Update on D1

M. Sugano, T. Nakamoto, S. Enomoto, H. Kawamata

KEK

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.

HiLumi LHC WP3 Meeting, Jun. 17, 2015

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44 turns

• Coil ID: 150 mm• Integrated field: 35 T m

– 5.59 T at 12 kA. Lcoil=6.6 m• Peak field: 6.45 T at center, 6.59 T at coil end• Load line ratio (SS): 76 %• Top: 1.9 K by HeII cooling• Coil layout: 1 layer of 15.1 mm cable

– Better cooling. Saving space for iron yoke. • Conductor: Nb-Ti LHC MB outer cable• Field quality: < 10-4 at Rref = 50 mm • Cold mass OD: 550 +10 x 2 = 570 mm• Cryostat OD: 914 mm, same as MB cryostat• Radiation, energy deposition:

Latest design parameters of D1

135 W in total, 2 mW/cm3 at local peak, Radiation dose >25 MGy

2D cross-section of D1

Shell: SUS304L

Horizontal split iron yoke: low-carbon steel (EFE by JFE steel)

Collaring keys

f60 mm HX holeNotches and f 34 mm holes for iron saturation effects

4 split stainless steel spacer collars: NSSC130S

NbTi SC cable (LHC MB outer) + Apical insulation

Radiation resistant GFRP (S2 glass + BT resin) wedges

Brass shoes

Single-layer coil, 4-split spacer collars, collared yoke by keying

HeII cooling channel

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QPH+Insulations

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Demonstration of yoking with modified yoke design

The second trial of 200 mm short model assembly

Side taper

YokeCollarTriangularnotch

Previous design of collar and yoke

We expected the yoke will touch side taper of the collar to prevent the collared coil from rotating with respect to the yoke

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Two alignment features were made on collars

1. Side taper for pre-alignment

2. Triangular notch for final alignment

Yoke

Collar

Taper

Reported at WP3 meeting on the 25th of Feb.

Result of the previous short model assembly

Soon after the yoke passed through the taper, the collared coil started to rotate Side taper was too short

Yoke Collar

Design modification of collar and yoke was needed 6

Side taperCircular shape

First short model assembly in Feb. 2015

Extension of side taper of collar

Rectangular notch like RHIC dipole

New design of collar and yoke

The second short model assembly was carried out with such newly designed collar and yokes 7

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Constituents and jig of 200 mm short model Coil: Cut-out from the 2m test coil

Insulation: 4 layers of polyimide sheets (t0.125 mm each)Brass shoe: t0.5 mm

Collar: newly designed, made by laser cutting for quick prototyping Strain gauge to monitor pole stress

Brass shoe

Pole shim Gap betweeninsulations

QPH dummy

Brass pole shim: t1 mm

4 layers of insulations

Collaring mandrel: Made by a 3D printer for test

QPH dummy: Polyimide sheet (t0.25 mm)

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Yoking1

Before pressing Hydraulic pressure = 2.8 MPa

Both side taper and rectangularnotch already have worked

Collared coil was aligned properly(There was still a gap between upperand lower yoke)

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Yoking2

Keys

Collaring mandrel could be removedCollared coil could be easily disassembledfrom yoke by crane

Key insertionYoking was completedHydraulic pressure=27 MPa

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Pole stress during yoking

Expected value80 MPa

Slightly lower pole stress will be mainly due to inaccurate size of laser-cut collar We will check this more precisely by using fine-blanked collars and yokes

Measured61 MPa

Loading

unloading

Upper/loweryokes touch

Key insertion(Maximum stress)

Remainingpole stress

Pole stress

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Summary of 2nd 200 mm short model assembly

- Mechanical simulation with ANSYS will be updated for a model with newly designed collar and yoke

- Modified collar and yoke worked well and collared coil could be aligned properly

- Structure of insulations would be OK. No overlap or unwanted wrinkle were observed

- Collaring mandrel was confirmed to work as expected Test with longer mandrel for 2 m model is planed

- Design of pole shim and brass shoe should be modified considering assembly of 2 m model

- The 3rd short model assembly with collars and yokes by FB is scheduled and it will be followed by shell welding and cooling test at 77 K

Design of collar and yoke has been fixed and dies for fine blanking (FB) were ordered

Next

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Impact of rectangular notch on field quality Original Rect. notch

Main field (T) 5.573 5.568

b3 (unit) -0.0585 5.08

b5 (unit) -0.0965 -1.47

b7 (unit) -0.111 0.191

b9 (unit) 0.284 0.224

b11 (unit) 0.360 0.371Coil block arrangement was optimized for theprevious design of yoke and it will be fixed

ROXIE model with rectangular notch

- Additional b3 and b5 will be able to be improved by slight coil block rearrangement- Effect of iron saturation became more remarkable in yoke with rectangular notch

From the view point of field quality,rectangular notch would be acceptable

Since coil block will not be re-optimized, additional b3 of ~5 unit will arise in 2 m model

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Preparation for fabrication and cold test of the 1st2 m model

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Preparation for winding of 1st 2m model

- Machining of end spacers is underway in KEK

- GFRP pole shims, wedges and ramp box have been delivered

Winding of 1st 2m model coil will be started soon

Pole shim and wedges Ramp box

End spacers

- Winding mandrel was machined and center post was partly replaced to fit to “Ver3” (the 1st 2 m model)

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Quench protection heater

- SUS strip (w15 mm, t25 mm, l1980 mm) 2.7 mW at cold

- SUS part covers 9 cables in the first coil block- Thickness of QPH from CERN will be 100 mm and 150 mm -thick polyimide sheet will be added for thickness compensation by ARISAWA

SUS strip

Baseline of quench protection scheme for D1 was changed in the last WP3 meeting: D1 will be protected by QPH w/o E.E.

QPH provided by CERN will be used for 1st 2 m model magnet(Thanks to Juan Carlos Perez )

2 sets of power supply for QPH will be provided by CERN. (by August?) Quench simulation with ROXIE (Thanks to Susana Izquierdo Bermudez)

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Delivery Date Objective Requirement Remark

Feb. 201310 stack meas.(a piece length > 0.3 m)

~50 m w/ MB type insulation

Both MB inner and outer cables w/ MB type insulation

Jan. 2014May 2014

1 practice coil* + 2 real coils for the 1st 2-m long model + 1 spare coil

220 m** x 4 LHC MB outer cables w/ MB type Apical insulation

April. 2015June 2015

2 coils for the 2nd 2-m long model + 2 spares

220 m x 4713 m x 1

LHC MB outer cables w/ MB type Apical insulation

JFY2016 (prospect)6 or 7 full-scale magnets + 4 practice/spare coils

600-640 m x 18 LHC MB outer cables w/ MB type Apical insulation

Done!!NbTi LHC MB outer cable supplied by CERN for the new D1 .

Done!!

• SC cables for the 1st model are in hand.• Cable for the second 2 m model + 2spares has been delivered on the 4th of June.

Done!!

Thanks to Frédéric Savary andAmalia Ballarino

SC cable supply and schedule

Procurement: Collar, Yoke

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• Fine-blanking dies for collars and yokes with a “original design” were completed.

• However, as reported, the fine-blanking dies need to be modified for the new cross section: vertical rectangular notches, horizontal extended tapers.– Refurbishment will be until the end of July.

Parts for the 1st model magnet will be ready for assembly in September.

– The meeting with AFB in next week. Iron yokes and SS collars made by FB (before modification).

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Preparation for Cold Tests• Procurement

– New header w/ larger warm bore– New 15 kA CLs, 15kA-DCCT, dump resistor (75 m )W .– New DAQ systems

• Modified 9m-deep vertical cryostat with new header must be inspected in accordance with High Pressure Gas Safety Act in Japan.– But, the procedure was stopped for 3 months because KHK (The High Pressure Gas

Safety Institute of Japan) additionally asked to confirm the pre-approval by the local government (Ibaraki Prefecture).

– The procedure resumed recently and the Completion Inspection for the vertical cryostat is scheduled in the middle of September.

– And then, the wiring and instrumentation will be followed.• Commissioning at 1.9K, 15kA without magnet previously planned in June was cancelled.

– Due to delayed schedule, a lack of budget.• First cold test of the 1st model will be possible in Nov. 2015 at earliest.

– We confirmed the operators will be available even in January to March 2016 and this period will be another timeslot.

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Schedule of the 1st model of MBXF*Work related to the 1st model fabrication

• July 2015 Coil winding, curing, size measurement, instrumentation (~August)A 200 mm mechanical short model with parts made by fine-blanking

• Aug. 2015 Preparation of SS collars and iron yokes• Sep. 2015Collaring and Yoking• Oct. 2015Shell, splice work

>> Completion of the 1st model• Nov. 2015 Cold test of the 1st model: 1st cycle• Jan. 2016 Cold test of the 1st model: 2nd cycle

Start of fabrication of the 2nd model (if no design change…)• March 2016 Shipping the 1st model to CERN.

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1st model for HTS coil development at CERN• Video meeting on May 12.• Information exchange on interface, specification

– weight, length, cross section.– SC leads, nominal current– support structure– stray field: check cryostat and environment.

• 3D model will be sent to CERN soon.