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11 T Nb3Sn Demonstrator Dipole R&D Strategy and Status
A. Zlobin, Fermilab
1st FNAL-CERN Collaboration Meeting Fermilab, May 13, 2011
Outline
• 11 T Nb3Sn Dipole R&D Program
• R&D phases, goals, design constraints• Comparison with other R&D programs• Single-aperture demonstrator R&D
– Status– Schedule
• Conclusions
13 May 2011, FNAL-CERN CM1 2 A. Zlobin - R&D Strategy
• In FY2011 Fermilab and CERN have started a joint R&D program with the goal of building a long twin-aperture Nb3Sn 11 T dipole by 2014.
• This R&D relies on the results of Nb3Sn magnet R&D programs at FNAL and Nb-Ti LHC magnet development at CERN.
• To meet the tight project schedule within the available budget, magnets are designed to make maximum use of the existing tooling, infrastructure, and magnet components at both laboratories.
• Practical orientation is a key feature for any sound Nb3Sn accelerator magnet R&D program at the present time.
11 T Nb3Sn Dipole R&D
13 May 2011, FNAL-CERN CM1 3A. Zlobin - R&D Strategy
Result Application
• LHC collimation system upgrade. – 11 T 11-m long twin-aperture Nb3Sn dipoles
compatible with the LHC lattice and major systems can provide the required space for cold collimators
• additional design constrains
• Space in the LHC lattice for different insertion devices – dynamic collimators, correctors, instrumentation, etc.
A. Zlobin - R&D Strategy413 May 2011, FNAL-CERN CM1
R&D Phases and Goals
Productive CERN-FNAL collaboration is a key to success!
Dates Description Comments R&D goals
December 2011
2-m single-aperture demonstrator dipole
Original design (cable, coil, collar) Construction and test at FNAL
Cable technology Coil technology Coil pre-load techniques Quench performance Margins Field quality (coil magnetization) Quench protection (heater study)
December 2012 June 2013
2-m twin-aperture demonstrator 1
Design iteration (cable, coil, collar) FNAL collared coils (2) Cold mass assembly and test at CERN
Technology transfer to CERN (cable, coil, collared coil) Coil pre-load techniques in 2-in-1 configuration Quench performance Margins Field quality (geometrical harmonics, coil magnetization, iron saturation, aperture cross-talk, end field quality) Quench protection (heater study) Performance reproducibility Two cold mass and collimator integration (alignment)
2-m twin-aperture demonstrator 2
CERN collared coils (2) Cold mass assembly and test at CERN
July 2013
5.5-m coil scale up Coil 1 at FNAL Coil 2 at CERN Structure assembly and test at CERN (FNAL)
Long cable technology Long coil technology Long coil performance Long heater design and performance
December 2013
5.5-m twin-aperture prototype
Collared coil 1 at FNAL Collared coil 2 at CERN Prototype assembly and test at CERN
Accelerator quality performance
13 May 2011, FNAL-CERN CM1 5 A. Zlobin - R&D Strategy
Constraints
11m Magnet
5.5 m Dipole Cold Mass
FNALFNAL
CERN CERN
• 11+ T at the LHC nominal current and operation temperature, 20% margin, field quality, quench protection
• Compatibility with MB cold mass and cryostat designs– aperture diameter and separation, cold mass OD, heat exchanger
• Nominal field >11 T => Nb3Sn
• 20% operational margin at 1.9 K => Bmax=13.2 T
• Common yoke and separate collared coils– collaring press capability limit at FNAL, lower risk
• Magnet length ~11 m, coil length ~5.5 m– Tooling limitations at FNAL, shorter strand and cable length, lower scale up
risk
13 May 2011, FNAL-CERN CM1 6 A. Zlobin - R&D Strategy
Single-bore Demonstrator
• Challenges: aperture, length, Bmax, W, schedule
Parameter MSUT (UT)
D20 (LBNL)
HFDA (FNAL)
HD2 (LBNL)
Demo-1 (FNAL/CERN)
Cross-section
Design Cos-theta Cos-theta Cos-theta Block Cos-theta Technology W&R W&R W&R W&R W&R Aperture [mm] 50 50 43.5 36-43 60 Length [m] ~1 ~1 ~1 ~1 ~2 Bmax (Bq_max) [T] 11.5(11.4) 13.35 (13.5) 12.2 (10.2) 15.4 (13.8) 13.62 Wmax [MJ/m] 0.46 0.88 0.30 0.87 0.744 L [mH/m] 2.5 46 1.5 7.3 5.6 Fx/quadrant [MN/m] 3.2 5.2 3.4 5.9 4.6 Fy/quadrant [MN/m] -1.5 -2.6 -1.4 -2.4 -2.5 Design published 1989 1993 1999 2005 2011 First test published 1995 1997 2005 2008 2012
13 May 2011, FNAL-CERN CM1 7 A. Zlobin - R&D Strategy
Twin-bore Demonstrator
• Challenges: 2-in-1 horizontal configuration, aperture, aperture separation, Bmax, length, schedule
Parameter RD3c (LBNL)
HFDC01 (FNAL)
DCC017 (BNL)
Demo-2 (FNAL/CERN)
Cross-section
Design Common coil Common coil Common coil Cos-theta Technology W&R R&W R&W W&R Aperture separation [mm] 220 (vertical) 290 (vertical) 220 (vertical) 197 (horizontal) Aperture [mm] 35 40 31 60 Length [m] ~1 ~1 ~1 ~2
Bmax (Bq_max) [T] 10.9 (10.03, 92%SSL)
10.0 (5.8, 58%SSL)
~10 (10.2, 100%SSL)
13.6 (11+20%margin)
Imax [kA] 11.9 23.6 12.7 15.0 Design published 1999 2001 1997 2011 First test published 2003 2004 2006 2012
13 May 2011, FNAL-CERN CM1 8 A. Zlobin - R&D Strategy
Scale Up ChallengesLARP:• 4-m long single-aperture quadrupole by 2014• Test in vertical dewar at VMTF (Fermilab) at
1.9-4.5 K11 T Dipole program:• 5.5-m long single coil test in MQXB prototype
cryostat in 2013 (Fermilab or CERN)• 5.5-m long twin-aperture dipole by 2014• Assembly with LHC MB cryostat and test at
CERN MTF at 1.9-4.5 K13 May 2011, FNAL-CERN CM1 9 A. Zlobin - R&D Strategy
11 T R&D Impact• Very interesting and challenging R&D
program• Benefit generic SC accelerator magnet
R&D
• Nb3Sn practical application in HL-LHC
• Step towards high-field magnets for HE-LHC
13 May 2011, FNAL-CERN CM1 10 A. Zlobin - R&D Strategy
Demonstrator R&D• R&D status
– Strand and cable – Magnetic design and parameters– Mechanical design and analysis– Quench protection– Magnet design and infrastructure
• Details in the following talks
13 May 2011, FNAL-CERN CM1 11 A. Zlobin - R&D Strategy
Strand and Cable
• Details by Daniele.13 May 2011, FNAL-CERN CM1 A. Zlobin - R&D Strategy12
Table 1: Cable parameters
Strand (OST):• 0.7 mm Nb3Sn RRP-108/127
• high-Jc, relatively stable
Cable (FNAL):• 15-mm wide, 40 strands
Cable insulation: • 0.075-mm E-glass tape• 2 layers butt lap • traditional insulation technique
Strand procurement• 60 kg RRP-151/169 – R&D (Aug 2011)• 152 kg RRP-108/127 (Dec 2011)• 152 kg RRP-108/127 (Jul 2012)
Cable fabrication• Practice cable fabricated and tested• Cable for demonstrator in progress
• Design– 2-layer 6-block design– 60-mm aperture
• Coil winding, curing, reaction and impregnation tooling designed and procured
• Coil components designed and procured– Coil end parts were designed
and fabricated by CERN
• Coil fabrication– 1st practice coil wound and cured
• Rectangular copper cable
– 2nd practice coil winding started• RRP-114/127 keystone cable
Coil Design
13 May 2011, FNAL-CERN CM1 13A. Zlobin - R&D Strategy
• Details by Mikko and Fred.
Dipole Parameters
13 May 2011, FNAL-CERN CM1 14A. Zlobin - R&D Strategy
Parameter Value
Aperture [m] 60
Nominal current Inom [A] 11850
Nominal bore field [T] 10.86
Short-sample bore field at 1.9 K [T] 13.6
Margin Bmax/Bnom at 1.9 K [%] 25.4
Maximum design field [T] 12.0
Inductance at Inom [mH/m] 5.6
Stored energy at Inom [kJ/m] 473
Fx per quadrant at Inom [kN/m] 2889
Fy per quadrant at Inom [kN/m] 1570
Coil length [m] 1.8
Magnetic length [m] 1.69
Mechanical Structure• Design
– 25-mm thick slightly elliptical stainless steel collar
– Vertically split iron yoke – Al clamps – 12.7-mm stainless steel skin – 50-mm thick end plates
• Structure design and mechanical analysis complete– Maximum stress in coil <160 MPa– stresses in structure are within
limits
• Collar design complete and procurement started.
• Assembly tooling design is in progress.
• Details by Igor and Fred.
13 May 2011, FNAL-CERN CM1 A. Zlobin - R&D Strategy15
Quench Protection• Demonstrator quench protection during test will be provided
by extracting the stored magnetic energy on the appropriate external dump resistor.
• In accelerator, the magnet protection is provided by quench heaters.
• Quench protection heaters composed of stainless steel strips will be placed inside the ground insulation, covering the outer-layer coil blocks.
• Quench protection analysis and heater design are in progress (Mikko).
13 May 2011, FNAL-CERN CM1 16 A. Zlobin - R&D Strategy
Schedule, Milestones, QA
A. Zlobin - R&D Strategy17
Structure review
Coil review
Cable review
Winding review
DOE reviewDemonstrator specs
Performance review13 May 2011, FNAL-CERN CM1
• 11 T Nb3Sn demonstrator dipole magnets for possible use in accelerators in particular for the LHC upgrades are being developed by Fermilab/CERN collaboration.
• The engineering design of the 60-mm single-aperture 2-m long magnet and fabrication tooling is nearly complete and practice coil winding is in progress.
• The cold tests are planned towards the end of 2011 – Primary goal: demonstrate the quench performance, nominal field,
and operation margins– Auxiliary studies: field quality, magnet quench protection
• The conceptual design of the twin-aperture 11 T dipole magnet has been started.
Conclusions
13 May 2011, FNAL-CERN CM1 18A. Zlobin - R&D Strategy