LARP Magnet RD Plan Overview Steve Gourlay LARP DOE by herhero

VIEWS: 20 PAGES: 32

									                                BNL -FNAL - LBNL - SLAC




       LARP Magnet R&D Plan Overview
                                               Steve Gourlay


                                    LARP DOE Technical Review

                                                 Santa Rosa
                                              November 2, 2005




LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   1
                                                   Outline

• Introduction                                                 • Program Management and
                                                                 Organization
       – Program Goals
                                                                      – Advisory and Support Committees
• Issues
                                                                      – Risk and Risk Management
       – Materials
                                                               • Survey of FY06 Activities and
       – Coil and Fabrication
                                                                 Budget
• Program Implementation
       – Goals 1 – 3
       – Documentation
       – Schedule and Milestones




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                                              Introduction

 As the LHC nears completion, there is increased interest in future
  improvement of the accelerator complex

 New magnet technology, based on Nb3Sn will be a key element in any
  upgrade scenario

      – Challenging performance parameters
          • Aperture:              > 90 mm
          • Gradient:              ~200 T/m

                – Operating in a high radiation environment


                     Improved LHC and new technology for future applications


LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   3
                                 Magnet Program Goals
              Provide options for future upgrades of the LHC Interaction Regions

“Demonstrate by 2009 that Nb3Sn magnets are a viable choice for an LHC IR upgrade”
                           (Developed in consultation with CERN and LARPAC)


     – Focus on major issues: consistency, bore/gradient (field) and length
  1.
       1. Predictable and reproducible performance
                     SQ and TQ series (1 m, 90 mm aperture, Gnom > 200 T/m, Bcoil > 12 T)

       2. Long magnet fabrication
                     LR and LQ series (4 m, 90 mm aperture, Gnom > 200 T/m, Bcoil > 12 T)

       3. High gradient in large aperture
                     HQ series (1 m, 90 mm aperture, Gnom > 250 T/m, Bcoil > 15 T)
  LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   4
                                             Target Program

                                           Length     Gradient        Aperture
 Model Magnets               Type                                                    FY05    FY06    FY07     FY08   FY09
                                            (m)        (T/m)           (mm)
 Series Description
 TQ Technology Quad        Cos-2theta        1          > 200            90                 3N + 1R 2N + 1R
 LQ   Long Quad            Cos-2theta        4          > 200            90                                    1N     1N
 HQ High Gradient Quad     Cos-2theta        1          > 250            90                                           2N

 Supporting R&D              Type          Length    Peak Field       Aperture       FY05    FY06    FY07     FY08   FY09
                                            (m)         (T)            (mm)
 Series Description
 SQ Sub-scale                block          0.3        10 – 11           110        1N + 1R 1N + 1R 1N + 1R    1N
 SR   Short Racetrack        block          0.3        10 – 12          N/A                   1N      1N       1N
 LR   Long Racetrack         block           4         10 - 12          N/A                           2N
 N = New Magnet
 R = Revised Magnet using existing coils




LARP DOE Technical Review, November 2, 2005         Magnet R&D Plan Overview - S. Gourlay                                  5
                                                    Issues

 The initial program is structured around the issues related to development
  of a technology base necessary to meet LARP requirements

 Base for the program comes from recent progress in the core programs

 LARP augments continuing work in core programs with focused
  development on LARP specific issues

 Main issues: Conductor/cable, support structures, fabrication techniques




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                                                Materials
     What do we need for LARP?

• Now:
   – Sufficient quantities of
     material for the magnet
     program                                                       54/61              90/91       126/127
              • Procurement plan in place

       – Cable with
              • Jc > 2,400 A/mm2
              • Is ~ X2 magnet Iss

• Later
   – Jc > 3,000 A/mm2
   – Smaller filaments                                           28-Strand                    27-Strand
                                                                    TQ                           TQ
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                                                     What is Is?

           1200


           1000


                   800
     Current (A)




                                                                                                     Ic

                   600
                                                                                                     Iq
                                                  Unstable
                                                                                                     Hq+
                   400
                                                                                                     Hq–
                   200
                                              Stable

                     0
                         0   2                4             6             8                10   12
                                                  Applied Field (T)
LARP DOE Technical Review, November 2, 2005        Magnet R&D Plan Overview - S. Gourlay                   8
                                                 Materials

 One US vendor capable of furnishing LARP conductor (OST)

 Strand Options
                                                           MD2
   – MJR – discontinued (no scale-up potential)
   – RRP – OST production wire (commercial applications, US magnet programs)
   – PIT – unreliable delivery, low Jc, high cost

    – Other routes to the future
         • SBIR program
         • DOE Conductor Development Program                                           Put risk outside
                                                                                       of LARP
         • Core program (FNAL procurement of PIT)




 LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay                      9
                                                Materials

 Two goals for the Materials group

      – Provide “workhorse” material for magnet program
      – Support R&D program for development of future LARP material
                     (augmented with significant core program support)


 Main issue for both MJR and RRP

      – Currently available materials exhibit “flux jump” instability
      – Not if: effective filament diameter is sufficiently small
                                                                                      MD3
      – Key concern: Will “flux jump” initiate a quench?
                                                                                      MD5 - MJR
      – Not if: local RRR is “high”

                             Evaluated by measuring Is                    ...
LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay               10
                                                Materials

 Keys to high Is

      – Strands with good sub-element bonding (long piece length)

      – Careful cabling
                                                                              MD4 – Cable qualification
          • Minimize filament distortion (small deff)
                                                                              Core program – in progress
          • Minimize damage to barriers
                                                                              MD6 – Conductor viability
      – Optimized heat treatment
          • Trade-off with Jc for stability
                                                                              MD2
 Excellent progress by Materials group

      – 54/61 (MJR or RRP) is acceptable for LARP “workhorse” conductor


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                                                Fabrication

Early focus . . . combine the best of the best from the core programs

 Exchange of coil fabrication tasks for TQ’s between FNAL and LBNL
   – Improved techniques
   – Improved documentation             MD9 – resource management,
                                                                  initial test at point of assembly

 Long Racetrack program
   – Technology exchange between LBNL and BNL
          • Length scale-up
             – Reaction
             – Impregnation
             – Handling

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                                          Support Structure

 The support structure is key to magnet performance (after conductor)

      – Two options are being explored – required to meet challenging
        properties of Nb3Sn

          • Traditional “collar and yoke” (TQC)
             – Proven for field quality and long length
             – Can it be extrapolated to higher fields?

          • Internal pre-stress with shrinking shell (TQS)
             – Good control of pre-stress
             – Length scale-up and alignment?

                Also provides an opportunity to investigate end-load questions


LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   13
                             Program Implementation

• Design Studies                                                   • Materials Support
       – Provide input on magnet parameters                               – Provide sufficient quantities of
         and lay groundwork for the program                                 well-characterized material
         – broad range of activities
                                                                          – Support R&D on ultimate
• Supporting R&D                                                            material

       – Wide range of technical issues         •                        Model Magnet R&D
         related to fabrication and operational
         parameters                                                       – Integrate input from other three
                                                                            areas to produce magnets with
       – LR, SQ, SR                                                         parameters relevant to LARP
          • Verify analysis models                                          goals
          • Performance related issues
                                                                          – TQ, LQ and HQ
          • Materials development
          • Support structure development

LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay                   14
                                 Magnet Program Flowchart




LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   15
                       Goal #1 Predictable and Reproducible Performance


• Sub-scale Quadrupoles (SQ)
       – Conductor evaluation
       – Analysis validation


• Technology Quadrupoles (TQ)
       – 90 mm aperture
       – Gradient > 200 T/m
       – Explore alternate structures                                    Skin

         using “identical” conductor                                                   Preload
                                                                                       Shim


       – Basis for scale-up                                       Yoke
                                                                  Gap

                                                                                        Collaring
                                                                 Yoke                   Key

                                                                   Control            Collar
                                                                   Spacer




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                              Goal #2 Long Magnet Fabrication


• Long Racetrack
       – Coil fabrication scale-up based on well-understood
         sub-scale coils
       – Explore scale-up of shell-based support structure


       Followed by . . .

• Long quadrupole (LQ)
       – 3.6 m quadrupole based on TQ cross-section

                                                       MD11 – length


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                      Goal #3 High Gradient in a Large Aperture

                                                                                3-layer: G=260-290 T/m

• High Gradient Quadrupole (HQ)

       – Explore ultimate performance

              • Increase peak field on the coil
                to ~ 15 T
              • Precursor to larger aperture                                    4-layer: G=280-310 T/m




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                                 Web-Based Documentation

 Facilitate communication and task tracking

    – Weekly reports from Task Managers
    – Task sheets
                                                                             Numerous meetings, video and
    – Meeting notes                                                          teleconferences
    – Current schedules

 Document decisions, results, lessons-learned

    – L2 managers distill archival data from all sources into high level document, e.g.
         • Requirements
         • Physical parameters
         • Strand test results
         • Cable dimensions
         • Fabrication procedures
         • Test results
 LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay                19
                                  Program Components
                                  Application                              Predecessors                     Milestones
           SR/SQ     Conductor evaluation                         Ongoing as required for program   SQ-02                10/05
                     Fabrication techniques                       support                           SR-01                 4/06
                     Rad-hard materials                           Design Studies
                     Model validation                             Introduction of new conductors
                     Establish baseline performance
            TQ       Goal #1 - Reproducible performance           SQ – analysis validation          First test
                     Fabrication techniques                       Conductor evaluation              5/06
                     Mechanical structure                                                           Evaluation Review     8/06
                     LQ baseline                                                                    Support Structure     7/07

             LR      Long coil fabrication issues                 Based on well-understood design   SR-01 Evaluation rev 5/06
                         -     reaction                           SR-01                             LR-01 complete      11/06
                         -     handling                                                             LR-02 complete       9/07
                         -     impregnation                                                                                      MD12
                         -     Long shell and bladder
                               validation

            LQ       Goal #2 – Long magnet fabrication            LR-01                             Coil Design Review 11/06
                     Integration of TQ and LR program             TQ’s                              Mech Design Review 7/07
                     Demonstration of long magnet technology      Design Studies                    1st completion target
                     with field and aperture                                                        9/08
                                                                                                    2nd completion target
                                                                                                    1/09
            HQ       Goal #3 – High gradient/large aperture       SQ/SR                             Coil Design Review 11/06
                     Push limit on field (~ 15T)                  TQ’s                              Mech Design Review 7/07
                     Precursor to larger aperture                 Design Studies                    1st completion target
                                                                  Conductor and Cable R&D           10/08
                                                                                                    2nd completion target
                                                                                                    2/09



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MD14 LR and LQ




 LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   21
                                                       Organization

                                              LARP Magnet Program                                Magnet Steering
                                                   S. Gourlay                                     Committee

    Design Studies                 Model Magnet R&D                    Supporting R&D                    Materials
      A. Zlobin                       G.L. Sabbi                         G. Ambrosio                     A. Ghosh


Task 1           Task 2            Task 3            Task 4          Task 5           Task 6       Task 7        Task 8


                                                    Test Integration Group
                 Superconducting
                    Magnets
                                                                                      Magnet Steering Committee (MSC)
                                                                                      – Define program, identify tasks and
                      S.Gourlay                                                       assign task managers


                      BNL
                                                                                      Lab Representatives and L2’s
    LBNL                                FNAL
                  Representative
Representative                      Representative                                    G. Sabbi, A. Zlobin, A. Ghosh,
  G.Sabbi            P. Wanderer      A.V.Zlobin                                      G. Ambrosio, S. Gourlay,
                                                                                      P. Wanderer, R. Stanek (J. Kerby)
  Lab representatives oversee
  tasks/sub-tasks at host laboratory

LARP DOE Technical Review, November 2, 2005        Magnet R&D Plan Overview - S. Gourlay                             22
                                Program Management

•    Advisory and Support Committees                                  •    Gourlay/MSC

       – US Executive committee                                              – Define program

       – US – CERN committee                                                 – Prioritize
              • Good communication with CERN
                liaison (Meetings/letters)                                   – Budget guidance
                                                       MD1
       – LARP Advisory Committee                                             – Assign tasks to appropriate
                                                                               organization
       – DOE reviews                                                                                   MD8
                                                                                    • Competencies/resources
       – Magnet Steering Committee (MSC)
                                                                             – Monitor program
       – Ad hoc reviews (external/internal
                                                                                    • External and internal reviews
         membership)
              • Milestones and branch points
                                                                      •    L2’s and task managers assemble
                                                                           tasks to implement program

    LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay                     23
                         Risk and Risk Management
•    LARP Magnet Program is very        • Schedule
     ambitious, but . . .                  – Program planning takes into
      – Based on success of core programs    account some unforeseen delays
      – Focus on the goals                   and difficulties
                                              • Multiple targets
      – Effective use of resources
                                                                             • Early schedule for completion
                                    MD8 – infrastructure,                    • Can recover additional schedule
•    Technical
                                    resources                                  slip by accepting additional risk
      – Materials
              • Extensive materials evaluation
                program
              • Priority on delivery of “workhorse”                         MD17 – sufficient budget
                material
       – Parametric studies                                   • Reassess budget in mid-FY06
              • Sub-scale magnets for early start                     – Submit modified proposal
                on technical issues
              • Increase number of tests


LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay                     24
                        FY06 Activities and Budget




LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay   25
                                          Design Studies


WBS                                                                                   BNL    FNAL   LBNL   Total
2.1            Design Studies                                      Zlobin              83     190    105    378
2.1.3           IR Cryogenics
2.1.3.2           Inner triplet cryo & heat transfer               Rabehl               22     49               71
2.1.3.3           Radiation heat deposition                        Mokhov                      30               30
2.1.4           IR Magnets
2.1.4.1           HQ conceptual design                             Sabbi                       39     62     101
2.1.4.2           LQ conceptual design                            Ambrosio              13     51     43     107
2.1.4.3           IR magnet study                                  Gupta                48     21             69




                                                                                MD10 – Dipole dropped




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                                                Materials


WBS                                                                                   BNL    FNAL   LBNL   Total
2.4            Materials                                            Ghosh              178    196    648   1022
2.4.1           Conductor Support
2.4.1.1           Strand R&D                                        Barzi              137    169     41        347
2.4.1.2           Cable R&D                                       Dietderich            41     27    233        301
2.4.1.3           Procurement                                      Ghosh                             374        374



     Increase of ~ $100k relative to June Review                                      MD2




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                                         Supporting R&D


WBS                                                                                   BNL    FNAL   LBNL   Total
2.3            Supporting R&D                                    Ambrosio             1282     67    504   1853
2.3.1           Subscale models
2.3.1.2           Small Quad SQ02 fab & test                      Ferracin                           155    155
2.3.2           Long Magnet Development
2.3.2.2           Racterack coil fab & test                      Schmalzle            1262     32     92    1386
2.3.2.3           Racetrack supporting structure                  Ferracin                           222     222
2.3.3           Test integration
2.3.3.1           Testing                                           Feher               20     35     35         90
                                                                                 Target

                                                                           MD7 – Long Racetrack coils




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                                                    SQ-02

 First thermal cycle
     – 1st quench: 60 % Iss
     – 90 % in 13 quenches
     – Imax = 95 % Iss


 Second thermal cycle
     – 1st quench: 95 % Iss
     – Imax = 97 % Iss

             • Imax = 9.6 kA                                                MD5 - MJR
             • Bpeak = 10.7 T
             • Gpeak = 81 T/m                                         MD13 – analysis
                                                                      benchmarks

                                                                         MD6 – Conductor viability

LARP DOE Technical Review, November 2, 2005   Magnet R&D Plan Overview - S. Gourlay                  29
                                    Model Magnet R&D


  WBS                                                                                 BNL    FNAL   LBNL   Total
  2.2            Model Magnet R&D                                    Sabbi              0    1334   1063   2397
  2.2.1           Quadrupole
  2.2.1.1          Technology Quad TQS01                            Caspi                      92    345     437
  2.2.1.2          Technology Quad TQC01                           Bossert                    432    161     593
  2.2.1.3          Technology Quad TQS02                            Caspi                      10    203     213
  2.2.1.4          Technology Quad TQC02                           Bossert                    502     25     527
  2.2.1.5          Coil/Structure exchange TQE01                   Ferracin                    37     50      87
  2.2.1.6          Technology Quad TQS03                            Caspi                     108    170     278
  2.2.1.7          Technology Quad TQC03                           Bossert                    153    109     262


                                                                                            MD5 - MJR




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                              Magnet Budget Summary
                   WBS                                                                BNL         FNAL      LBNL      Total
                   2         Magnet R&D                                Gourlay       1543         1787      2320      5650
                   2.1        Design Studies                             Zlobin             83       190       105        378
                   2.1.3        IR Cryogenics
                   2.1.3.2        Inner triplet cryo & heat transfer     Rabehl              22        49                     71
                   2.1.3.3        Radiation heat deposition              Mokhov                        30                     30
                   2.1.4        IR Magnets
                   2.1.4.1        HQ conceptual design                   Sabbi                         39        62       101
                   2.1.4.2        LQ conceptual design                  Ambrosio            13         51        43       107
                   2.1.4.3        IR magnet study                        Gupta              48         21                  69
                   2.2        Model Magnet R&D                           Sabbi              0       1334      1063      2397
                   2.2.1        Quadrupole
                   2.2.1.1        Technology Quad TQS01                   Caspi                        92       345       437
                   2.2.1.2        Technology Quad TQC01                  Bossert                      432       161       593
                   2.2.1.3        Technology Quad TQS02                   Caspi                        10       203       213
                   2.2.1.4        Technology Quad TQC02                  Bossert                      502        25       527
                   2.2.1.5        Coil/Structure exchange TQE01          Ferracin                      37        50        87
                   2.2.1.6        Technology Quad TQS03                   Caspi                       108       170       278
                   2.2.1.7        Technology Quad TQC03                  Bossert                      153       109       262
                   2.3        Supporting R&D                            Ambrosio       1282           67       504      1853
                   2.3.1        Subscale models
                   2.3.1.2        Small Quad SQ02 fab & test             Ferracin                               155       155
                   2.3.2        Long Magnet Development
                   2.3.2.2        Racterack coil fab & test             Schmalzle       1262           32        92       1386
                   2.3.2.3        Racetrack supporting structure         Ferracin                               222        222
                   2.3.3        Test integration
                   2.3.3.1        Testing                                Feher            20           35        35        90
                   2.4        Materials                                  Ghosh          178          196       648      1022
                   2.4.1        Conductor Support
                   2.4.1.1        Strand R&D                              Barzi             137       169        41           347
                   2.4.1.2        Cable R&D                             Dietderich           41        27       233           301
                   2.4.1.3        Procurement                            Ghosh                                  374           374


LARP DOE Technical Review, November 2, 2005              Magnet R&D Plan Overview - S. Gourlay                                      31
                                               Summary

 The LARP Magnet Program is off to a great start

      – Converging rapidly on an efficient collaboration

      – Excellent progress since the last review

          • Challenges still ahead but more success is on the way




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