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BNL - FNAL - LBNL - SLAC
Long Quadrupole (LQ) Coil Fabrication Status & Plans
Fred Nobrega
12th LARP Collaboration Meeting April 8-10, 2009
• Fabrication Status Overview
• Coil Status»Winding and Curing
»Reaction
»Impregnation
• FY10 Proposals
LQ Status & Plan for FY09 Fred Nobrega 212th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ Practice Coil Fabrication Overview
• LQ01» copper cable» Al- bronze pole pieces
• LQ02» Nb3Sn unusable sharp corners» pole design change to Ti» reaction tooling bow
• LQ03» short unit length of cable
now practice coil» high cable tension after
reaction» introduced mica
reduce friction during HT» introduced stiffener plate
reduce bow (HT)
• LQ04» shortened pole pieces after
coil curing as a result of LQ03
» shipped to BNL for practice reaction and impregnation
• LQ05» impregnation problem practice coil » used 2nd impregnation
technique to find solution for LQ06 (already wound and cured)
» used for quench heater test in LN2
» shipped to LBL for practice shell structure assembly
All coils wound and cured at FNAL
LQ Status & Plan for FY09 Fred Nobrega 312th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ Production Coil Fabrication Overview
• LQ06 – 1st production coil» internal production readiness
review» impregnation problem, dry S2» used 2nd impregnation
technique from LQ05 to repair coil
» shipped to LBL for the LQS01 magnet
• LQ07 – 2nd production coil» shipped to BNL for reaction
and impregnation
• LQ08 – 3rd production coil» reacted at Fermi» being prep’ed for
impregnation
• LQ09 – 4th production coil» shipped to BNL for reaction
and impregnation
• LQ10 – 1st production coil for second magnet series» waiting for reaction tooling
from LQ08 for HT» this coil is also the spare coil
for LQS01
• LQ11 – 2nd production coil for second magnet series» cable paid out onto 2 spools
waiting for winding mandrel used by LQ10
All coils wound and cured at FNAL
LQ Status & Plan for FY09 Fred Nobrega 412th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil winding & curing LQ01- LQ10
• Controlled process» modified with input from reacted coils
• Well documented» drawings» travelers» discrepancy reports
• Coil studies» LQ03 high cable tension after HT CTE of Ti pole WRT
tooling• result reduce/eliminate cable tension after curing• Added mica to reduce friction
– LQ04 after curing pole shortened– LQ05 and subsequent coils anchor system, releases
winding tension after curing
LQ Status & Plan for FY09 Fred Nobrega 512th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil winding gaps LQ03- LQ10
* Began using anchor system to introduce gaps during winding. Release anchor system results into near zero winding tension.
3 no
4 no
5 yes*
6 yes*
7 yes*
8 yes*
9 yes*
10 yes**
11-13 yes**
Coil Winding Gap # gap (mil) post HT (mil)
no
no
no
no
no
no* * Revised anchor tooling (stiffer).
LQ Status & Plan for FY09 Fred Nobrega 612th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil winding & curing LQ01- LQ10
• Coil studies (continued)» LQ04 midplane Fuji pressure film of cured coil in
reaction tooling• results indicate higher layer 2 coil stress than layer 1
• possible cause double cure of inner layer
– being studied by R. Bossert
» LQ05 used to for quench heater test with LN2 • successfully passed
LQ Status & Plan for FY09 Fred Nobrega 712th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil Heat TreatmentLQ-05, 06, 08, 10
LQ08 Thermocouple Location on Reaction Tooling
Witness samples
argon
flow thru
Lead End
Return End
T/C 11*
T/C 14
T/C 13*
T/C 12
T/C 10
T/C 2
T/C 1
T/C 15
T/C 4
T/C 9
Furnace Door
LQ Status & Plan for FY09 Fred Nobrega 812th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil Reaction CycleLQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09)
• LQ03 » High cable tension after reaction in LQ03
» Added stiffener plate to reaction tooling and mica to coil to eliminate tooling bow and reduce friction respectfully
LQ Heat Treatment CycleStep # Type Start Rate/time
1 Ramp 20C 25C/hour
2 Soak 210C 72 hours
3 Ramp 210C 25C/hour
4 Soak 400C 48 hours
5 Ramp 400C 50C/hr
6 Soak 640C 48 hours
7 Ramp 640C -100C/hrDays
Program
Measurement
LQ Status & Plan for FY09 Fred Nobrega 912th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil Reaction LQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09)
• Found problem after coil #3 heat treatment• Performed analysis further analysis needed
• Developed solution for LQS01 coils LQ02 coils
Further analysis by core programsCoil Layer Starting Gap Gap Pole parts Load
gap before HT after HT ave. DL/partmil mil mil mil lbs
3 OL 0 0 0 -3.6 03 IL 0 0 0 -17.2 12004 OL 128 18 1.5 1.2 04 IL 270 182 22 05 OL 120 15 0 -3.7 <1005 IL 230 157 0 -6.7 200-3006 OL 179 102 206 IL 225 147 07 OL 179 07 IL 225
Notes 1, 2 4 5 3
1 for coil 4 and 5: material removed from pole parts; for coil 6: gaps during winding2 in coil 6 and 7 the OL gaps depend on the IL gaps3 computed by measuring pole parts: 1-4, 6-10 (no central part)4 time between measurement and HT vary from coil to coil (==> possible error)5 Coil 4 outer layer gap: 1.5 mil at the last gap at the NLE (RE), all other gaps closed
Coils 4 and 5 will be used for practice assembly
Coils 6 to 9 will be used for LQS01
LQ Status & Plan for FY09 Fred Nobrega 1012th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil Reaction with MicaLQ03-06, 08, 10 & subsequent, (BNL LQ04, 07, 09)
10 milceramicand bindersheet
titanium outer pole
titanium inner pole
10 mil ceramic and binder sheet
20 mils
10 mils
10 mils
LQ with Mica
During Reaction5 mil micasheet
5 mil micasheet
5 mil mica sheet
LQ Status & Plan for FY09 Fred Nobrega 1112th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
• LQ04» L1 center pole length reduced by 0.270” (6.86mm) and L2
center poll shortened by 0.124” (3.15mm) to reduce cable tension.
Note: Tension was reduced by removing material from L2 (part #461135) and then L1 (part # 461133) Center Pole Spacers.
• LQ05 » L1 pole shorten by.073” (1.85mm) & L2 by 0.101” (2.57mm) to
remove winding tension in cable before HT.» Also used anchor system on winding mandrel that effectively
introduced gaps longitudinally between pole pieces during winding. Anchors released after winding closing gaps and reduces nearly all the cable winding tension. Used on LQ06 and subsequent coils without shortening center pole pieces.
• LQ06 - LQ09 successful reaction• LQ10 - LQ13 not reacted,
» LQS02 coils with LQ10 spare for LQS01
Coil Reaction LQ01-03, 05, 06, 08, 10, (BNL LQ04, 07, 09)
LQ Status & Plan for FY09 Fred Nobrega 1212th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Coil ImpregnationLQ05, LQ06, LQ08 (BNL LQ04, 07, 09)
• LQ05» filled in one hour (4 times faster than design) and had epoxy
leak» used for quench heater test in LN2 pool, no visible damage to
coil or heaters» used to successfully develop and demonstrate a 2nd
impregnation of a potted coil (pictures & details in following slides)
» shipped to LBL for practice assembly of LQS01• LQ06
» successfully potted a second time (pictures & details in following slides)
» shipped to LBL for assembly into LQS01• LQ08
» being prepared for impregnation complete and ship to LBL by the end of April for assembly into LQS01
LQ Status & Plan for FY09 Fred Nobrega 1312th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ05 1st Impregnation
• rapid epoxy fill flow Problem: low visibility of epoxy in vacuum oven
Fix: add Pyrex clear glass tube at fill end of coil
• O-ring leak during coil cureProblem: O-ring diameter too small
Fix: increase O-ring diameter
LQ Status & Plan for FY09 Fred Nobrega 1412th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ06 1st Impregnation
• Same impregnation process as LQ02» changed 7 mil ceramic cloth to 5 mil S2 glass after LQ02
» process has short soak time
» increase soak time in LQ08 (next week), more similar to BNL process
LQ Status & Plan for FY09 Fred Nobrega 1512th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ05 & 06 2nd ImpregnationDAY DATE TIME HRS DESCRIPTION
FRIDAY 3/6/2009 7:00 A.M. 0 started vacuum pump down and heating @ 60 C
SATURDAY 3/7/2009 12:00 P.M. 29 continue vacuum pump down
SUNDAY 3/8/2009 12:00 P.M. 53 continue vacuum pump down
MONDAY 3/9/2009 7:59 A.M. 61 total pre epoxy impregnation pump down time8:00 A.M. 0 start mixing, heating and out gassing10:00 A.M 2 start flowing epoxy to magnet 1 CM/sec
12:30 P.M. 4.5 see epoxy in overflow tube1:30 P.M. 5.5 fill 3 feet of overflow hose, time estimated1:30 P.M. 5.5 clamp off epoxy input hose, stop vacuum and start soak time
10:00 P.M. 14 remove from vacuum vessel and remove .010 shim11:30 P.M. 15.5 completed shim removal and retightened bolts12:00 P.M. 16 start 60 C overnight heating in oven
TUESDAY 310/2009 7:00 A.M. 23 start 110 C ramp8:30 A.M. 0 begining of 110 C for 5 hours cycle 1:30 P.M. 5 start 125 C ramp2:30 P.M. 1 beginning of 125 C for 16 hours cure cycle
WEDNESDAY 3/11/2009 6:30 A.M. 16 end of cure cycle oven door auto opens, need to shut off fans
24 hrMaxper
CTD17.5 hr
soak
LQ06 process schedule
LQ Status & Plan for FY09 Fred Nobrega 1612th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ05 & LQ06 2nd Impregnation
LQ05
LQ06
LQ Status & Plan for FY09 Fred Nobrega 1712th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ05 & LQ06 CMM Measurements of 1st & 2nd Impregnation 1664 mm
from LE
LQ05 1st
LQ05 2nd
LQ06 1st
LQ06 2nd
One square = 100 microns
LQ Status & Plan for FY09 Fred Nobrega 1812th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ Coil Ground Insulation
LQ Status & Plan for FY09 Fred Nobrega 1912th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ CoilGround Insulation
LQ Status & Plan for FY09 Fred Nobrega 2012th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
FY10 Vertical Collaring• Coil assembly is up
righted with the up-ender tooling. The picture to the left is the MQXB in ICB. This scheme requires 2 cranes. (LQ design uses 1)
• Collar keying is done in several passes while coil strain gauges are monitored
• Coil is brought to horizontal using the up right process in reverse
LQ Status & Plan for FY09 Fred Nobrega 2112th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ Up Ender Fixture Assy
LQ COIL-COLLAR ASSY MANDREL ME-461301
FNAL internal review completeAction items completeCollaboration review
LQ Status & Plan for FY09 Fred Nobrega 2212th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQC Vertical Collaring
Collaring is done incrementally in
many passes. Col
lari
ng
Dir
ecti
on
Col
lari
ng
Dir
ecti
on
LQ Status & Plan for FY09 Fred Nobrega 2312th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
LQ Coil Assembly Table
LHC MQXB CoilsDuring Assembly
LQ Status & Plan for FY09 Fred Nobrega 2412th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
FY10 Proposal: Dipole Collar-based LQ Structure
Main vertical press force
Side Key Pushers
Collaring can be done along the full magnet in a single pass, eliminating degradation risk and reducing construction time.
• Use Dipole Collaring – if TQC with dipole style collars is successful then propose to LARP their use for LQC
• Use Up-Ender – if dipole collaring is unsuccessful» Design complete» Internal review complete» Drawing package ready for release and procurement
Horizontal collaring uses weld press and dipole-symmetric collar laminations.
LQ Status & Plan for FY09 Fred Nobrega 2512th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Dipole Collar
TQ Dipole CollarsCould be used for LQ
LQ Status & Plan for FY09 Fred Nobrega 2612th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
FY10 Proposal: LQ Mirror
• Use Mirror Magnet - if LQS is unsuccessful to further evaluate issue
OR
• Commit to LQ mirror now and begin iron part procurement before we have results merge with TQM parts
LQ Status & Plan for FY09 Fred Nobrega 2712th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
FY10 Proposal: Bolted Skin
• Use 4m bolted skin for both LQM and LQC
Where C= vertical or horizontal collaring)
3/16 in.
3/32 in.
LQ Status & Plan for FY09 Fred Nobrega 2812th LARP Collab. Meeting – Napa, Apr. 8-10, 2009
Conclusions
• Many problems overcome to reach long coil production
• 50% of LQS01 coils complete and shipped to LBL with remaining coils complete within 2-3 weeks
• Possible changes to LQ dipole style collar design depending on TQC02Eb & TQC03E test results
• Changing welded shell design to long bolted shell saves money and time if more than one LQC magnet and/or LQ mirror is built