CdS Milano 8 luglio 2014
20
The End
Giovanni Volpini, CdS Milano 8 lulgio 2014
21
HiLumi-MAGIX schedule
2014
v. February 2014
2
3
4
5
6
7
2015
8
9 10 11 12 1
2
3
4
5
6
7
2016
8
9 10 11 12 1
2
3
4
5
6
7
2017
8
9 10 11 12 1
2
Project Management
WP0
M 0.1
Feb 2014
Kick-off meeting with specification transfer
M 0.2
Dec 2014
1st year activity monitoring
M 0.3
Dec 2015
2nd year activity monitoring
M 0.4
Dec 2016
3rd year activity monitoring
M 0.5
Jun 2017
4th year activity monitoring
M 1.1
M 1.2
D 1.3
D 1.4
Jul 2014
Dec 2014
Mar 2014
Mar 2015
Oct 2016
Dec 2015
Mar 2016
Jul 2016
Oct 2016
Apr 2015
July 2016
Feb 2017
Mar 2017
June 2017
M 2.1
D 2.1
June 2015
M 2.2
D 2.2
WP1
CORRAL
D 1.1a
D 1.1b
D 1.2
M 1.3
M 1.4a
M 1.4b
M 1.5
M 1.6a
M 1.6b
M 1.6c
WP2
*
*
**
***
***
****
****
****
Sextupol engineering design.
Sextupol construction.
Preliminary 2D design of the five magnet types
Preliminary 3D design of the five magnet types
Executive design of the five magnet types
MgB2 quadrupole design.
Octupole and decapole construction
Quadrupole and dodecapole construction
MgB2 quadrupole construction
Test of the sextupole
Test of the octupole and decapole
Test of the dodecapole and quadrupole
Corrector magnet test report
Corrector magnets final check, packing and transport to CERN
PADS
2D magnetic design to minimize the cross talk between the two dipoles.
Dec 2015
2D mechanical design.
M 2.3
Feb 2016
3D magnetic design including the coil ends.
M 2.4
Apr 2016
Quench preliminary analysis.
M 2.5
Jun 2016
3D mechanical design with the axial pre-load study.
Dec 2016
Final Engineering design.
M 2.6
Notes
*
**
***
****
1
D 2.3
These two deliverables are grouped in one in the MAGIX project
Note the change of scope wrt to the MAGIX project
These two milestones are grouped in one in the MAGIX project
These two milestones are grouped in one in the MAGIX project
Explanation
Activity
Milestone
Deliverable
Giovanni Volpini, CdS Milano 8 luglio 2014
22
3
4
5
6
2D cross sections: 6-pole
Yoke radius = 160 mm
Bpeak iron = 3.7 T
Jeng (overall)
~ 260 A/mm²
Bpeak coil = 2.0 T
Recooler bore D 60 mm @ r = 185 mm,
so it’s outside the yoke
03.12.2013 p 140
Giovanni Volpini, CdS Milano 8 luglio 2014
23