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sse Monthly Report

November 1987

November 1987 sse Monthly Report SSC-153

PROJECT SUMMARY

CDGREPORT

BNLREpORT

FNALREPORT

LBLREPORT

PROJECT COST DATA

1

1

2

2

3

4

10

13

15

15

17

18

20

21

21

23

25

25

27

CENTRAL DESIGN GROUP (COG)

BROOKHAVEN NATIONALLABORATORY (BNL)

FERMI NATIONALACCELERATOR LABORATORY (FNAL)

LAWRENCE BERKELEY LABORATORY (LBL)

TEXAS ACCELERATOR CENTER (TAC)

MAGNET PROGRAM

ACCELERATOR PHYSICS

ACCELERATOR SYSTEMS

CONVENTIONAL FACILITIES

PROJECTPLANNINGAND MANAGEMENT

MODEL MAGNETS

TOOLINGAND FACILITIES

TESTS AND MEASUREMENTS

CRYOSTATDEVELOPMENT

MAGNETICMEASUREMENTS

LoNG MAGNET FABRICATION

SUPERCONDUCTOR AND CABLE

DIPOLE MODELS

INDEX

PROJECT SUMMARY

CENTRAL DESIGN GROUP (CDG)

This was John People's first full month as Head of the Magnet Division following the resigna­tion of Victor Karpenko for reasons of health. Work continued on a wide range of activities.Most important was the coordination and direction of the magnet R&D program at BNL, FNAL,and LBL. In addition, considerable progress was made in the area of magnet modeling andanalysis. A two-dimensional model is now fully operative, and work is progressing well on athree-dimensional model that will treat axial as well as radial and azimuthal stresses and strains.A review was conducted of the Iteration B cryostat design, and a number of topics were recom­mended for further analysis. Finally, work was started by outside contractors on further thermalanalysis of the magnet, on the properties of magnet materials, and on magnet failure modes andreliability.

The Accelerator Physics Division efforts for November included magnetic corrector schemestudies, beam-tube corrector tolerance specifications, horizontal-vertical decoupling simulations,examinations of new LEB designs and space-charge calculations for the SSC and all its boosters,and modeling the beam-beam "flip-flop" effect.

Four visiting experts on various aspects of radiation joined the Accelerator Systems Division instudying radiation at the SSC. The division also started work on a design of a quench protectiondiode system, which involved adapting complicated time-dependent [mite-element codes. A new

photodesorption experiment was started at the Synchrotron Radiation Center at Stoughton,Wisconsin. As usual, most of the division's effort involved helping with magnet development.

Activities for the Project Planning and Management Division centered on support functions forthe Director's office and other COG Divisions. A significant amount of effort went into theupdating and improvement of R&D magnet production planning and tracking activities at BNL,FNAL, and LBL. The accounting group began organizing for the new fiscal year.

BROOKHAVEN NATIONAL LABORATORY (BNL)

Testing of DOOOZ at Fermilab was curtailed by an electrical failure. The magnet was returned toBNL for disassembly and detailed inspection.

Long magnet DDOOlO was shipped to Fennilab for testing. The continuing cold mass construc­tion effort focused on DD0012, DDOO14, and DDOO15. (These will incorporate stainless steelcollars with tapered keys.)

sse MONTHLY REPORT 1 NOVEMBER 1987

Short magnet DSS9 was tested with excellent results. It reached the short sample performance

after a single training quench.

FERMI NATIONAL ACCELERATOR LABORATORY (FNAL)

Magnet DOOOZ was removed from the test stand on November 7 after developing a ground fault.

The cold mass was removed from its cryostat and returned to BNL for study.

The cold mass for magnet DDOOlO was received from BNL on November 20. Although the cold

mass passed all initial tests, the eDG has asked FNAL to modify the bore tube anchor to accom­

modate the partially crushed bore tube. (The bore tube, which was deformed during collaring at

BNL, is now wedged against the collar poles near the middle of the magnet.) The assembly of

the magnet is now under way and is expected to be on schedule.

Mechanical work is nearly complete on the second test stand (M1F stand 5). Magnet DOOOX is

being mounted in preparation for commissioning of the stand The initial test ron with magnet

DOOOX is expected to be finished in January.

Tooling parts for dipole winding, curing. collaring. and yoking l-m dipole model coils continue

to arrive from vendors. The first parts of the coil winder have arrived from BNL. Alignment

and mounting of the winder have begun.

Cryostats are being prepared for magnets DDOOl2 and DDOO14. Magnet DDOO12 will be

mounted in the cryostat removed from DOOOZ.

LAWRENCE BERKELEY LABORATORY (LBL)

Magnet model DSS9, an LBL design. was built at BNL with LBL parts and personnel. It was

tested at BNL with excellent results. At 4.45 K, there was only one training quench at 6130 A;

all subsequent quenches were at the short-sample limit of approximately 6800 A. It reached

7900 A (short-sample limit) at 3.5 K and retained its training after a thermal cycle to roomtemperature. Field quality was excellent.

While LBL personnel assembled long magnet DDOOll at BNL. turn-turn shorts developed in the

ends of the inner coils. Similar shorts were also found in the inner coils for magnet DDOO13.

A repair procedure was developed to completely reinsulate the ends with more substantial insula­

tion. Several coils were produced to test the improved insulation scheme and ease of repair of

flush LBL inner coil ends. As a test, the repair procedure was carried out on one inner coil end

in model D15A4. Subsequently. the procedure was performed on long model DDOOII inner coil

sse MONfHLY REPORT 2 NOVEMBER 1987

ends. Several additional changes will be made to further enhance the electrical integrity of theflush ends. Model Dl5A4 is collared and ready for testing.

TEXAS ACCELERATOR CENTER (TAC)

Preliminary tests of the new DS6000 diodes were conducted in preparation for reactor run 4. Sixdiodes survived. multiple thermal cycles to 4.5 K with a full series of tests performed at 300 K,

80 K, and 4.5 K. Tests were also performed. at several temperatures during cooldown to provide

a pre-irradiation database for parameter variation versus temperature. Three diodes failed prior tothe thermal cycling and testing. Two dipoles failed under reverse bias testing up to 400 V at

room temperature. These failures can probably be attributed to overstress, since the catalog Vron

specification is 200 V. A third diode failed under high current forward testing at roomtemperature with an unknown failure mechanism.

The cryostat was modified after each thermal cycle in an effort to improve the cooling at the

diode positions and to reduce the overall heat load at 4.5 K. Significant improvements wereachieved, and at least one more thermal cycle will be performed to evaluate the latest modifica­

tions.

sse MONTHLY REPORT 3 NOVEMBER 1987

eDG REPORT

MAGNET PROGRAM

Magnet Meetings

Two magnet meetings were held in November: the regular monthly COO Magnet Systems

Integration meeting and a one-day meeting to review instrumentation and design modificationsfor future SSC magnet tests. Both meetings took place at Fermilab. There was a fair amount ofoverlap in subjects discussed at the two meetings, as is reflected in their respective summariesgiven below.

The agenda for the MSI Meeting on November 5 was as follows:

Report on LBL magnet A3

BNL DSS6 et al.

DOOOZtests

DOOOX tests

Axial instrumentation and measurements

Progress report on the BNL strain gauges and theiruse in DSS6 and DDoolO

Description ofLBL in-coil load cells

Instrumentation for magnet ends

General discussion of measurements of magnets D15A4,D15A5, D15A6, DSS9. DSSlO. DSSll, DSS12,DDOO1O, DD0011, DD0012, and DDoo13 and discussionof additional measurements on D15A3, DSS6, DDOOZ.

LBL

BNL

FNAUCDG

COG

COG

BNL

LBL

LBL

The meeting began with a review of the excellent performance of D 15A3, the third dipole toincorporate aluminum collars with tapered keys. The magnet required only one training quench

to reach -6800 A at 4.3 K. and it trained to 9400 A at 1.8 K. Next came a report on the equallyencouraging performance ofDSS6, nominally identical to DSS4 and DSS5 (Cu:SC = 1.6:1,alumina/epoxy-filled ends) except for having no iron end laminations. It required virtually notraining to reach its short sample plateau of -6500 A at 4.5 K and exhibited satisfactory multipolecoefficients.

Considerable discussion was devoted to DOOOZ. Its early training curve was quite similarto that of DooOX, but it failed on a ramp during quench run 14. Pan of the discussion concernedthe so-called power lead events, or voltage excursions in the negative lead. These appeared asquenches to the quench protection system but did not, in fact. seem to be true quenches. The

sse MONTHLY REPORT 4 NOVEMBER 1987

bulk of the discussion centered on the evolution of the ground fault over the final 3-4 quenchesand on a detailed analysis of quench 14.

Most quenches, and all training quenches, in DOOOX originate in the feed end of the

magnet. This is puzzling, because the feed end of the magnet is systematically about 40 mKcolder than the return end, and one would therefore expect most of the quenches to be at thereturn end. Plotting quench current versus temperature at the quench location indicates that all

the return end quenches, and only the return end quenches, are at the short sample limit. It isconcluded that quenches at the feed end are due to something other than reaching short sample;that there is something mechanically wrong with the feed end of the magnet; and that the behaviorof the return end is normal.

Axial instrumentation (extensiometers) in OOOOZ appeared to be functioning properly andindicating gradual built-up strains with each quench event ("ratcheting''). BNL's new beam-type

strain gauge transducer program was reviewed. including the deployment of these gauges in000010 and DSS6. The system appears to be working well. An absolute calibration of thegauges in OSS6 will be made in the near future when that magnet is uncollared. LBL's transdu­

cer measurements were also reviewed. It was proposed that a quantitative comparison of the two

types of gauges in a l-m or 1.8-m model magnet be made.An important consensus reached at the meeting was on the mounting evidence for large

axial forces in the long coil ends, pointing to the need for redoubled effort to understand these

forces better and the difference between long and short magnets in this respect.The second meeting was held close on the heels of the first (November 5), according to the

following agenda:

Relevant recent test results CDG

BNL plans for tapered-key steel collars BNL

BNL proposals for near-term end improvements BNL

Tapered-key aluminum collars LBLa) What we've learnedb) Proposed improvements

LBL proposals for near-term end improvements LBLa) Internal support for straight endsb) Bulged end

Magnetic considerations of end design LBL

General discussion of implementation of near-termimprovements in FY88

Laboratory thoughts for longer term end improvements.

This time the specific purpose was to review design modifications and instrumentation thatmight be incorporated in DOOO14 and subsequent long magnets. The meeting, therefore, began

sseMONTHLY REPORT 5 NOVEMBER 1987

where the last one left off, with further discussion of both axial and azimuthal instrumentation,

including extensiometers, strain gauges, and thermometers. Next, discussion turned to BNL's

plan for implementing stainless steel collars with tapered keys. DSS 12 could serve as a test

vehicle, and the collars could be implemented in DDOO14 and in subsequent long magnets. The

existing collar design can be retained with minor modifications. At the same time, LBL now hasa great deal of experience with the aluminum collar approach and discussed proposed improve­

ments of their own.BNL's proposals for near-term end modifications include: a) measures to avoid insulation

scuffing, b) alumina/epoxy filling during molding, c) use of "prepreg" fiberglass-epoxy for all

spacers, and (later) d) replacing layered fiberglass with randomly oriented material. Longer-term

modifications will probably also involve modified end geometry for better distributing forces and

compensating harmonics. LBL is also examining a number of possible end improvements,including better internal support of straight coil ends, and an end variant known as "bulged"ends. LBL's proposed changes, however, would have a considerable impact on productiontooling and therefore do not affect plans for the immediate future.

The new challenge for short models was reiterated: to simulate end forces characteristic oflong magnets (the reverse simulation being less readily implemented).

The fourth in the series of long magnets, DOOOZ, exhibited unusual behavior and

eventually failed while undergoing cold testing, as reported in the October report. The magnet

was removed from the test stand and dismantled, and the cold mass was sent back to BNL for

further disassembly and inspection. A committee was formed to examine the probable cause or

causes of failure and to maximize the contributions of this magnet to the magnet program. Themembers of the committee are J. Zbasnik (LBL), R. Lundy (FNAL), W. Schneider (BNL), P.Wanderer (BNL), R. Coombes, Chairman (CDG), K. Mirk (CDG), and J. Tompkins (CDG).

The committee met at FNAL November 17-18 to determine an initial disassembly proce­

dure. By the end of November the cold mass had arrived at BNL, and the disassembly hadstarted.

When inspection of the magnet has been completed and the committee has reviewed thefindings, a preliminary report will be presented, to be followed in January by a fmal report

Several significant increases in data analysis capability were realized, both at CDG and inthe field. The magnet data obtained during testing ofDOOOZat FNAL were transferred viaDecnet to the LBL VAX cluster for analysis by CnG personnel. In this way, FN AL staff wereable to concentrate on test details while COO staff were able to analyze the results and suggest

additional measurements. CDG has transferred this analysis software to FNAL, resulting in anincrease in on-line analysis capability at FNAL. Also, several CnG staff members participateddirectly in the measurements at FNAL. The results of this cooperative effort will be seen infuture experiments: there will be additional, trained personnel to help with data acquisition andanalysis; there will be a shorter turn-around time for analysis; and additional data channels can bemonitored conveniently to watch for incipient magnet problems.

sseMONTHLY REPORT 6 NOVEMBER 1987

Magnet data obtained during the testing of OSS9 at BNL were also made available viaDecnet, the first time such a link has been established. Both voltage tap and strain gauge datawere transferred and analyzed, which considerably shortened turn-around times. COG staff

developed analysis routines for the voltage tap results and are performing a detailed study of the

data; such experience will be necessary in analyzing data to be obtained from magnet 000010.Analytical studies have continued on the axial mechanics of dipole magnets. Experimental

results have been obtained for end-plate forces due to preload, cooldown, and magnet energiza­tion in magnets OSS6, DSS9, and DOOOZ. A mathematical model that represents the magnetcomponents by a system of springs coupled together by friction adequately describes at least the

results due to cooldown and energization. The magnet ends may need to be modeled in consid­erably more detail to describe the preload results. More detailed experimental data are requiredfrom additional magnets to adequately verify the model.

Cryostat Design Review

A review of the Iteration B cryostat design was conducted by the COG at FNAL on November10. The object of this review was to evaluate the capability of the proposed design to perform

satisfactorily under end conditions stipulated in the system requirements (SSC-MAG-D-lOl) and

to meet the objectives of the next series of tests planned at FNAL. During the review, committeemembers and attendees recommended 46 actions. The recommendations were transmitted to

FNAL and others for response. Although the cryostat design may be suitable for the next series

of tests at FNAL, considerable work remains to be done to meet system requirements.A contract specifying three tasks was issued to the EQE Company. Past analyses conduc­

ted by EQE have indicated that stresses in the posts supporting the dipole magnet cold mass

exceed allowable values for both seismic and transportation loadings. Design changes have beenrecommended that, if implemented, should reduce these stresses. The changes include increas­

ing the lateral stiffness of the outer vacuum vessel and increasing the thickness of the composite

cylinders that comprise the posts. The first task is to modify the mathematical models to reflectthe design changes and to conduct dynamic analyses to assess responses to the seismic

environment and to transportation.The second task is to evaluate magnet response to the ambient ground motion environment.

Such vibration can be either man-made (caused, for example, by rail or vehicle traffic) or natural,(caused by ground subsidence or other geological phenomena). The previously constructedmathematical models for assessing response to seismic environment will be utilized Beammotion will be predicted for various levels of input and compared to the allowable tolerances

specified in the Conceptual Design Report.The third task involves a review by EQE of the stresses allowable for various materials (as

specified in the Magnet System Requirement document) together with recommendations for

sse MONTHLY REPORT 7 NOVEMBER 1987

improvements or modifications, if necessary. This review includes both allowable stresses for

selected materials and their loading conditions.

ThermalModeling ofMagnet

General Dynamics has begun work to further utilize the previously completed Integrated Thermal

Model to do selected parametric studies of dipole magnets. This effort includes studies to exam­

ine the effects of vacuum quality and shield temperature on heat leak, the sensitivity of the annu­

lar helium temperature to the radial thermal resistance of the cold mass, and the effect of the

post-quench winding temperature on the post-quench thermal behavior. Modeling sensitivity of

the temperature rise in the beam tube, trim coil, and helium channel to assumptions and uncer­

tainties in the thermal properties used in the model is being examined.

This study also involves validation of predicted coil temperature rise due to synchrotron

heating, and exploration of necessary design changes to reduce the temperature rise to less than

0.06 K In particular, an estimate will be made of the benefit derived from mixing the helium in

the beam tube annulus and the yoke cooling channels, caused by natural connection in the gaps

between collar and yoke lamination sub-assemblies.

Mathematical Modeling and AnalysisofMagnetStressesand Strains

The effects of manufacturing errors (tolerances) on field quality for the ring dipole magnets

continued to be studied. Analyses have been published of the effects of random turn-to-turn

variations in the conductor thickness and of a linear taper in the thickness of the conductor from

one end of a winding to the other. Analyses of the effect of a step change of conductor thickness

within the coil has been completed; a report is being written. The effects of random conductor

thickness changes at random positions along the conductor are being examined.

The electromagnetic forces in the bore tube during quench have been reevaluated using

resistivity ratio measurements on 3-mil copper platings. A report is in progress.

Following the observation of a deformation of the beam tube at the center of the recently

collared magnet 000010, an analysis was performed to understand the effect of such defor­

mations. Hand calculations based on the assumption of no clearance between the beam tube

bumpers and coil and the observed deflection of the tube indicated that large stresses would be

produced and significant plastic flow would occur. As a result of this conclusion, computer

calculations were performed with the observed deformation of the beam tube included. The

results obtained from fringe plots indicate significant differences in the stress state in the coil,

both at the end of cool down and at the end of energization, between the case in which the beam

tube is distorted as observed and the case in which there is no distortion of the beam tube.

Hand calculations and computer calculations of longitudinal stresses and strains in a magnet

are in progress. All the codes necessary for three-dimensional analysis are up and running. The

three-dimensional mesh for the lead end is almost finished. This will then complete all the com-

sseMONrHLY REPORT 8 NOVEMBER 1987

ponents for the entire three-dimensional model, which will be used to study a variety of prob­

lems. Analysis has been undertaken to incorporate the longitudinal effects of collar and yoke intothe previous two-dimensional calculations. A computer calculation of the effects of a slot in themodel of the collar with a collar pack is nearly competed.

Assistance was given to BNL in the analysis of models of magnet behavior; coordination ofthe work at BNL and the CDO was initiated

A series of lectures on magnet analysis was given at the CDG.

Evaluation ofMagnetMaterials

Tests using sections of coil to measure material properties and coefficients of friction werebegun.

Magnet yoke steel property studies in collaboration with BNL, LBL, and the COG areunderway. The goal is to determine technical procurement specifications that are both costeffective and satisfy magnet system performance and reliability requirements. The yoke steelmaterial costs will be large, so it is important to accurately identify and quantify those yokematerial properties necessary to obtain the required SSC magnet performance. More sensitivityanalyses of the impact of yoke steel magnetic properties on magnet performance are required.

A meeting was held at BNL in November with participants from Armco, BNL, and theCOG to discuss the steel magnetic-property requirements and special test data on candidate steelmaterials. Typically, steel vendors produce steel to chemical composition standards, not tomagnetic property standards, whereas the COO is interested primarily in magnetic properties.Armco presented "typical" magnetic-property data from their steel furnished for the ISABEU..Eproject, but they did not have data on statistical deviations of these properties. For the sse, the

statistical variations in magnetic properties are very important.The National Bureau of Standards is proceeding with special tests for the beam-tube welds

(Program A) and for the aluminum alloys that may be used in the aluminum collared magnets(Program B). Phase I of the Nitronic-40 beam-tube weld tests has been completed. Thepurpose of Phase I was to select the best two of three candidate stainless-steel materials (304L,316LN, Nitronic 40) that were tested to simulate the beam tube flange. At 4 K, these tests

showed that:

1. The 316LN specimens had the highest strength and the best ductility.

2. The N40 specimens showed signs of brittle behavior.

3. The 304L specimens had a higher strength than the N40 specimens, but also failedbefore reaching the yield strength displacement criterion (0.2 percent plastic strain).

It has been decided that type 316L (an acceptable alternate for 316LN, which is difficult toobtain) and type 304L should be the two flange materials that advance to Phase 2 of the program.

sse MONTHLY REPORT 9 NOVEMBER 1987

Phase 2 will determine the regions most susceptible to crack growth by placing notches in four

locations in the tensile specimens. Finally, Phase 3 will determine the fatigue strength of the

specimens at 40,000 cycles.Aluminum alloy is being considered as analternate collar material for the dipole magnet. In

1986, Westinghouse participated in a dipole cost analysis study based on stainless steel collars.They were recently asked to compare aluminum collar cost with the previous study and havesubmitted. a report for Magnet Division review. The preliminary conclusion is that more than$25 M could be saved for 7075-T6 aluminum alloy collars. However, complete suitability ofthe 7075-T6 for dipole collars is still in question. A literature search by Westinghouse confmns

the necessity of the aluminum-alloy properties evaluation currently underway at NBS.

AnalysisofMagnetFailureModes andReliability

A listing of failure modes and effects analysis for critical dipole magnet components was pre­

pared. Approximately 40 critical areas were identified, and failure rates were assigned to them.Prof. R. Barlow and his staff constructed a revised fault tree based on FMEA results. Failurerates in this study will be based on results found in the literature, Tevatron results, or judgment.Failure rates of the order of -1o-lOJhr for each critical component are required to meet the ssemagnet system requirements of 96 percent These required failure rates are far below currentnorms for such systems. Failure rates of -10-9/hr are needed for an availability of 85 percent

ACCELERATOR PHYSICS

Magnetic Corrector SchemeStudies

The magnetic correctors described in the Conceptual Design Report consist of distributed correc­tion coils wound inside the dipole coils, which are used to compensate for the systematic dipoleand persistent-current errors, as well as a relatively small number of localized correctors intendedfor accelerator functions. such as chromaticity and, possibly. resonance corrections. There aresome potentially difficult engineering problems associated with the bore-tube windings. As a

result, other corrector schemes are under study as back-up options. Several schemes, consistingonly of lumped correctors, were examined. These various schemes differ in the number of cor­rectors per half cell and in their distribution within the cell. Many of these schemes appear to beadequate to correct the expected systematic errors.

The different approaches were also studied with respect to their effectiveness in correctingrandom multipole errors in the dipoles. A method for optimizing the relative strengths of the

lumped elements was developed and shown to be effective. The abilities of several

lumped-corrector distributions to reduce the "smear" produced by the random multipoles were

compared An arrangement of three correctors per half cell has been shown to be very effective

sse MONTHLY REPORT 10 NOVEMBER 1987

in correcting all expected errors, and different distributions of two correctors per half cell also

seem to be acceptable. Further analytical studies are in progress, as are tracking simulations ofcorrector schemes involving two or fewer correctors per half cell.

Bore Tube Construction and AssemblyTolerances

The tolerance to random errors in the manufacture and assembly of the beam-tube correction

windings was estimated on the basis of the tolerable error multipoles produced in each windingwhen energized. The tolerable random multipoles for the beam-tube windings were taken to be

one third of those for the SSC dipoles listed in SSC-N-183 and translated into tolerances on thebeam-tube-winding parameters using the error matrices from SSC-N-226. The results areshown below. The implication of these tolerances for the system design is under study.

TOLERANCE FOR RANDOM ERRORS

Responsible ToleranceError (Standard Responsible

Coil Parameter rms Tolerance Multipole Units) Coil

Displacement !:iX,8.y O.3mm al,bl 0.23,0.23 sextupole

Rotation 0.5 0 a2 0.20 sextupole

Gap 0.90Q2 0.20 sextupole

EllipseAr 0.8 mm b2 0.13 decapole

Wire Position 0.5 mm Q2 0.20 sextupoleBlock Position 0.5 nun a3 0.23 sextupole

(an, bn represent the skew and normal coefficients of the 2(n+1) multipole.)

Feed-Down Corrections for Magnetic Measurements

A method was proposed and studied for determining the feed-down corrections in magnetic mea­

surement data due to errors in locating the measuring device relative to the magnetic center of thedipole. This method. involves the powering of individual coils of a dipole. Although the entiredipole has been designed to have very small multipole components, each separate coil layer hasstrong sextupole and decapole coefficients. The inner layer of l-m dipole D15A3. for example,

has b2 =194 units and b4 =18 units in the central section of the magnet. The feed-down of thesemultipoles to apparent quadrupole and octupole errors is readily observable with a 10 A excitation

of the inner coil. Further studies of the effectiveness of this method are being carried out.

sse MONTHLY REPORT 11 NOVEMBER 1987

Decoupling Simulation

The 90 degree lattice. tuned for injection optics. was decoupled with a global decoupling schemesimilar to that used in existing accelerators. Only measurable quantities (the fractional parts ofthe tunes) were examined in order to set two families of skew quadrupoles. The strengths ofthese quads were adjusted to minimize the separation between the two measured tunes. Allquadrupoles were misaligned with rms errors of 0.5 mm and an rms rotation error of 1 me.Tracking simulations using four random seeds were studied. The orbit was corrected. withresulting rms orbit distortions in the horizontal and vertical planes of approximately 0.2 mm.After one iteration of setting skew quadrupole strengths. the tunes were brought closer than

0.0008 in all cases studied. When the tunes were separated again to the nominal operating valuesof 0.285, 0.265. the coupling coefficient was less than 0.0013. The strengths of the skewquadrupoles needed were less than one tenth that of the arc quads.

Low EnergyBoosterLattice

The study of a possible redesign of the LEB lattice has been started. The design given in theConceptual Design Repon was dominated by the desire to avoid crossing transition, as well as tominimize the space-charge tune shift. The CDR design accomplished those goals. but at theexpense of having a very large dispersion wave (eta varied between 11 and -5 meters). Severalnew designs have been examined that have a more regular lattice and achieve a high transitiongamma through an increased horizontal tune. The designs studied have super-period three. withregular FOOO cell arcs and dispersion-free straight sections. The arc dispersion function ismatched to the cells and has a maximum of approximately one meter. The typical transitiongamma is to. One disadvantage of these designs is that, compared with the CDR design, theyhave both a larger circumference (3~350 m compared with 250 m) and more elements. due tohigher tune and shorter cells. Additionally. the space-charge tune shifts become larger. Thesedisadvantages may be offset by the reduction in the required magnet aperture and a well-behavedlattice. The studies continue. and more detailed examinations of the space-charge effects (bysimulations) and microwave instability thresholds are being undertaken.

SpaceChargeEffects

The incoherent linear space-charge tune shifts (horizontal and vertical) were evaluated for theSSC and its three injectors at their respective injection energies (SSC-N-403). The tune shiftsare very small for the SSC main ring and for the HER Previous calculations showed that thetune shifts for the LEB were significant. and the present linear calculation agrees well with thoseresults (SSC-lIS). For the MEB, however, it was found that the tune shifts are !:iuH =-0.085,

!:iuv = -0.096, only slightly smaller than those of the LEB. This can be understood qualitatively.

In comparing the LEB with the MEB, competing effects almost cancel each other. The increase

sse MONTHLY REPORT 12 NOVEMBER 1987

in circumference and the decrease in both bunch length and transverse beam size combine to

increase the tune shift in the MEB by a factor of approximately 100, which is just slightly lessthan the tune-shift reduction due to the increase in energy.

Beam-Beam "Flip-Flop" Effect

A simple model that qualitatively explains some of the observed "flip-flop" phenomena in elec­

tron machines was further studied in November. The model is qualitatively successful, but the

required numerical range of the parameters is unrealistic for the SSC. This work is being sum­marized in a report.

ACCELERATOR SYSTEMS

TaskForce Meeting

A task force on radiation levels in SSC experimental halls met at the CDG November 9-13. Forthis effort, as well as for a broader class of SSC radiation studies, a number of simulation

experts assembled at the COO for extended visits: Alberto Fasso (CERN), Johannes Ranft(Leipzig), Graham Stevenson (CERN), and Todor Stanev (Bartol Institute). In cooperation withthe radiation physics group at SLAC, they brought the CERN hadronic cascade code FLUKA

online on the SLAC mM mainframe and used it to study hadronic cascades initiated by 20-TeVprotons. With appropriate conversion, the calculated interaction density provides a measure ofenergy deposition, neutron flux, and radioactivation.

A better understanding of low-energy particle spectra from the collision of 20-TeV beamswas achieved; these particles dominate in creating the detector and interaction hall radiationenvironment. As a result of the workshop and the extensive work done before and after, there

seems to be a good convergence between particle production models and the resulting radiation

effects. Simulations continue of energy deposition, especially in the coils, from beam loss in the

arc dipoles.

Cryogenic Systems

A contract is being prepared with Air Products and Chemicals, Inc., for writing software to beused for dynamic modeling of the sse cryogenic system. At a meeting held in Allentown,November 11-12, all of the technical issues associated with the scope of work were resolved.The final details of the contract are now in the process of being resolved, and work on this veryimportant project will begin soon.

sse MONTHLY REPORT 13 NOVEMBER 1987

Quench Protection Diodes

The LLNL codes MAZE, TOPAZ, and ORION were adopted to perform non-linear,

time-dependent thermal analysis.The codes were used to calculate the junction temperature of cold quench protection diodes

during current pulses that are used as part of irradiation tests. Knowledge of the junction

temperature is important to properly analyze the measurements of radiation damage indicators and

to relate those measurements to a "dose limit" criteria for theSSC.The design of the quench protection diodes mounting assembly started with the thermal

design of the heatsink. This design consists of an optimization ofcopper block dimensions.

The optimization criteria are based on the maximum junction temperature calculated for anirradiated diode during a simulated SSC quench current pulse. Future work on the mounting

assembly design will include calculations of transient thermal stresses and deformations duringthe thermal cycling, and general structural analysis. BBC has agreed to review the mounting

assembly design for proper diode operation, and to provide us with specifications such as contact

surface roughness, flatness, and measured values of contact thermal resistances. The mounting

assembly design is based on the HERA and BNL designs, modified for the sse. It is important

to have an adequate mounting assembly design in the near future, because the reliability tests of

cold quench protection diodes have to be made with the final mounting assembly to ensure

accurate results.

Thermal Analysis ofDOOOZ Ground Fault

The ground fault during quench 13 of DOOOZ was thermally analyzed. From numerical simula­tion of the heat diffusion process within the cable it was learned that at a point of maximum cabletemperature the heating was very localized (a few mm from the grounded area). It is not unrea­

sonable to expect additional insulation damage and some copper melting in the cable due to

power dissipated during the ground fault. This damage may have been the cause of the very lowcurrent quench of quench 14.

Photodesorption Studies

During November an experiment to measure photodesorption from sse beam tube surfaces at4.2 K and at room temperature was set up at the Synchrotron Radiation Center, in Stoughton,Wisconsin. Initial data were taken the last week of November. This measurement will allow an

independent determination of gas density within the sse beam tube when the beam is present, tocompare with the measurements previously made at the National Synchrotron Light Source.

...

sse MONTHLY REPORT 14 NOVEMBER 1987

Participation in MagnetDivision Work

The Accelerator Systems Division participated in the test of long magnet DOOOZ at FNAL and in

subsequent analysis and disassembly procedure discussions. A COG account was set up on theFNAL Vax cluster, and analysis software previously developed at the COG was installed.

J. Tompkins began work as DDOOlO test coordinator. Information on instrumentation, testprocedure, and schedules was gathered, and a magnet test plan is being developed in conjunctionwith Fermilab. New diagnostic and analysis software appropriate to this magnet is beinggenerated

Analysis routines for voltage tap data from short magnet DSS9 were developed and

preliminary analysis began. Routines were generated to extract, plot, and fit both collar stressand end plate force data versus current

Database Development

Accelerator Systems Division personnel participated in the database task force. The sse'sdatabase needs were discussed at several meetings. Discussions were held with Fermilab staffabout implementing and using a database system with magnet test data

CONVENTIONAL FACll..ITIES

The work of the Conventional Facilities Division during November focused on preparation of thedraft Safety Review Document. P. Dahl returned from Brookhaven National Laboratory for aweek to supplement the work ofL. Jones (on sabbatical from the University of Michigan) andK. Edwards (on sabbatical from Carleton University). By the end of the month the draft wascompleted. The draft will be reviewed by the members of the SSC Coordinating Committeeduring December.

D. Shuman continued the cataloging of conventional and technical requirements for astandard arc sector. Three-dimensional conceptual arrangements have been developed using thenew Interpro CADlE system.

PROJECT PLANNING AND MANAGEMENT

A new activity for the PP&M Division involved development of a spreadsheet-based method forgenerating rapid estimates of SSC cost variations associated with hypothesized or contemplatedtechnical changes in SSC technical systems. Microsoft's spreadsheet program Excel serves as abasis for this effort. The goal was to have a simple, reliable, and flexible tool for generating costvariations relative to the base estimate in the Conceptual Design Report. The ability to carryalong estimated uncertainties in the cost elements (down to the eighth level ofWBS) was incor­porated in the resulting product, as was the ability to extrapolate results into appropriate fiscal

sse MONfHLY REPORT 15 NOVEMBER 1987

year dollars. Accordingly, each cost estimate exercise carries with it a dollar uncertainty relatedto the new estimate in chosen fiscal year dollars. This package has already been used for several

such exercises.Support continued for the Open Plan project management program, especially in relation to

the R&D Magnet work at BNL, FNAL, and LBL. In particular, all magnet production scheduleswere carefully reviewed by COO management, the results captured in appropriate Open Plan

activities, and the activities linked one to another by precedence logic. For example, the effect ofa delay in coil winding at BNL can now be directly linked to its effect on magnet measuring at

Fennilab. Now that the system is up and running and linked to the participating laboratories,

SSC managers can now use it to keep track of schedules. Effort on Open Plan will now shift to

other SSC activities and to putting into place a regular update pattern, to insure that scheduleinformation is kept current.

Considerable effort went into a draft report on results of the SSC Workshop on DistributedMultipole Correction Coils (see the October Monthly Report). Further work was done on

improving the communication links among CDO Apple and Sun computers. A unified Apple-Sunserver system is being developed.

CDO software and computer projects are also aided each month by less identifiable, butequally necessary file backup, equipment installation, and maintenance tasks. These were carried

out as usual. In particular, some very useful utilities were developed for transport, editing, and

concatenation of Open Plan files across the United States via DECNET or BITNET. A newOpen Plan node was set up at the COO for the Magnet Division.

Finally, the new fiscal year, combined with recent personnel changes in the COG account­ing area, ensured that there were plenty of opportunities for spending long hours in compilingnew and ongoing fiscal reports, as well as for maintaining customary activities and services.

Responsibility for processing and tracking CDO purchase requisitions was added to the PP&MDivision this month.

sse MONTHLY REPORT 16 NOVEMBER 1987

BNL REPORT

MODEL MAGNETS

DOOOZ

Dipole DOOOZ was tested at Fennilab. It achieved close to short sample performance, but an

electric discharge caused the magnet to fail on the 14th quench run. The magnet was removed

from the test stand and cryostat, wrapped up, and shipped to BNL. BNL measurements of endplate deflections, of electrical parameters, etc., agreed rather well with earlier values obtained byFennilab. The main expansion bus was removed, strain gauges were installed on the shell, andthe fiducials were trepanned from the shell. At the end of the month, preparations were beingmade to remove the shell. The magnet disassembly was undertaken to serve two independent

purposes. The more immediate purpose was to get as much information as possible about the

location and cause of the insulation failure so that steps could be taken to prevent similar inci­dents in the future. However, an equally or more important purpose was to exploit this firstpost-mortem of a full-length magnet to make detailed measurements of dimensions and stresses

subsequent to thermal and magnetic cycling. This is an opportunity to achieve a better under­standing of this highly complex mechanical system.

DDoolO was shipped to Fermilab on November 18. Two anomalies were observed during

assembly operations and final preparations of this cold mass prior to shipment: (a) A local boretube deformation was observed near the longitudinal center of the cold mass. This deformation

may mechanically couple the bore tube to the coil at this location. (b) Arcing between the boretube and voltage tap wires at the return end was observed during hipotting of the magnet.

Special precautions will have to be taken if this magnet is to be tested, as planned, at Fermilab.

Assembly ofDD0011 and DDO013 was delayed, due to coil shorts. To compensate forthis delay, the assembly of magnets 000012,000014, and 000015 was accelerated. Magnet000012 is using parts salvaged from DOOOZ (collars, yoke, and electrical bus). Magnets

DOoo14 and 000015 will use the tapered key system developed at LBL. An important objective

of 000012 and 000014 will be to test a "frictional lockup scheme" that is designed to constrainaxial coil motions. This will be done by "locking" the collared coil to the yoke with special

shims. Later magnets, in contrast, will free the coil for elastic axial motions by providing alow-friction slip-plane between collared coils and yoke. The new collar die for magnets 000014and ODOO15 was constructed in two weeks at H&J and is presently undergoing the usual adjust­ments to bring all of the dimensions into tolerance. Unlike 000011 and DDooI3, these collars

will be made of stainless steel, not aluminum. Yoke laminations have also been ordered from

H&J for DO00 14 and DDooI5. Magnets 000012 and 000014 utilize new, thicker end platesagainst which the fixed, collared coil ends will bear; 000015 will use a modified yoke to permitsliding of the collared coil.

sse MONfHLY REPORT 17 NOVEMBER 1987

Calibration of strain gauges for DDO012 continued; results for DSS6 showed excellentcorrelation of the gauges with Lorentz forces.

Much of the month was spent developing end potting of coils in situ in the curing press.The type of material to be used, its location, layup, and the number of layers to optimize coilradial size were determined. Sample coils were made, collared, and cycled thermally with posi­tive results. This procedure is to be implemented in DDOO14.

Other R&D activities included measurements of longitudinal thermal coil contraction,photographing coil positions in DSS4, measuring longitudinal coil modulii, ANSYS work oncollars and end plates, evaluation of weld qualities of Armco 311 stainless steel, and physicalproperty evaluation of high-manganese stainless steel.

In industrialization program work, good progress was made on preparation of assemblyprocedures, flow chart sequences, and video tapes of actual steps in lamination cleaning and

block assembly. Design work progressed on ramp solder joints for the tapered key collars andon improvements of flexible joints.

Trim coil work centered on superconductor evaluation, insulation of 14-mil diameter wire,evaluation of O.6-m long multiwire trim coil samples, radiation hardening and evaluation of sub­

strate materials.The Nitronic-40 beam tubes for FY 88-89 have been shipped from Trent tube. The beam

tube for Doool2 has been extended 6 in to accommodate the voltage trap hipot clearances. Beamtube flange material has been changed from 304 to 326 LN stainless steel to improve welding

compatibility with Nitronic 40.

TOOLING AND FACILITIES

Coils

Design of the inner and outer formblocks has been completed Modification of the tooling at theends of the mandrel to minimize scuffing of the coils has been completed

Collars

Work concentrated on the tapered key insertion tooling.

Shell Welding

Progress continued on preparations for evaluating atomic shell welding procedures.

sseMONrHLY REPORT 18 NOVEMBER 1987

AcceleratedLifeTest

Progress included collection of fabricated parts, design of the lead end can support fixtures, thecover support fixture, and the tum-around can. Investigations began on bellows compressionand welding tooling and on updating the specifications for the cut-off tooling.

Field Measurements

Work centered on the design of Mole C and on fabrication of the Mole inspection system.

SUPERCONDUCTOR

Cable Procurement

The outer cable from Furukawa has been insulated and is ready for winding into coils. The innercable manufactured by Furukawa and shipped to Brookhaven from LBL is presently beinginsulated. These cables will be used in magnets DDOO14 and DDOO15.

Tooling

Modifications were made to prevent a recurrence of the problem of the collapsed cable, caused bya defect in the in line degreaser, In addition, a Branson representative was brought in to inspectthe degreaser, All standard parts found to be worn or defective were replaced. Additionalchanges to the system, involving non-standard Branson parts, are planned for the future.Because of the age of this machine and its unsuitability for mass production, an investigation intothe purchase of a new "straight through" high speed machine was begun.

Although adequate fiberglass is on hand to cover our near-term insulating requirements, anorder for 500 square yards of pre-impregnated fiberglass has been placed to supplement our

present supply and to ensure that cable insulation is not interruptedTwenty-four wood spools, to be used in cable insulation in coil winding, were ordered for

delivery in early 1988.

Miscellaneous

As previously reported, a source of woven fiberglass that may be able to provide the fiberglass"to size" in long lengths is being investigated. This would eliminate the need for slitting andslicing. The vendor has supplied Brookhaven with a pre-impregnated production size sample.This sample is presently being tested. In addition to the standard tests, tests are planned to see ifwoven fiberglass is more resistant to scuffing, fraying, and general abuse than the present

Hexcel slit fiberglass.

sseMONTHLY REPORT 19 NOVEMBER 1987

TESTS ANDMEASUREMENTS

Tests were mainly confined to DSS9. a 1.8-m dipole incorporating LBL design features. notably

aluminum collars with tapered keys. Performance was excellent. One training quench at 4.5 Kwas required to reach the short sample quench plateau. No retraining was necessary after athermal cycle. Multi.pole coefficients were excellent.

Wann measurements were made on DDOOlO before shipment to Fermilab. Multipole coef­ficients were reasonable.

sse MONTHLY REPORT 20 NOVEMBER 1987

FNAL REPORT

CRYOSTAT DEVELOPMENT

Laboratory evaluations of cast cold mass connections began. The connections will be evaluated

for response to structural loads, performance as a slide, and outgassing properties. A cast con­

nection was successfully loaded laterally and vertically to design loads. Measurements of the

performance of the connection as a slide in vacuum and at 80 K, parallel to those of welded con­struction slides, were made. The results of the measurements indicate superior performance tothe welded slide. Outgassing measurements are under way.

Work continues on suspension system analysis. Currently under consideration is a com­parison of the results of the FNAL and EQE analyses of the suspension system response to

dynamic loads.The analytical model was run for shield bowing with temperature distributions as predicted

by the General Dynamics Space Systems integrated thermal model. Results of the predictions are

being reviewed The detailed test plan for shield bowing measurements is being developed.Preparation of insulation blankets for magnet DDOO12 and for subsequent long magnet

models was delayed due to material and manpower shortages. Production of blankets for the

next six long magnet models is scheduled for December.Work continues on the cryostats for the long magnet models DDOOlO, DDOO12, and

DOOOI4. Both models 000010 and DDOO12 will incorporate design A cryostats. Model

DDD014 will employ the next generation cryostat. Extensive cryostat instrumentation is planned

for long magnet model DDDO14. Both structural and thermal performance of the support post,

anchor system, and shields will be monitored.The CDO Design Review of the design B cryostat took place during November. The

action items were reviewed. Work to facilitate the preparation of MlF stand 5 and to provide

instrumentation capability for cold mass motion measurements began.

MAGNETICMEASUREMENTS

DOOOZ was removed from the test stand following room temperature electrical checks and visual

inspection. Reports on these measurements have been forwarded to the OOOOZ ReviewCormnittee.

Activities at MlF centered around preparation for the commissioning of test stand 5 in itsbasic configuration, using magnet OOOOx. Test stands 4 and 5 will be upgraded to handle thehighly instrumented magnets scheduled to be tested in the next several months. The test stand 5feed can and turnaround box assembly were completed; they were moved to MTF for installation

in November. The power lead subassembly, a separate cyrogenic vessel attached to the feed can,was installed, and the high current bus was connected. The connection of the feed can and turn-

sseMONTHLY REPORT 21 NOVEMBER 1987

around box to the gauge panel with its pressure transducers was 80 percent completed. Magnet

DOOOX was mounted on the stand in preparation for a run to appraise the stand's performance.Attempts to install the turnaround end vacuum bellows revealed that the flange on the turnaround

box was unacceptably out-of-round. The offending flange was removed, adjusted. and rein­

stalled. Recent changes in the length of the long development magnets has required modifica­

tions to the test stand to allow the turnaround box to be installed in various locations without

major grinding of welds. Warm piping to connect test stand 5 to the MTF cryogenic system was

80 percent completed. Helium and nitrogen transfer lines are complete, except for flexible hose

sections. Delivery of the hose was delayed by the vendor until early December, and the transfer

lines are expected to be complete by mid-December. Instrumentation electrical connections arebeing installed, and the shakedown ron is expected to be finished before the end of December.

The vacuum pump for low-temperature operation was shipped by the manufacturer after many

delays. Low-temperature operation requires a warm-up heat exchanger to protect the vacuum

pump from low temperatures. Material for the heat exchanger was delayed by the vendor; it is

now expected to arrive in time for low-temperature testing of test stand 5 in January. Almost all

the front end and read-out electronics needed to commission stand 5 exist and are currently being

cabled.

The expanded instrumentation for subsequent magnets, beginning with 000010, includes

extra voltage taps, more strain gauges, a new system designed by BNL for making high absolute

accuracy static readings of some strain gauges, and a method for making dynamic strain meas­

urements. Isolation amplifiers for the extra voltage taps are being assembled by an outside

vendor; they are expected at the end of December. The commercial electronics needed for the

BNL strain gauge read-out system have been ordered, and BNI.. has promised to lend anyequip­

ment that the vendors do notdeliver on time. Dynamic measurements of strain gauges read by

this system will be made possible by amplifier modules that are being built at LBL. NIM mod­

ules are being built to allow both dynamic and high accuracy static measurements of strain

gauges that are not read by the BNL read-out system. LeCroy data loggers and Keithly relay

scanners to read the voltage taps and extra strain gauges have been ordered. They are expected at

the end of December. To accommodate the increase in the number of electronic modules. anauxiliary control room is being built in the southeast corner of Industrial Building 1. The walls,

cable trays. and relay racks have been installed, and installation of electronics and cables has

begun.

The cryogenic read-out software has been upgraded to handle two test stands. This

improvement will shorten the time required to take a set ofdata with the DVM and relay scanner,

allow more read-out channels. and allow the time interval between data scans to be changed by

the operator. Work with BNL is in progress to integrate the BNL strain gauge read-out system

and FNAL's cryogenic monitoring program. The measurement program has been modified to

accommodate two test stands. Code to handle the additional data logger channels is being

written.

sse MONTHLY REPORT 22 NOVEMBER 1987

LoNG MAGNET FABRICAnON

DOOOZ

DOOOZ was removed from the test stand and disassembled. The cold mass was returned to BNLfor disassembly and analysis. During the disassembly of the cryostat it was noted that the MLIinsulation on both the 20 K and 80 K shields had shortened. Seams of the outer layer of the80 K shield MLI had separated at the ends. Possible causes for these conditions are underreview. All other systems appeared normal.

Before returning the cold mass to BNL, the flatness of the end plates was measured. Theywere bulged outward approximately 12 mils.

DDOOJO

The cold mass was received from BNL on November 20. Actual cold mass preparation andcryostat assembly began on November 23. Magnetic vertical plane measurements were omittedfrom the cold mass preparation because of the deformations in the beam tube at the center of themagnet. The deformation will double the time necessary to do the vertical plane measurement.Time permitting, the magnet's vertical plane will be measured after the cryostat is completed. Thecryostat construction resembles magnet DOOOZ. except that the MLI is 1.5 in. longer and not astightly wrapped circumferentially. The beam tube bellows will not be installed on this magnet.because MTF requires the beam tube holes in the end cans for routing the numerous voltage taps.Per CDG directions, the lead end of the beam tube has a blind plate welded in place. The beamtube anchor has been removed. to allow the center deformation to act as the anchor. To test theeffectiveness of the inadvertent center anchor. a load of 100 pounds was applied axially to thebeam tube. There was no motion of the beam tube relative to the cold mass. At BNL it wasfound that a force of 500 pounds was required to move a beam pipe that had been deformed in thesame way. An extensiometer supplied by the CDG will be installed on the return end. to monitormotion of the beam tube relative to the cold mass outer shell. The schedule calls for the magnet tobe complete by mid-December.

DDOO12

The cryostat parts salvaged from DOOOZ are being refurbished for use in magnet DDOO12.

Cold Mass Tooling

Cold mass tooling is proceeding more or less on schedule. with some exceptions in the modelprogram. Laminations for collaring tooling had been delayed by flatness problems. due to poormaterial. (The vendor has ordered new material. resulting in one to two weeks) delay.)

sse MONTHLY REPORT 23 NOVEMBER 1987

The shuttle support system parts for the BNL winding machine arrived. It will be assem­bled and installed on the Industrial Center Building shop floor.

Previously reported lamination edge problems have been corrected. The vendor has sub­mitted satisfactory samples for all laminations except for the inner and outer mandrel. The

mandrel's specification has been changed from a 1050 to a 1020 steeLConductor for model winding has been received from the COG. The inner coil conductor

is identical to that used in the LBL short models. The outer material is different; it is a cable

supplied by Furukawa.

ACCELERATOR

Theory

Progress continues on a detailed energy deposition document. Production runs should startshortly. Approximately 50 runs are planned, which will lead to about 60-75 graphs for pre­sentation in the document.

String Test

A leak was found and repaired in the single phase. The hipot following the single-phase weldingwas questionable. Further testing was performed in nitrogen, and the hipot was deemed accep­table. Welding of the four other cryogenic lines has begun. Installation of the cryostat vacuumsystem was completed.

Photodesorption

The cold finger for the gas desorption experiment was completed and tested at FNAL. Higherthan anticipated flow was necessary to dampen oscillations. which may have been caused by theoutlet warm-up heater. The unit was installed at SRC in Wisconsin. Cooldown took placeNovember 23, and data were taken November 25. New circular samples/holders were designedand built They will be installed at SRC December 1.

sse MONfHLY REPORT 24 NOVEMBER 1987

LBL REPORT

SUPERCONDUCTOR AND CABLE

In order to provide cable for the accelerated dipole fabrication program at BNL, the followingcable was shipped during November:

• SC364, 1600 ft - outer layer cable with 15-llm diameter filament, for use in coil windingtests and magnet connections.

• S06230, 1879 ft - Furukawa inner layer cable for use in a new inner coil for DDOO13.

An order was placed with IGC for final processing of 290 pounds of 15-J.U11 filamentdiameter material into .0255-in. diameter wire. The wire was completed on November 23 and

shipped to New England Electric Wire for cabling during the week of December 7. This will

provide back-up cable for two coils (one magnet).

DIPOLE MODELS

General Progress

The concept of magnetically designing dipoles with conical ends has been established. We have

developed all formulas necessary to describe the path of each turn from the straight section up

and around the cone end. Portions of this concept have been programmed and checked with a

computer.The coils for model D15A5 are assembled and ready for collaring. Gauge packs for these

are complete.Reduction and analysis of coil prestress and end plate force data from DSS9 are reported in

SSC-MAG-174 and -179, respectively.Several coils were produced to test the improved insulation scheme and the ease of repair of

flush LBL inner coil ends. The repair procedure was carried out on one inner coil end in modelD15A4 as a testand subsequently in long model DOO011 inner coil ends. Several additionalchanges will be made to further enhance the electrical integrity of the flush ends. Model D15A4

is collared and ready for testing.Three shorts were discovered in the ends of dipole model D15A4F during assembly. The

shorts all occurred across the fine edge of the largest G-lO end spacer, near the transition fromcopper wedge number 3 in the straight section. This model is now repaired and ready for col­laring.

sse MONTIlLY REPORT 25 NOVEMBER 1987

Tum-turn shorts developed in the ends of the inner coils during assembly of long magnetDDOOll at BNL (by LBL personnel). Similar shorts were also found in the inner coils for mag­netDDOO13.

New inner coil prestress gauges are being fabricated and tested. These gauges shouldeliminate suspected problems that may be affecting the present LBL inner gauges.

Tests at LBL

No magnets were tested at LBL during November.

DSS9 Tests at BNL

LBL-SSC dipole model DSS9 (1.8 m) was tested at BNL with excellent results. This magnetwas built at BNL by LBL personnel with LBL parts.

At 4.45 K. there was only one training quench at 6130 A; all subsequent quenches were atthe plateau value of approximately 6800 A. At 3.5 K, the lowest temperature available in theBNL cryostat, there were a few training quenches before the short sample limit of 7900 A was

achieved. After a thermal cycle through room temperature. there was no training at 4.45 K, andone training quench at 3.5 K.

The magnetic field was measured for an initial 4000 A cycle, and later for a 6600 A cycle.Field quality is excellent New voltage tap instrumentation worked well. and the locations ofquench initiation sites can be deduced from the voltage versus time traces.

Analysis

Orders were placed for a Sun IV computer and for two Sun III workstations for general magnetanalysis. Parts of the interface between AutoCAD and field computation programs were testedon a pilot program running on an IBM PC.

Formulas were programmed for calculating magnetic fields from polygonally shapedconductors and their images.

sseMONTHLY REPORT 26 NOVEMBER 1987

PROJECT COST DATA

INDEX

SSC PROGRAM Table

Central Design Group C-lBrookhaven National Laboratory C-2Fermi National Accelerator Laboratory C-3Lawrence Berkeley Laboratory C-4sse Program Summary C-5Monthly and Cumulative Summary C-6

sseMONTHLY REPORT 27

Fi~ure

12345

NOVEMBER 1987

1.1

1.2

1.3

1.4

1.41

TABLE c-t

CENTRAL DESIGN GROUP . SUPERCOLLIDER

NOVEMBER 1987 COST REPORT (K$)

MAT'L & MONTH YEAR TO ANNUALPROGRAM ELEMENT LABOR SERVICES G &A TOTAL DATE BUDGET... ------------ ... --- .-.---- ...

ADMI NISTRATION 69.4 n.o 87.0 228.4 264.4 3818.3

PROGRAM PLANNING & MANAGEMENT 43.8 3.9 17.5 65.2 84.6 686.8

ACCELERATOR R&D 165.1 149.5 108.4 423.1 385.3 5644.7

CONVENTIONAL SYSTEMS DEVELOP. 12.0 10.5 8.3 30.7 25.0 726.3

PROGRAM COSTS 290.3 235.9 221.2 747.4 759.3 10876.0

RTK COSTS 0.0 0.0 0.0 0.0 21.0 175.0

CDG/RTK COSTS 290.3 235.9 221.2 747.4 780.3 11051.0

COMMITMENTS 288.0CHANGE IN COMMITMENTS (Delta) -175.0EQUIPMENT COSTS 0.0 229.0

TABLE C·2

BROOKHAVEN NATIONAL LABORATORY' SUPERCOLLIDER

NOVEMBER 1987 COST REPORT (K$)

MAI'L & MONTH YEAR TO ANNUALPROGRAM ELEMENT LABOR SERVICES G & A TOTAL DATE BUDGET---------_ .. _._. - ... - .. - ..

2.1 LONG MAGNET FABRICATION 130.6 101.2 88.1 319.9 547.9 2980.0

2.2 TOOLING & FIXTURES 38.7 115.0 58.4 212.1 402.1 2594.0

2.3 SHORT MODEL MAGNETS 24.2 0.0 9.2 33.4 63.6 616.0

2.4 INDUSTRIALIZATION 9.7 5.2 5.7 20.6 33.6 250.0

2.5 ACC. LIFE TEST (CRYO) 19.3 22.0 15.7 57.0 94.0 1560.0

PROGRAM COSTS 222.5 243.4 177.1 643.0 1141.2 8000.0

COMMITMENTS 1949.0CHANGE IN COMMITMENTS (Delta) 352.0EQUIPMENT COSTS 0.0 500.0EQUIPMENT OPEN COMMITMENTS 99.8

TABLE C·3

FERMI NATIONAL ACCELERATOR LABORATORY - SUPERCOLLIDER

NOVEMBER 1987 COST REPORT (KS)

MAT I L & MONTH YEAR TO ANNUALPROGRAM ELEMENT LABOR SERVICES G &A TOTAL DATE BUDGET----_ ....... ----- ----- .-------

3.1 GENERAL 0.0 15.6 5.2 20.8 26.9 195.0

3.2 LONG MAGNET FABRICATION 51.0 33.0 27.8 111.8 201.5 834.0

3.3 MAGNETIC MEASUREMENTS 76.4 89.9 55.1 221.4 357.8 1206.0

3.4 COLD MASS FABRICATION 11.6 15.9 9.1 36.6 119.1 3083.0

3.5 INDUSTRIALIZATION 0.0 0.0 0.0 0.0 0.0 190.0

3.6 CELL TESTS 0.0 0.0 0.0 0.0 0.0 222.0

PROGRAM COSTS 139.0 154.4 97.2 390.6 705.3 5730.0

COM4ITMENTS 440.3CHANGE IN COMMITMENTS (Delta) -37.5EClUIPMENT COSTS 0.2 6.4 0.0 6.6 10.6 271.0EQUIPMENT OPEN COMMITMENTS 13.7

__ a __________ • ___________ .... _________ ~ ____________ •• _____________ ••• __ ~ __________ ••• __________

4.1

4.2

4.3

4.4

4.5

4.6

TABLE C-4

LAWRENCE BERKELEY LABORATORY - SUPERCOLLIDER

NOVEMBER 1987 COST REPORT (KS)

MAT'L & MONTH YEAR TO ANNUALPROGRAM ELEMENT LABOR SERVICES G&A TOTAL DATE BUDGET*---_.... ----_ .. .-------

GENERAL 5.0 0.0 2.4 7.4 13.3 190.0

SUPERCONDUCTOR 0.7 0.0 0.0 0.7 11.3 1170.0

QUADRUPOLE DEVELOPMENT 0.0 0.0 0.0 0.0 0.0 300.0

COMPo DEVELOP. &TESTS 63.2 26.7 41.8 131.7 317.1 975.0

INDUSTRIALIZATION 0.0 0.0 0.0 0.0 0.0 50.0

MAGNET R&D TOTALS 68.9 26.7 44.2 139.8 341.7 2685.0

ACCELERATOR PHYSICS R&D 31.0 3.6 16.7 51.3 79.9 410.0

LBL/THEORY COSTS 99.9 30.3 60.9 191.1 421.6 3095.0

COMMITMENTS 432.0CHANGE IN COMMITMENTS (Deltal 0.0

TABLE C-5

PROGRAM SUMMARY • SUPERCOLLIDER

NOVEMBER 1987 COST REPORT (1($)

MAT'l & MONTH YEAR TO ANNUALPROGRAM ElEMENT lABOR SERVICES G & A TOTAL DATE BUDGET..... _---- ........... --- ......

1. COG PROGRAM 290.3 235.9 221.2 747.4 759.3 10876.0

1.41 RTK PROGRAM 0.0 0.0 0.0 0.0 21.0 175.0

2. BNl SSC PROGRAM 222.5 243.4 177.1 643.0 1141.2 8000.0

3. FNAL sse PROGRAM 139.0 154.4 97.2 390.6 705.3 5730.0

4. lBl sse PROGRAM 99.9 30.3 60.9 191.1 421.6 3095.0

TOTAL SSC PROGRAM COSTS 751.7 664.0 556.4 1972 .1 3048.4 27876.0

COMMITMENTS 3109.3CHANGE IN COMMITMENTS (Delta) 139.5EQUIPMENT COSTS 10.6 1000.0EQUIPMENT OPEN COMMITMENTS 113.5

TABLE C-6

MONTHLY AND CUMULATIVE SUMMARY OF PLANNED ANO ACTUAL COSTS ANO COMMITTMENTS

1.0 CENTRAL DESIGN GROUp· SUPERCOLLIDER--~- ..- _____ . ____ . - _~ _____ .____ .

MONTHLY FY MONTHLY FY MO ACT. CUM ACTPLANNED PLANNED ACTUAL ACTUALS DELTA + CURRENT DELTA

DATE COSTS CUMULAT COSTS CUMULAT COMMITS COMMITS COMMITS COMMITSOCT 920.9 920.9 33.0 33.0 496.0 496.0 463.0 463.0NOV 920.9 1841.8 747.4 780.4 572.4 1068.4 288.0 -175.0DEC 920.9 2762.8JAN 920.9 3683.7FEB 920.9 4604.6MAR 920.9 5525.5APR 920.9 6446.4MAY 920.9 7367.3JUN 920.9 8288.3JUL 920.9 9209.2AUG 920.9 10130.1SEP 920.9 11051.0

2.0 BROOKHAVEN NAT'L LAB - SUPERCOLLIDER~----_ .. _- ----- .. - - --- .. -----._.

MONTHLY FY MONTHLY FY MO ACT. CUM ACTPLANNED PLANNED ACTUAL ACTUALS DELTA + CURRENT DHTA

DATE COSTS ClIIJLAT COSTS CUMUlAT COMMITS COMMITS COMMITS COMMITSOCT 666.7 666.7 498.0 498.0 2095.0 2095.0 1597.0 1597.0NOV 666.7 1333.3 643.0 1141.0 995.0 3090.0 1949.0 352.0DEC 666.7 2000.0JAN 666.7 2666.7FEB 666.7 3333.3MAR 666.7 4000.0APR 666.7 4666.7MAY 666.7 5333.3JUN 666.7 6000.0JUL 666.7 6666.7AUG 666.7 7333.3SEP 666.7 SOOO.O

3.0 FERMI NAT'L ACCEL LAB - SUPERCOlliDER.-.-- ----- .... - --- . ---_..... _----

MONTHLY FY MONTHLY FY MO ACT+ CUM ACTPLANNED PLANNED ACTUAL ACTUALS DELTA + CURRENT DELTA

DATE COSTS CUMULAT COSTS CUMULAT COMMITS COMMITS COMMITS COMMITSOCT 4n.5 4n.5 314.7 314.7 792.5 792.5 4n.S 477.8NOV 477.5 955.0 390.6 705.3 353.1 1145.6 440.3 -37.5DEC 4n.5 1432.5JAN 4n.5 1910.0FEB 4n.5 2387.5MAR 477.5 2865.0APR 477.5 3342.5MAY 477.5 3820.0JUN 417.5 4297.5JUL 477.5 4775.0AUG 477.5 5252.5SEP 477.5 5730.0

4.0 LAWRENCE BERKELEY LAB - SUPERCOLLIDER----_._- .. _---.- --- - -_ .._---- ... -

MONTHLY FY MONTHLY FY MO ACT+ CUM ACTPLANNED PLANNED ACTUAL ACTUALS DELTA + CURRENT DELTA

DATE COSTS ClMILAT COSTS CUMULAT COMMITS COMMITS COMMITS COMMITSOCT 257.9 257.9 230.5 230.5 662.5 662.5 432.0 432.0NOV 257.9 515.8 191.1 421.6 191.1 853.6 432.0 0.0DEC 257.9 m.8JAN 257.9 1031.7FEB 257.9 1289.6MAR 257.9 1547.5APR 257.9 1805.4MAY 257.9 2063.3JUN 257.9 2321.3JUL 257.9 2579.2AUG 257.9 2837.1SEP 257.9 3095.0

0.0 PROGRAM SUMMARY - SUPERCOLLIDER........ ---- .. - -----------.-

MONTHLY FY MONTHLY FY MO ACT+ CUM ACTPLANNED PLANNED ACTUAL ACTUALS DELTA + CURRENT DELTA

DATE COSTS ctMJLAT COSTS CUMULAT CCMUTS CCMlITS COMMITS CCJ4MITSOCT 2323.0 2323.0 1076.2 1076.2 4046.0 4046.0 2969.8 2969.8NOV 2323.0 4646.0 1972.1 3048.3 2111.6 6157.6 3109.3 139.5DEC 2323.0 6969.0JAN 2323.0 9292.0FEB 2323.0 11615.0MAR 2323.0 13938.0APR 2323.0 16261.0MAY 2323.0 18584.0JUN 2323.0 20907.0JUL 2323.0 23230.0AUG 2323.0 25553.0SEP 2323.0 27876.0

1.0 CENTRAL DESIGN GROUPCumulatives in K$

12

11

10

9

8

""'1/1"d 7>::

*I!l6~ 1/1

~0.c 5Eo<'-/

4

3

2

o+

0

OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

-- PlannedFISCAL YEAR 1988

+ Aclual o Aclual+Commil

1.0 CENTRAL DESIGN GROUPMonlhly Cosls in K$

lZ::Zl Planned

OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

FISCAL YEAR 1988cs:::sJ Actual ~ Actual+Delta Commit

Figure 1

2.0 BROOKHAVEN NAT'L LABCumulatives in K$

8

7

6

,-.. 5III'0'I:::

f#«l4~ ;

0.at-t

3'-'

2

1

o

+

SEPJUL AUGMAY JUNFEB MAR APRJANNOV DEC

0-+---T"""'"------,------r----.---,--------,---r---,---,...----...-----1

OCT

-- PlannedFISCAL YEAR 1988

+ Actual (> Actual+Commit

2.0 BROOKHAVEN NAT'L LABMonthly Costs in K$

2.1 -r----.-,.,-----------~---------~---------_,

2

1.91.81.71.6

1.5

1.4

1.31.21.1

1

0.9

0.8

0.7

0.6

0.50.4

0.3

0.2

0.1O--'-J.,-L<:.L...;L.l.,..l.Ll-l..-..L,--.L....L,----l...L,--...L....Je,-----':......L,----L-.L,--.L....L..------L....L,--...L....Je,-----':......L,---'

lZ2J Planned

OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

FISCAL YEAR 1988[:s::sJ Actual lZ::ZJ Actual+Delta Commit

Figure 2

3.0 FERMI NAT'L ACCEL LABCumulatives in K$

6,..---------------------------------,

5

4»<I'l'0C

* III 3~ I'l;:I0

..c:Eo<'-"

2

1

+

SEPJUL AUGMAY JUNFEB MAR APRJANNOV DEC

O--!---..,-----,------r---.----..,-----,r--'"-----r----,----.....----r----!

OCT

-- PlannedFISCAL YEAR 1988

+ Actual o Actual+Commit

3.0 FERMI NAT'L ACCEL LABMonthly Costs in K$

700

600

500

~ 400

300

200

100

IZZl Planned

OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

FISCAL YEAR 1988cs:::::sJ Actual f2:Z:2d Actual+Delta Commit

Figure 3

4.0 LAWRENCE BERKELEY LABCumula t ive s in K$

3.2

3

2.8

2.6

2.4

2.2

""ro 2'Clc

1.8l#~

~ ;1.60

.c:E-o 1.4'-'

1.2

1

0.8

0.6

0.4

0.2

OCT

+

NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

-- PlannedFISCAL YEAR 1988

+ Actual 0 Actual+Commit

4.0 LAWRENCE BERKELEY LABMonthly Costs in K$

I2::ZJ Planned

700 -,---------------------------------,

600

500

400

300

200

100

OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

FISCAL YEAR 1988cs=sJ Actual !Z22d Actua1+Delta Commit

Figure 4

o

Cumula tives in K$PROGRAM SUMMARY - SUPERCOLLIDER0.0

28

26

24

22

20

r.. 18III'lj 16I::

f#«I~ (/J 14

;l0

J:: 12Eo<'--' 10

8

6

4

2

0

OCT

+

NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

-- PlannedFISCAL YEAR 1988

+ Actual 0 Actual+Commit

0.0 PROGRAM SUMMARY - SUPERCOLLIDERMonthly Costs in K$

4.5 -.-------~----------------------__,

4

3.5

3r..(/J

'lj

~ 2.5fhl'l

~ ;0 2J::Eo<...."

1.5

1

0.5

OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP

lZ:ZJ PlannedFISCAL YEAR 1988

rs:sJ Actual ~ Actual+Delta Commit

Figure 5