Title – xxxx 1

LARP & US-HiLumi Contribution to the Inner Triplet Quadrupoles

G. Ambrosio

Cost and Schedule ReviewCERN, March 9th-11th 2015

Title – xxxx 2

LARP & US-HiLumi

• LARP (LHC Accelerator Research Program) — A collaboration among BNL, FNAL, LBNL & SLAC— Goals:

• make more luminosity, earlier• collaborate in interaction region upgrades, to make even

more luminosity, later• use, develop, and preserve unique U.S. resources and

capabilities.

— May not deliver deliverables

• US-HiLumi will be a Project— LARP has been charged to prepare the path for this

future project

Title – xxxx 3

SQSM TQS

LR

LQS

HQTQC

LARP Magnets (2003-now)

Title – xxxx 4

90 mm Aperture QuadsShort & Long

Short models (1 m):

• Understanding stress vs degradation safe preload

• 1000 power cycles with no degradation

Long models (3.4 m):

• Demonstration of scale-up• Demonstration of excellent

training memory

Title – xxxx 5

• Goal: demonstrate all performance requirements for Nb3Sn IR Quads in the range of interest for HL-LHC (magnetic, mechanical, quench protection etc.)

• Main design parameters and features in the latest models tested (HQ02a/b):

Conductor and cable

Strand diam. (mm) 0.778

Cu/Sc 1.2

No. strands 35

Cable width (mm) 14.8

Cable thickness (mm) 1.375

Keystone angle (deg.) 0.75

HQ02 Short Sample Performance

Param. 4.5K 1.9K

Iss [kA] 16.4 18.2

Bpk [T] 12.9 14.2

Gss [T/m] 186 205

Al shell

Coil

Bladder locations Alignment key

Iron yoke

Al collar

120 mm Aperture HQ

Title – xxxx 6

Accelerator Quality

• Order of magnitude reduction of dynamic effects (ramp rate, field quality) with cable core

Quench performance

• HQ02b: fast training to 95% level with 200 MPa pre-load

• HQ03: 1st quench at 81.5 SSL

Quench protection

• 380K quench temperature without degradation

• Successful first test of the CLIQ system in Nb3Sn

250K

320K

380K

HQ02/03 Test Results

Title – xxxx 7

LARP Development of QXF Short Models & Prototypes

• The LARP plan has been presented by P. Ferracin

• LARP & CERN short model plans are tightly correlated, and support and strengthen each other

• By working together LARP & CERN achieve optimization of resources, maximization of return and back-up

Title – xxxx 8

US-HiLumi Project Plan

• US-HiLumi Magnets Preliminary:— Scope— Top-Level Schedule— Fabrication Plan— Early US Project Milestones— Summary

Based on presentation by R. Carcagnoat HiLumi-LARP Collaboration MeetingNovember 19, 2014Note: assuming 8.0 m magnetic length

Title – xxxx 9

Preliminary US-HiLumi Magnet Scope

MQXFA

MQXFA

LMQXFA (Q1)LMQXFB (Q3)

• Five Q1 Cold Masses (LMQXFA) and Five Q3 Cold Masses (LMQXFB)

— Each cold mass includes two ~ 4.8m Nb3Sn magnets (MQXFA) installed in a SS helium vessel with end domes, ready for insertion into a cryostat by CERN

— Option: deliver magnets (MQXFA) after vertical test

Title – xxxx 10

US-HiLumi Magnets Timeline Tentative plan:

— Assumes Q1 and Q3 tunnel installation in CY-2024— Provides 3.5 years for CERN Q1 and Q3 scope (cryostating, test, etc)— Production Coil winding must start in January 2018 (US Critical Decision 3 DOE approval, CD-3)— Two years of preparations needed for strand and series production tooling procurements, start cable

fabrication, etc.— Production throughput based on June 2013 MQXF fabrication plan

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4CY-2025CY-2021 CY-2022 CY-2023 CY-2024

US-HiLumi Magnet Preliminary Timeline - November 2014CY-2015 CY-2016 CY-2017 CY-2018 CY-2019 CY-2020

#8

CERN Long Shutdown 3 (LS3)

Ends

MQXFA 1/2

LMQXF #1 Delivered #8 Delivered #10 Delivered (#9 and #10 Spares)

19/20

Production: Two Production LinesMultiple Coil Fabrication Tooling

CD-3

Pre-Production: Strand, Cable, Tooling, Parts, etc

Coil Fab Starts

CERN Scope: Cryostating, Tunnel Installation, Commissioning

Q1, Q3 Tunnel installation Starts

15/16

LQXF #1

Title – xxxx 11

US-HiLumi Preliminary Top Level Schedule

• Assumes Q1 and Q3 tunnel installation in CY2024

• First LMQXFA/B cold mass delivered to CERN summer 2020

• Last LMQXFA/B cold mass for tunnel installation delivered to CERN summer 2022

• Last LMQXFA/B cold mass spare delivered to CERN summer 2023

Title – xxxx 12

Preliminary Fabrication Plan

Plan is based on the production plan presented by M. Anerella during the June 2013 DOE review of LARP plus additional information

• Nb3Sn:

— First strand delivery one year after placing purchase order. Last

delivery 2 years later. A total of 9,400 Kg will be needed for 90 coils

• Cable and Insulation (LBNL):

— Starts three months after first strand delivery

— Throughput starts at 2 UL/month, ramping to a peak rate of 3

UL/month

— A total of 90 ULs are needed for 90 coils

— Insulation by vendor

— Total duration ~ 3 years

CERN is back-up for cabling, and LARP is for CERN

Title – xxxx 13

Preliminary Fabrication Plan (Cont.)

• Coil Fabrication:— Two production lines (FNAL and BNL)— Peak rate: 1 coil every 15 working days

• First two coils in each facility assumed to take twice as long• First 4 coils: 8 months after coil production starts

— Total duration for 90 coils ~ 3.5 years— Additional tooling needed at each production line to

sustain throughput:• One additional winding mandrel assembly• Two additional reaction fixtures• One additional impregnation fixture Looking at optimizing

parts procurement between LARP & CERN

Title – xxxx 14

Preliminary Fabrication Plan (Cont.)

• Magnet Assembly (LBNL):— Starts ~ 8 months after coil fabrication starts

• As soon as a set of four coils are delivered

— Includes Yoke/Shell structure assembly, coil pack insert assembly, and magnet assembly

— Two production lines. In each line, peak rate:• 1 coil pack insert every 60 working days• 1 yoke/shell assembly every 75 working days

(concurrent)• 1 magnet assembly every 34 working days

— Peak overall rate: 1 magnet every ~ 2.2 months• First magnet assumed to take twice as long

— Total duration for 20 magnets is ~ 4 years

Title – xxxx 15

Preliminary Fabrication Plan (Cont.)

• Magnet Test (BNL):— Test and train each magnet in BNL vertical test stand prior to

cold mass assembly• Needed quantity under consideration• It takes ~ 38 working days for a production vertical test

• Cold Mass Assembly (FNAL):— Connection of two magnets, installation of stainless steel skin

and end domes, heat exchanger, bore tube, etc.— Peak rate: 1 cold mass every ~2 months

• First assembly assumed to take 3 months

• Cold Mass Test (FNAL):— Insert cold mass in re-usable cryostat and test cold mass in

Fermilab’s Horizontal test stand— Peak rate 1 cold mass test every ~3.5 months

• First test assumed to take 1.5 times longer, second test 1.25 times longer• Assumes no prior magnet training• Assumes 30 training quenches per magnet

Title – xxxx 16

US-HiLumi Early Milestones

Frozen Baseline:— Definitive

scope— Detailed

resource loaded schedule

— Time-phased budget

— EVMS-ready

Baseline must be frozen before March 2016

• Earned Value Management System (EVMS) monthly reporting is required six months prior to the independent Director’s CD-2 review, which is required before a DOE CD-2 review

• EVMS requires a frozen baseline– Changes after baseline freezing require going through a change control and approval process– Monthly Cost/Schedule variances must be explained and corrective actions put in place

Title – xxxx 17

Summary

• Plan is based on Q1 and Q3 tunnel installation in 2024• Q1 and Q3 cold masses delivered to CERN starting in summer 2020

— Last cold mass for tunnel installation delivered summer 2022— Last spare delivered summer 2023

• Plan requires start coil production (DOE CD-3 approval) in January 2018

• DOE CD-2 approval needed by ~April 2017— EVMS monthly reporting must start by March 2016 to support

Director’s CD-2 review prior to DOE CD-2 review• US-HiLumi project baseline must be frozen before March 2016

— Definitive scope, detailed resource-loaded schedule, time-phased budget, EVMS-ready

• This is a preliminary plan, more details and analysis needed (e.g., incorporate rework/re-test activities)

Title – xxxx 18

Risks & Opportunities

Nb3Sn superconducting strand 2 strand producers

Cable fabrication 2 cabling machines (LARP & CERN)

Coil fabrication Complete lines at 2 US labs

Coil parts Share procurement with CERN

Magnet assembly Baseline is one lab, but could set up 2nd line at another lab

Structure parts Stamped laminations

Magnet performance Vertical test of each magnet allows for fast coil substitution