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					          MECO Magnet Conceptual Design
                   Overview
                                 Bradford A. Smith
                                         MIT-PSFC

                                 November 13, 2002




November 13, 2002   Brad Smith     GA Industrial Study Kickoff   Conceptual Design Overview   1
                                  Contributors
Massachusetts Institute of Technology
      Bradford A. Smith, Leader & Co-PI                          John G. Brisson
      Joseph V. Minervini, PI                                    Alexi Radovinsky
      Joel H. Schultz                                            Joseph L. Smith
      Peter H. Titus
M-Technology, Inc
       Richard J. Camille, Jr.                                    Steven Fairfax

MDMG and Other Oversight
       William Hassenzahl (Previous Head, MDMG)
       William Molzon (UCI, MECO Spokesperson, MDMG)
       Mike Iarocci (BNL, MDMG)
       Michael Hebert (MECO Program Manager)


 November 13, 2002   Brad Smith    GA Industrial Study Kickoff   Conceptual Design Overview   2
                      Conceptual Design Status
• MIT-PSFC completed in Feb02 a conceptual design* for the magnet
  system with a successful final review by a national review committee.
• Conceptual design effort also included a detailed cost and schedule
  estimate for final design and fabrication
• CDR Chapters
    1. Introduction and summary                 10. Power supplies, dump resistors and switches
    2. Interfaces                               11. Structural design criteria
    3. Field specs and field matching           12. PS system stress analysis
    4. Conductor design                         13. TS system stress analysis
    5. Insulation design                        14. DS system stress analysis
    6. Joint design                             15. Cryogenics system design
    7. Current lead and bus bar design          16. Magnet assembly
    8. Quench detection system                  17. Magnet installation
    9. Quench protection system

    *Available: http://meco.ps.uci.edu/MIT_MECO_CDR.pdf
  November 13, 2002    Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview      3
                                   System Overview
                 5,805mm

2,600mm                                                        Transport solenoids
                                                                29,000 kg + 28,000 kg
                      R2,926mm
                     Production solenoid                           Cosmic ray shield (Iron)
                                                                                                         11,156mm
                     53,000 kg
                                                               Detector solenoid
                                                                53,000 kg




                                                                               13,164mm

                                                    25,703mm




 November 13, 2002          Brad Smith     GA Industrial Study Kickoff      Conceptual Design Overview              4
                                        Interface List
Item         (issue/impact)
PS Shield and Clear Bore Vacuum (coil ID, structural design)
Incoming Proton Beam (space allocation)
Outgoing Proton Beam and Required Clear Bore Access (space allocation)
Heat and Radiation Load on the Production Solenoid (coil heating)
Service Ports for the Production Solenoid (radiation, iron/field performance, service access)
Service Ports for the Transport Solenoid (space allocation, service access)
Beryllium Window for Vacuum Isolation (TS-TS RT spacing of cryostat end flanges)
Service Ports for the Detector Solenoid and Vacuum Interface (cosmic ray shielding, service access)
Use of Cryostat as Vacuum Vessel for Transport and Detector Solenoids (structural design)
Support of Collimators Off the Transport Solenoid (structural design, field quality)
Vacuum Port at the TS-DS Interface (cryostat warm bore interface)
Support of Experimental Equipment Off Detector Solenoid (structural design, field quality)
Steel Cosmic Ray Shield and Muon Beam Dump (field quality, structural design)
Electrical Noise Environment (quench detection/protection)
Gravity Supports (facility interface)
Procedure for Transportation to and Installation at BNL (40 T crane limit, accessibility, local rigging)
Facilities interfaces—cooling water, ac power, compressed air, LN2 supply, compressor room, power
supply room, floor layout, etc.
   November 13, 2002       Brad Smith     GA Industrial Study Kickoff   Conceptual Design Overview         5
                            Field Requirements
• Magnetic field varies more or less monotonically from 5 T at the high
  field end of the PS to 1 T at the low field end of the DS.
• Field matching is required over a curvilinear cylindrical volume around
  the magnet axes as defined by a detailed specification.



                                                                          Field specification characteristics
                                                                                L     Zmin    Zmax        Rfs          |B/B|       dB/ds**
                                                                   Coil
                                                                               (m)     (m)     (m)       (m)      max      where      (T/m)
                                                               PS0            4.00     0.00    4.00      0.30     0.050      r=0       <0
                                                               TS1            1.00     4.00    5.00      0.15     0.005      r=0     < -0.02
                                                               TS2            4.60*    5.00    9.60      0.15     0.010     r<Rfs       na
                                                               TS3            1.95     9.60   11.55      0.19      na         na     < -0.02
                                                               TS4            4.60*   11.55   16.15      0.15     0.010     r<Rfs       na
                                                               TS5            1.00    16.15   17.15      0.15     0.005      r=0     < -0.02
                                                               DS1            4.00    17.15   21.15   0.30-0.70    na         na    var< 5%
                                                               DS2            4.00    21.15   25.15      0.70     0.002     r<Rfs       na
                                                               DS3            2.00    25.15   27.15      0.70     0.010     r<Rfs       na
                                                                          *
                                                                                Corresponds to Rmajor = 2.929 m
                                                                          **
                                                                                where r<Rfs




    November 13, 2002   Brad Smith   GA Industrial Study Kickoff                Conceptual Design Overview                                 6
                          Field Solution Method
•   Postulate a set of n coils, coil builds
    and ampere-turns that might meet
    the field requirements.
•   Calculate fields at n points and
    influence coefficients for each coil at
    each point.
•   Calculate the field contributed by the
    DS iron.
•   Compare the field at n points
    against the field required by the
    specification.
•   Invert the influence coefficient
    matrix to obtain a corrected set of
    ampere-turns for each coil.
•   Check the field against the spec
    along three paths.
•   Iterate as required.                                             Field specification paths
•   Final iteration and field calculation
    done with actual conductors, NI and
    builds

     November 13, 2002   Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   7
                                      Field Solution
• A system of 94 solenoids, some                                               0.1400




                                                                               0.1200



  with generally similar axial extent,                                         0.1000




  but generally different radial builds                                        0.0800




                                                                      dr (m)
                                                                               0.0600



  meet the field requirement.                                                  0.0400




                                                                               0.0200




• Coils are powered in 6 sets:                                                 0.0000




                                                                                                9

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                                                                                                                                        15
                                                                                                                                              dz (m)



    • PS               3500 A
                                                            6.0

    • TS13u            1500 A                               5.0
                                                                      PS
                                                                       9                                    TS
                                                                                                          30 + 32
    • TS2              4000 A                          B (z)
                                                            4.0                                                                                             DS
                                                                                                                                                            23             B left
                                                       (T) 3.0                                                                                                             B axis

    • TS3d5            1500 A                               2.0
                                                                                                                                                                           B right



    • TS4              4000 A                               1.0

                                                            0.0
    • DS               4000 A                                     0                     5                       10                       15
                                                                                                                                        z (m)
                                                                                                                                                       20        25   30




  • Conductor placement                                        • TS Straight sections                                                                            1500 A
    tolerance study indicated
                                                               • TS Bends                                                                                        4000 A
    maximum current limits for
    TS and DS coils.                                           • DS                                                                                              4000 A

   November 13, 2002     Brad Smith    GA Industrial Study Kickoff                          Conceptual Design Overview                                                       8
                                   Conductors 1
• MECO has permission to draw from existing inventories of
  SSC inner and outer cable
                                                                   SSC         SSC
                             Parameter                Unit
                                                                  Inner        Outer
                      Strand Diameter                (mm)            0.81         0.65
                      Cu:SC                                           1.3          1.8
                      Filament Diameter           (microns)             6            6
                      Strand Twist pitch            (mm)             12.8         12.8
                      Number of strands                                30           36
                      Cable Twist Pitch              (mm)              94           86
                      Cable area                    (mm2)            15.5         11.9
                      SC area                       (mm2)             6.7          4.3
                      Width                          (mm)           12.13         11.7
                      Average thickness              (mm)            1.46         1.17
                      Keystone angle              (degrees)          1.23          1.0
                      Availability*                  (km)            120          300
• Conceptual design focused on and succeeded in achieving
  a design with acceptable margins using SSC cables

  November 13, 2002   Brad Smith    GA Industrial Study Kickoff    Conceptual Design Overview   9
                                   Conductors 2
• Design guidelines
    – Fraction of critical:                  0.65 (will be revised to  0.4), and
    – Temperature Margin:                    1.5 K
    – SSC cables will be soldered into half-hard copper channels to meet
      protection guidelines (Max V = 2 kV, Max T = 150 K).      Coil boundary
                                                                                                (1st PS coil)
• PS is subject to nuclear heat load                                           He




                                                                                        He

                                                                  Contours of constant temperature
                                                                     margin in high field PS coil

  November 13, 2002   Brad Smith    GA Industrial Study Kickoff    Conceptual Design Overview              10
                                     Conductors 3
PS: 3500 A
• Current limited by nuclear heating and
  temperature margin
• 41 km of SSC Inner Cable
  (includes 25% overage)
• fc = 0.31
• Bmax = 5.9 T

TS: 1500 & 4000 A
• Current limited by conductor placement tolerances
• 30 km of SSC Outer Cable
  (includes 25% overage)
• fc = 0.12, 0.28 respectively
• Bmax = 3.5, 2.8 T, respectively

 DS: 4000 A
• Current limited by conductor placement tolerances
• 30 km of SSC Outer Cable
  (includes 25% overage)
• fc = 0.26
• Bmax = 2.03 T
    November 13, 2002   Brad Smith    GA Industrial Study Kickoff   Conceptual Design Overview   11
                             Electrical Joints
• Joints are lap solder joints




• Joints must meet the same margin requirements as the
  conductor:
           – Fraction of critical current:               0.65 ( 0.4 when updated)
           – Temperature Margin:                         1.5 K

• Conceptual design showed these margins can be achieved
  with the proper choice of solders and overlap lengths
    • Channel solder: 60Sn-40Pb
    • Hands solder: 44In-42Sn-14Cd (Indalloy #8)
    • Overlap length 2 cable twist pitches (~19 cm)
  November 13, 2002   Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   12
                                   Insulation

• Turn + ground insulation is epoxy impregnated
  – Turn insulation
        • 1-mil, half-lapped Kapton + 3 mil, half-lapped fiberglass
        • Voltage stress is about 10 V/mil on dump, max. for combined thickness
  – Ground insulation
        • Turn insulation plus 40 mil (1 mm) of fiberglass
        • Voltage stress is about 40 V/mil on dump
• Insulation must be designed to withstand nominal 22.5 Mrad
  – Radiation level is not significant for insulation compressive or shear
    strength.
  – Gas evolution deserves to be minimized.
        • Better for some resins than others.
        • Industrial study will address this further.



  November 13, 2002   Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   13
                Quench Detection and Protection
•   Because all coil inductances are generally not alike, a digital quench detection
    system is proposed.
     – Each coil and coil-coil joint is voltage tapped.
     – In addition, all coil currents are monitored and dI/dt values are calculated.
     – System calibration is performed at installation during charge and discharge.
•   External dump minimizes helium loss and recovery times
•   MIT quench code (SOLQUENCH) has been run on the highest field coils in
    each of the PS, TS and DS; temperature distributions are output to ANSYS for
    structural analysis.
                                                        Quench protection analysis results for all coils evaluated
                                                                                                                  TS3u
                                                   Parameter                Units PS          TS1         TS2     cable    DS
                                     Iop                                      A      3500 1500           4000      1500   4000
•   Maximum hot spot                 Coil set
                                     stored energy                            MJ   109         3.26     4.72      3.26    30.8
    temperature and                  Rdump                                    Ohm 0.529        1.23     0.463     1.23    0.463
    maximum voltage                  L/Rdump time constant (excludes time
                                     varying effect of Rcoil)                  s  33.64 2.36            1.27      2.36    8.32
    requirements are met,            Vmax for coil                             V  1900 1853             1876     1862     1863
    while stresses and               Vmax for normal zone                      V   532    4.6           41.4      27.4     145
                                     Maximum normal resistance                Ohm 0.427 0.0053         0.0179    .0708    0.118
    temperatures remain              Maximum hot spot temperature              K  88.5    33            74.5      65.8     123
    below allowables.                Maximum Al shell temperature              K   53     na             na        na       na
                                     Energy dissipated in coil                MJ  27.2 9.6e-3          175e-3    56e-3    2.69
                                     Energy dissipated in all Al shells       MJ   6.6    na             na        na       na



    November 13, 2002   Brad Smith       GA Industrial Study Kickoff        Conceptual Design Overview                            14
                      Structural Design and Criteria
Overview
  • MECO magnet system is divided into 4 magnet assemblies, each with its own
    cryostat: PS, TSu, TSd, and DS.
  • Division is based on shipping limitations and natural boundaries formed by each
    magnet’s function.
  • Loads between assemblies are reacted through their respective cold mass supports
    to the facility foundation.
  • Any or all coil groups may be energized
  • Warm bores may be at atmosphere or vacuum
Design criteria
  • Combination of fusion and ASME criteria are used for guidance in coil structural
    design.
  • Fusion criteria allow primary membrane stress to be based on the lesser of 2/3 Yield
    (Sy) or ½ Ultimate (Su) when coils are supported by cases.
  • Otherwise ASME code criteria are used
      • Bases primary stress on 1/3 Su
      • Bending discontinuity and secondary stresses
  • Bolting and column buckling guidance is taken from AISC
  • Sy and Su are taken at the loaded temperature

  November 13, 2002      Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   15
                                  Coil Structures
• Production Solenoid
  (epoxy impregnated coils, bath cooled)
 • Outer Al shells provide hoop load support
 • Spherical-end rods take TS attractive loads
 • He can designed for 5 atm (quench)

• Transport Solenoid
  (epoxy impregnated, conduction cooled)
 • Coils are wound outside H-shaped SS mandrels
 • Horizontal V formed by spherical-end-rod pair
   restricts horizontal motion at Be window
 • Mid-span rod reacts centering load and is
   designed for tension only
 • Vertical V spans proton beam port, provides lateral
   restraint and assists with gravity load

• Detector Solenoid
  (epoxy impregnated, conduction cooled)
  • Uses spherical-end rods and H-shaped SS mandrels
    like TS

     November 13, 2002   Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   16
                      Cryostats and Cryogenics
All cryostats have stainless steel vacuum shells and LN2-cooled
thermal radiation shields.                                                                                                                                                      open
                                                                                                                                                                                 to


• Production solenoid
                                                                                                                                                                             atmosphere           open
                                                                                                                                              1.5 atm(differential)                                to
                                                                                                          PS Safety line                           burst disk                                  atmosphere

                                                                                                                                               1 atm(differential)                                          3.0 atm

   – Natural convection/force-cooled with 6700 liter LHe
                                                                                                                                                   Check valve                                              (differential)
                                                                                                                                                                                                            burst disk
                                                                                                                                         LN2 cooling lines

     volume to safely remove 192 W of nuclear heat load                                                                                  cooling inner wall
                                                                                                                                              of pipe


     at 4.5 K                                                                                                                                    10 " ID pipe

   – 25 cm diameter quench vent stack keeps quench                                                                                                       Super insulation

                                                                                                                                           Nitrogen shield

     pressure below 5 atmospheres
                                                                                                                                                              Shielding


• Transport and detector solenoids                                                                                         PS cryostat

   – Lack of nuclear heat load enables conduction
     cooling
   – Inner and outer copper shells intercept radiation heat
     load and take it to He-traced copper heat sinks at                                                                    Copper
                                                                                                                            Rib
                                                                                                                                    Copper
                                                                                                                                     sheets
                                                                                                                                                  Thermal
                                                                                                                                                  "bridge"
                                                                                                                                                                   Helium
                                                                                                                                                                 cooling tube


     the top of each coil
                                    Mandrel Flange
                                                                                                                                                    Coil
                                                                                                                                                  Mandrel
                                                                               Helium cooling tube

                                                                                                     Cl
                                                                               Thermal bridge



                                                                               Outer copper sheet                                                     Mandrel

                                                                                                                                                         Coil

                                                                                  Copper rib



                                                                                                                                                                            Copper    Copper
                                                                                                                                                                             sheets    Rib




  November 13, 2002    Brad Smith                GA Industrial Study Kickoff              Conceptual Design Overview                                                                                   17
                         Cryogenic Heat Loads
                            System component                          Refrigeration Liquid helium
                                                                       at 4.5 K      consumption
                                                                      [Watt]        [Liter/hour]
                             TS 1 totals                               20.18         17.6
                                 Supports                              12.8
                                 Valves                                1.37
                                 Vacuum separators                     0.86
                                 Thermal radiation from 80 K           1.96
                                 Conductor electrical joints (qty 35)  3.19
                                 Current leads                                       17.6
                             TS 2 totals                               20.13         17.6
                                 Supports                              12.8
                                 Valves                                1.37
                                 Vacuum separators                     0.86
                                 Thermal radiation from 80 K           1.96
                                 Conductor electrical joints (qty 33)  3.14
                                 Current leads                                       17.6
                             DS totals                                 20.63         12.8
                                 Supports                              6.04
                                 Valves                                1.37
                                 Vacuum separators                     0.86
                                 Thermal radiation from 80 K           8.26
                                 Conductor electrical joints (qty 24) 4.10
                                 Current leads                                       12.8
                             Control dewar                                           1.3
                             PS totals                                 208.37        11.2
                                 Supports                              8.0
                                 Valves                                2.99
                                 Vacuum separators                     0.86
                                 Thermal radiation from 80 K           3.28
                                 High energy radiation                 192
                                 Conductor electrical joints (qty 10) 1.24
                                 Current leads                                       11.2
                             PS dewar                                                1.3
                             GRAND TOTALS                              269.31        61.8



November 13, 2002   Brad Smith         GA Industrial Study Kickoff          Conceptual Design Overview   18
                          Cryogenic Flow Diagram
• Refrigerator either will be
  refurbished CTI 4000 at
  BNL, or purchased new
  (Industrial Study)
• System is designed to be
  flexible and accommodate
  all modes of operation




      November 13, 2002   Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   19
          Conclusions on Conceptual Design
• Feasibility has been demonstrated.
• Review (February 2002) was successful.
• Led to further specific industrial studies that are
  now in process to reduce risk
    – Insulation study
    – Refrigerator/liquefier study
    – Winding and impregnation approach and cost study
• Results from Conceptual Design + Industrial
  Studies will be factored into the Magnet
  Technical Specification and SOW for Final
  Design, Manufacturing, Installation and
  Commissioning.

 November 13, 2002   Brad Smith   GA Industrial Study Kickoff   Conceptual Design Overview   20

				
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