Racetrack Progress and Near-Term Plans

WBS 2.3.3.n

Peter WandererDOE Review of LARP

June 12-14, 2006

Peter WandererJune 12, 2006

Topics• LRS: long racetrack + shell support; SRS = short …

• 0.3 m SRS tasks (status, schedule)• LBL to BNL: support structure, some parts, cable• BNL - Wind coils, react, pot, assemble, test

• 4 m LRS tasks (status, schedule, examples of work)• LBL to BNL: support structure, tooling for assembly:

design, build, assemble w. dummy coils• BNL (mostly) + LBNL + Fermilab: wind, react, pot

coils, assemble in support structure, test

• FY06 Budget overview

Peter WandererJune 12, 2006

Short racetrack SRS01 (0.3 m)

•Technology transfer from LBL to BNL• also-BNL engineering, technical staff spent time at LBL

•Test will begin this week

Peter WandererJune 12, 2006

LRS “shell” support structure (4m)

• Design of support structure complete• 2D, 3D models• Magnetic, mechanical analysis• Based on 0.3 m SRS support structure• Full-length aluminum shell• Half-length bladders and keys

Peter WandererJune 12, 2006

3D LRS support structure design

Magnetic model

Mechanical Model

Model has 300 mm straight section

Peter WandererJune 12, 2006

LRS support structure tooling• Handling rafts (green)• Installation beam (purple)

Peter WandererJune 12, 2006

LRS support structure status

•Procurement:•Shell, tie rods, dummy coils at LBNL (photos)•Assembly rafts fabricated•Pads shipped to LBL•Yoke by end of June

Peter WandererJune 12, 2006

LRS support fixture next steps• June - July

• Handling structure design & detail drawings• Cradles (detail drawings in progress)• Assembly beam (to be designed)• Winch mounts & pulling structure (to be designed)

• Design and fabrication of shell trace• Aug – Sept

• Shell instrumentation• Assembly preparation, and pre-assembly

• October• Magnet assembly with dummy coils• Load test (pressurize bladders, measure shell tension)• Ship to BNL

Peter WandererJune 12, 2006

BNL - coil winding machineExisting equipment

Built for LARP 4m coils

Peter WandererJune 12, 2006

Lift coil in reaction fixture• Want coil strain < .05% (25% of conductor limit)• Fixture, support beam keep coils strain < .01%• Max deflection 0.003” (0.08 mm)

•Two-point support•Lift from center

Peter WandererJune 12, 2006

Install coils into support fixture

Existing flat support beam

Piston to remove bladders

Fixtures from LBL

Peter WandererJune 12, 2006

Quench protection, instrumentation

• Sketch shows concept for coil sides w/o taps, heater.• Quench protection: (4 parallel ss heater strips) X 2 (redundant)

• each strip ~ 3, 100A, 0.001” thick; 334 V p.s.• design uses data from LBL dipole HD1

• Instrumentation: spot heater with nearby voltage taps• “Quench origin” voltage taps in critical areas (9/inner coil)

Peter WandererJune 12, 2006

LRS01 – LBL/FNAL/BNL items• Items to come from LBNL to BNL:

• ProE models of support structure, fixtures that will be used at BNL: July 1 - ok

• Support fixture: late October• Item coming from Fermilab to BNL:

• Insulated copper practice cable: July 1 - ok• Joint LBNL/FNAL/BNL item:

• Insulated Nb3Sn cable: July 15 - ok• Joint LBL/BNL item: kapton/ss instrum. “trace”

• Conceptual design completed• Traces needed mid-September

Peter WandererJune 12, 2006

LRS01 critical path highlights• Wind copper practice coil: July 1

• Winding base plate, insulated Cu practice cable• React first Nb3Sn coil: September 19

• Nb3Sn cable due July 15• Reaction oven due August 4 (a good vendor …)

• Impregnate first Cu/Nb3Sn coil: Aug. 1/Oct. 3• Trace (conceptual design ok) + tooling (in shops)

• Assemble LRS01: November 15• Support fixture, tooling

• Test: December, 2006• Minor test facility work

Peter WandererJune 12, 2006

FY06 LRS, SRS Budget• Budget ($k) by institution: total/BNL/FNAL/LBL

• WBS 2.3.2.2 + WBS 2.3.2.3

• FY06 – Initial: $1608 / $1262k / $32k / $314k

• FY06 – Final: $ 1737 / $1399k / $24k / $314k• BNL increase (items > $10k): reaction oven,

coil reaction tooling, winding machine design carryover, copper practice coil (not in baseline)

• FNAL decrease: FNAL staff travel to BNL

Peter WandererJune 12, 2006

Summary• Schedule

• SRS01, LRS01 schedules somewhat delayed, relative to baseline. No fundamental problems.

• Rearrangement of magnet construction sequence (SRS02 before test of LRS01), addition of a winding base plate LRS02 still on schedule, Sept. 07, for use in LQ construction decisions.

• Cost• Cost growth mostly due to added cost of oven,

added scope.

Peter WandererJune 12, 2006

Appendix• Web site and talks for work at LBL:

• https://dms.uslarp.org/Presentations/LRS01_review/• “Support Structure Design…” (Ferracin)• “Support Structure Fabrication…” (Cheng)

• Web site for talk for work at BNL:• http://larpdocs.fnal.gov/LARPpublic/DocDB/ShowDocument?docid=213 • Racetrack coil fabrication (Schmalzle)

• Web site for LR schedule (pages 6-8)• http://www.bnl.gov/magnets/Magnet_Schedule/smdplan.pdf

Peter WandererJune 12, 2006

SRS, LRS sched., highlight test dates

LRS01

SRS01

LRS02

SRS02