UPDATE ON THE LHC MAIN MAGNETS. Lucio Rossi CERN - LHC MAC 15

Transcription

1 UPDATE ON THE LHC MAIN MAGNETS Lucio Rossi CERN - LHC MAC 15

2 Content Cable Components Production of dipoles and learing curves Fiedl quality Collared cois CM production Results and Delivery Plan for dipoles Main Quads Field quality Production concerns Delivery 13 July MAC15 L. Rossi - LHC Main Magnets 2

3 Tunnel one day 392 main quadrupoles corrector magnets 1232 main dipoles multipole corrector magnets 13 July MAC15 L. Rossi - LHC Main Magnets 3

4 Dip X-sect 15 m long (14.3 L m ), coil aperture 56 mm, and curved (sag is 9 mm) Correctors are fixed on magnet CM end 13 July MAC15 L. Rossi - LHC Main Magnets 4

5 Huge size reduction during process Nb-Ti billets for LHC, courtesy Wah Chang Strand have thousands of Nb-Ti strands < µm in diameter 30 cm diameter 13 July MAC15 L. Rossi - LHC Main Magnets 5

6 T, K (24 Feb 2003) Spec Sc Cables - M and Rc 01B 01E Date : 21/6/2004 Contract: F266 Prepared by DRICHTER 1000 Few billets have been refused based on Magnetization For many we requires mixing (dilution of bad wires) friction in production Average Sc measured by CERN Map from 01E00001 to 01E Inter-strand resistance Tinning lines OK Results good to excellent 100 number of billets July MAC15 L. Rossi - LHC Main Magnets 6 Magnetization E00001 E00006 E00011 E00018 E00023 E00028 E00033 E00038 E00047 E00052 E00057 E00063 E00068 E00075 E00080 E00085 E00090 E00095 E00100 E00105 E00110 E00116 E00121 E00126 E00138 E00144 E00151 Average Sc [ks] Conductivity Sc Specified Sc No worry limit

7 The success delivery: cable Number of UL's Contractual UL-1 delivery UL-1 delivery promised by the firms in Feb 2002 UL-1 delivered UL-1 stock at CERN UL-1 stock ready for delivery to CMA Projected UL-1 delivery Required for CMA production (planning Oct 2003) Delivered to CMA LHC cable 01 status: 59.6% produced One vendor is still not fulfilling his commitment Number of cold masses Cable for 50 dipoles more is being ordered fˇv. 00 mai. 00 ao.00 nov.00 fˇv. 01 mai. 01 ao.01 nov.01 fˇv. 02 mai. 02 ao.02 nov.02 fˇv. 03 mai July MAC15 L. Rossi - LHC Main Magnets 7 ao.03 nov.03 fˇv. 04 mai. 04 ao.04 nov.04 fˇv. 05 mai. 05 ao.05 nov.05 fˇv. 06 mai. 06 A. Verweij, AT/MAS/SC, 1/7/2004 0

8 FG Collars - Laminations FSG Inserts - φ5mm holes C27_L C27_R Hole diameters (mm) FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG FG July MAC15 L. Rossi - LHC Main Magnets 8

9 1400 Critical delivery: collars Equivalent dipoles Concerns about steel delivery from Nippon Steel Concerns about one vendors for juridic status and quality - serious extra-cost built up in one CMAs Effect of second line in main collar puncher still to be seen 0 1.jan.01 1.jan.02 1.jan.03 1.jan.04 1.jan.05 1.jan.06 1.jan.07 Contractual austenitic steel Delivered austenitic steel Contractual collars Delivered collars Just-in-time 13 July MAC15 L. Rossi - LHC Main Magnets 9

10 Critical delivery:yoke lam. Concerns about one vendors for juridic status and quality His capacity to produce collars AND lamination is OK Increase of the second punchers is still to be seen 13 July MAC15 L. Rossi - LHC Main Magnets 10

11 Winding-Curing-Coil Best case 0.3 Firm 3: Inner layers coil size and E-modulus Collared coil number 13 July MAC15 L. Rossi - LHC Main Magnets Coil E-modulus at 80 MPa [GPa] updated on Inner layer coil size (average of left & right sides) Inner layer E-modulus at 80 MPa

12 Winding-Curing-Coil Worst case Inner layer coil size (average of left & right sides) 0.3 Outer layer coil size (average of left & right sides) Firm 1: Assembled poles coil size cured with shim mm (Kapton) starting from PS136, only one pole per magnet is measured Collared coil number 13 July MAC15 L. Rossi - LHC Main Magnets 12

13 X-section 1 Steering production through Field Measurements - CERN supply 10 Data reduced to nominal shims upper target for single magnet (3 sigma) X-section X-section 1 X-section 2 X-section 3 Data reduced to nominal shims Cold mass Firm 1 Firm 2 Firm 3 lower target for single magnet (3 sigma) Data reduced to nominal shims lower target for systematic Magnet progressive 100 number Magnet progressive number upper limit for systematic lower limit for systematic 13 July MAC15 L. Rossi - LHC Main Magnets Collared coil Units upper target for systematic X-section 3 Firm 1 Firm 2 Firm 3 Collared coil Firm 1 Firm 2 Firm Collared coil progressive number AT-MAS & MTM

14 mag.meas. in CMA - FQ and QA :13 decollared, 11 faults Time lag from construction to cold test Intercept constructive defects at early stage 13 July MAC15 L. Rossi - LHC Main Magnets 14

15 Personnel training in Coil production 13 July MAC15 L. Rossi - LHC Main Magnets 15

16 4 LHC: Learning Curve collared coil production at BNN Not including manufacturing hours for breakdowns, repairs and interruptions Including estimation for started but not yet completed collared coil no. dipole- Expected Learning Curve Actual Target 13 July MAC15 L. Rossi - LHC Main Magnets 16

17 Snapshot at Industry: coils 13 July MAC15 L. Rossi - LHC Main Magnets 17

18 Snapshot at Industry- CC 13 July MAC15 L. Rossi - LHC Main Magnets 18

19 Longitudinal welding Pre-developed at CERN Installed directly CMAs Two weldings synchronized Root welding STT: high quality very sophisticated control, a world PRIMA for this conditions and austenitic steel Each CM leak tested 26 bar!! 13 July MAC15 L. Rossi - LHC Main Magnets 19

20 Welding time Longitudinal welding Problem solved! All CMs beyond 3 Welding/week in average, and is at 4/week. Repairs decreased by a factor 3-10 in the last 5 months. Today is not an issue neither for time nor for cost Getting the curvature out of the press right is NOW consolidate 13 July MAC15 L. Rossi - LHC Main Magnets Dates of welding Welding time Welding time including repair Targeted learning curve

21 Geometry learning curve Curvature and 3D assembly Geometrical measurement with LEICA LEICA measurements Mean time targeted Cold Masses Cold Masses Targeted learning curve 13 July MAC15 L. Rossi - LHC Main Magnets 21 Hours

22 6 LHC: Learning Curve Completion to cold mass at BNN 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 13 July MAC15 L. Rossi - LHC Main Magnets 22

23 Snapshot at Industry: dipole CM waiting delivery 13 July MAC15 L. Rossi - LHC Main Magnets 23

24 Snapshot at Industry- CM 13 July MAC15 L. Rossi - LHC Main Magnets 24

25 CERN- CEA collaboration Cu-NbTi 1.9 K. G op = 223 T/m Two-in-one concept (two apertures are de-coupled both magn. and mech. 3.5 m long, coil ap.56 mm, straight, alignment given by inertia tube Correctors are fixed on the inertia tube 13 July MAC15 L. Rossi - LHC Main Magnets 25

26 Warm Field Measurements in Factory Sextupole field errors in apertures 10 8 b6 integral (units) 6 4 upper target systematic systematic 2 lower target systematic Dodeca-pole field errors Aperture progressive number AT-MAS & MTM 13 July MAC15 L. Rossi - LHC Main Magnets 26

27 3.130 Magnetic length upper limit (3 sigma) average lower limit (3 sigma) gradient/current (T/kAm) Aperture progressive number AT-MAS & MTM (units) lower limit (3 sigma) upper limit (3 sigma) Transfer function average (units) July MAC15 L. Rossi - LHC Main Magnets 27 Aperture progressive number AT-MAS & MTM

28 Collared apertures, bare quadrupoles and finished cold masses at ACCEL 13 July MAC15 L. Rossi - LHC Main Magnets 28

29 Cold mass turning tool 13 July MAC15 L. Rossi - LHC Main Magnets 29

30 Snapshot at MQ fabrication 13 July MAC15 L. Rossi - LHC Main Magnets 30

31 QUENCH is good (memory is excellent) -show of ramping up production 16 CM/month -Be able not to avoid friction from components, covers, etc. -extra costs Delivery MQ 13 July MAC15 L. Rossi - LHC Main Magnets 31

32 Dipole performance relevant to machine op Histogram of the number of quenches to reach 8.33 Tesla (11850 A) after thermal cycle Reduction in MagMeas Reduction in testing criteria (2 Quenches to nominal) 5% rejected only (from 11% in 2002 and 8% last year) AIM: 2-3% 13 July MAC L. Rossi 3- LHC Main 4Magnets 5 No TC not reached32 Number of quenches to reach 8.33T No TC

33 Contract: end June 06 Expected: Sept. 06 DIPOLE CC and C.M. Delivery and Schedule (1 July 2004) Collared Coil Forecast (May 2003) 800 C.M. Forecast (May 2003) company ahead: BNN! Collared coil 2 CMAs delayed CM spare & some reallocation to BNN? 200 C.M. Delivered 0 sep.06 juil.06 mai.06 mars.06 jan.06 nov.05 sep.05 juil.05 mai.05 mars.05 jan.05 nov.04 sep.04 juil.04 mai.04 mars.04 jan.04 nov.03 sep.03 juil.03 mai.03 mars.03 jan.03 nov.02 sep.02 juil.02 mai.02 mars.02 jan.02 nov.01 sep.01 juil.01 mai.01 mars.01 jan.01 Years 13 July MAC15 L. Rossi - LHC Main Magnets 33

34 Magnets are on the right track Production is out of the critical path (but situation may revert soon!!) Improve quality 150 CMs waiting test Storage of 800 magnets on surface is to be faced 13 July MAC15 L. Rossi - LHC Main Magnets 34