Update on Main Dipoles

Transcription

1 Update on Main Dipoles Lucio Rossi Accelerator Technology Div. LHC Machine Advisory Committee MAC14 12 December 23

2 Content Superconducting cable Components Main tooling Update on coils Update on welding press Update on geometry Problems Low performance of a group of magnets (feedback delay) Diodes (not impeding production) Delivery and plan 2

3 Superconducting cable Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual Commitment Feb'2 Accepted strands Delivered Just in time Buffer store A. Verweij AT-MAS 3

4 Superconducting cable Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual Commitment Feb'2 Accepted strands Delivered Just in time Buffer store A. Verweij AT-MAS 4

5 number of direct workers / number of kg per direct worker Cable: Productivity is OK number of direct workers number of kg per direct worker running average of kg per direct worker 2 Courtesy of P. Mocaer -ALSTOM 21 period 22 23

6 Still on critical path:the small cables The only case where we did not supply NbTi; Now changed 6

7 Dipole austenitic steel collars Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual austenitic steel Delivered austenitic steel Contractual collars Delivered collars Just-in-time F. Bertinelli AT-MAS 7

8 Dipole low-carbon steel yoke 14 laminations 12 1 Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual low-carbon steel Delivered low-carbon steel Contractual yoke laminations Delivered yoke laminations Just-in-time F. Bertinelli AT-MAS 8

9 Dipole austenitic steel end 14 laminations Units Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual austenitic steel Delivered austenitic steel Contractual end laminations Delivered end laminations Just-in-time F. Bertinelli AT-MAS 9

10 LHC Progress Dashboard EST MF Dipole heat exchanger tubes Units Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual bare tubes Delivered bare tubes Scheduled finished tubes Delivered finished tubes Just-in-time Updated 3 Nov 23 Data provided by F. Bertinelli AT-MAS, G. Favre EST-MF

11 Dipole end covers Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual end covers Delivered end covers Just-in-time F. Bertinelli AT-MAS 11

12 Dipole half shells Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual half shells Delivered half shells Just-in-time F. Bertinelli AT-MAS 12

13 Dipole cold bore tubes Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual bare tubes Delivered bare tubes Scheduled insulated tubes Delivered insulated tubes Just-in-time F. Bertinelli AT-MAS 13

14 Bus bars Equivalent cryomagnets Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual dipole Contractual SSS Delivered dipole Delivered SSS Just-in-time dipole Just-in-time SSS J.L. Perinet-Marquet AT-MEL 14

15 Coil Winding Line BNN is more advanced in winding Slow ramp up of ALS-JEU and ANS partly due to slow feed back (1year) ALSTOMJEUMONT 2 wdng lines in operation 2 curing press all working after long effort Today they at 2.5/week (occasionally they went to 3/week with extra shift). They need contingency and Saturday shift or period of 3rd shift. ANSALDO Winding line not yet finished: they have only two out of the quasi-4 they plan. Today they are 2/week, they need 3/w. Situation to be assessed in Feb4 BNN (Noell) 4 wndg machine; 2 curing press Rate to be measured in Oct 3 : they are OK, steadily at 3.5/week (curing is critical, however they even produced 4/week!!) 15

16 winding and pole assembly time JEUMONT LHC LEARNING CURVE Average Unit Objective Staff 5 4 TIME (A-U) 3 2 1% 75% 5% 1 15% NUMBER OF MAGNETS

17 Quality is improving - Ansaldo Inner Outer Rejected% 4 3, , sept

18 Collaring Press 1 Collaring press per firm > 2 MN/m, 2 micron accuracy Today ALL working!! But ANSALDO press weaker(even more considering that new X-sect requires higher prestress); here there are some risks. We are planning to upgrade. 18

19 Detection of bad coil quality : 232 Red alarms (more than 8 sigma of what normally observed) in b8 b13 a6 a7 a9 a11 Small anomalies in absolute terms (.5 units of b8,.2 units of a6) Problem located in four positions along the magnet axis Reconstruction of coil error: Anomalies could be obtained by inner shift of block 6 of.5 to 1.5 mm in one quarter Decollaring asked in June 23, done in November A B C D E Magnetic length status ok Average straight Variation straight Heads CS Heads NCS positions 2 to 19 positions 2 to 19 position 1 position 2 Main field status ok status ok status ok status ok Angle status ok status ok status ok b2 status ok yellow alarm status ok status ok b3 status ok status ok status ok yellow alarm b4 status ok yellow alarm status ok status ok b5 status ok yellow alarm status ok status ok b6 status ok yellow alarm status ok status ok b7 status ok yellow alarm status ok status ok b8 yellow alarm red alarm status ok status ok b9 status ok status ok status ok status ok b1 status ok yellow alarm status ok status ok b11 yellow alarm yellow alarm status ok status ok b12 red alarm yellow alarm status ok status ok b13 status ok red alarm status ok status ok b14 status ok yellow alarm status ok status ok b15 status ok yellow alarm status ok status ok a2 status ok status ok status ok yellow alarm a3 status ok yellow alarm status ok status ok a4 yellow alarm yellow alarm status ok status ok a5 status ok status ok status ok status ok a6 yellow alarm red alarm status ok yellow alarm a7 yellow alarm red alarm status ok status ok a8 yellow alarm yellow alarm status ok status ok a9 status ok red alarm status ok status ok a1 status ok status ok status ok status ok a11 status ok red alarm status ok status ok a12 yellow alarm yellow alarm status ok yellow alarm a13 status ok yellow alarm status ok status ok a14 status ok status ok status ok status ok a15 status ok yellow alarm status ok status ok Coil Positioning red alarm mm 19

20 We found what expected! mm 2

21 Recent disassembly of dipole 126 Dissassembly due to low cold performance 21

22 Field quality vs. beam dynamics: main field spread Thanks to E. Todesco AT-MAS Integr. transf. fun. (Tm/kA) Spread within targets Around 14 units between Firm3 and Firm1averages in coll. coil This difference is reduced by iron yoke (around 8 units) No corrective action is taken, waiting for more data of X-section Firm 1 Firm 2 Firm 3 upper limit for single magnet (3 sigma) lower limit for single magnet (3 sigma) Collared coil progressive number Collared coil 4 2 AT-MAS -2-4 Units 22

23 Field quality: effect of the midplane shims (X-sect 3) about 18 dipoles have X-sect 1 or 2 b3 straight part (units) Firm 1 Firm 2 Firm 3 aim of X-section correction X-section 1 Data reduced to nominal shims upper limit for systematic lower limit for systematic Collared coil X-section 2 X-section 3 Thanks to E. Todesco AT-MAS Collared coil progressive number AT-MAS & MTM 23

24 44 coils manufactured X-sect 3 4 AT-MAS 2 9 b b3 b5 Targets Measured X-s 1 Measured X-s 2 Measured X-s 3 Data reduced to nominal shims 24

25 BNN learning curve for CC 4 LHC: Learning Curve collared coil production 3 Learning factor 2 1 Not including manufacturing hours for breakdowns, repairs and interruptions Including estimation for started but not yet completed dipole-magnets collared coil no. 25 Expected Learning Curve Actual Target

26 First automatic STT welding press 26

27 Improvements Fix some defects of the press Laser for gap reading Controls Realignemt of the press and check of the mould shape (this has aslo improved geometry) Put the press according to (new) EU norms Review of the welding law Work on shell shape (better bevel, better gap) Reduce class of inspection (using margin given by design and material : 316 LN) Training, training, training for us and for CMAs, directly from manufacturers of single equipment 27

28 Overview on radiographic examination results at BNN Training in Zeitz with Lincoln 28

29 Welding and repair time - Alstom Learning Curve - Longitudinal Welding Total Time including repair News from yesterday: Alstom did 5 consecutive magnets without repairs Time under the press 2 Mean time targeted Cold Masses 29

30 Geom. Meas. -Leica at Alstom Geometrical measurement Average time actual mean time tagreted actual time average time actual Log. (actual time ) 2 1 Mean time t t d Cold Masses 3

31 BNN learning curve CM assembly 6 LHC: Learning Curve Completion to cold mass 5 4 Learning factor Not including manufacturing hours for breakdowns, repairs and interruptions Including estimation for started but not yet completed dipole-magnets cold mass no. Expected Learning Curve Actual Target 31

32 Spool piece positioning The spool piece positioning measurement after the mounting of the cold mass end covers is not available at present To estimate their position, we use an estimation based on the hypothesis that the end of the cold mass moves rigidly and that we can assume that the spool piece position relative to either tube, flange or end-cover is the same even if the cold mass shape is changing [m] difference between flange movement (WP8-ITP2) and end cover movement (WP8-ITP2) Horizontal plane Series1 Courtesy of E. Wildner [mm] 13,18 Flange/polynomial ap1 dx [mm] Movements are very similar, measurement data reliable, with a few exceptions (13, 14) Tanks to E. Wildner 32 poly

33 Results: spool piece position at WP8, all magnets Spool piece positioning at WP8 aperture 1 1 Spool piece positions aperture dz dz dx Sextupoles ap1-1 dx Octupoles ap1 Avg Stdev Hor.13.3 Vert Avg Stdev Hor.8.34 Vert Beam Dynamics requirements: avg=.3, rms=.5 Ongoing work: compare results from a few existing measurements of the spool piece positioning Tanks to E. Wildner 33

34 The revised tolerance Tanks to B. Jeanneret 34

35 Tolerance on curvature Tanks to B. Jeanneret 35

36 Sagitta error after cold test (by E. Wildner) Sagitta error firm 1 Sagitta error firm Sagitta (mm) ITP2-GEO WP8-FID Sagitta (mm) ITP2-GEO WP8-FID Magnets -2 Magnets Sagitta error firm 3 Sagitta (mm) ITP2-GEO WP8-FID -2.5 Magnets 36

37 Quench: good but less than beginning Number of magnets Histogram of the number of quenches to reach ultimate field of 9 Tesla at FIRST cool down for the first 92 LHC dipoles cold tested Magnets reaching ultimate field with no more than two quenches earn a 1% bonus Not reached Number of quenches to reach 9T 9 T has to be reached in not more than 7 quenches; beyond 5 quenches a second run after thermal cycle is requested) 37

38 Quench behavior for the machine test long term training properties 52 Number of quenches to reach nominal field of 8.33 Tesla after additional thermal cycle for the first 92 dipoles 48 Number of dipoles After thermal cycle no quench below nominal field is allowed 51 dipoles have NOT been submitted to additional thermal cycle because of GOOD performance at the first excitation run (reaching 9T in not more than 5 quenches ) No Additional Thermal Cycle Number of quenches to reach 8.33T after thermal cycle Rejected 38

39 Problems Understand better what process controls geometry At the construction Moderate movement during manipulation Diode problems (test from October 23) Connections not good and not sure over the life time of the machine After 15 magnets stop to assembly diode at factory Problem almost cured (new surfacing, new type of washer, small change in the connection) It is not delaying anything but necessity of a serious task force at CERN to cope with the problem. 39

40 The MAS dashboard 35 Production Status (Alstom + Ansaldo + Noell) 3/11/ sep. 4

41 Dipole cold masses Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Contractual Collared coils Delivered cold masses Just-in-time P. Lienard AT-MAS 41

42 Cryodipole overview Equivalent dipoles Jan-1 1-Jan-2 1-Jan-3 1-Jan-4 1-Jan-5 1-Jan-6 1-Jan-7 Cold masses delivered Cryodipoles assembled Cryodipoles cold tested Cryodipole installed D. Tommasini AT-MAS 42

43 Dipole n154:1 octant! But still 178 to built Thanks for the attention 43

44 Appendix 1 : Flange positions after cold test (by E. Wildner) Flange position ap 1 connection side No reshaping 1.5 dz Tolerance: Radial.87-1 dx Flange position ap 2 connection side Reshaping 1.5 dz dx Tanks to E. Wildner 44

45 Appendix 2 : Field direction <Mag_Angle> (mrad) Field direction wrt median plane. Green if lfdl 1 Yellow if-1< lfdl 1.45 Red if 1.45< lfdl aperture 1 aperture a bad case, however the local twist follows the field direction (correlation.89), studies going on magnet Studies so far: Courtesy S. Sanfilippo Possibility for measurement in industry of field angle w.r.t. median plane are being set up No indications found that can explain the integrated field angle from construction (collars) The two apertures are co-linear (σ =.1mrad) Movements of the cold mass in the cryostat have been seen (re-measurements after cold test) of up to 1mrad roll 45