SHMS Magnets Introduction and Standard Design Approach

Paul BrindzaSept. 26, 2006

Introduction to SHMS Magnet Designs

• SHMS Magnets & Design Selection• Design Tools and Designers• Integration of Safety Into the Designs• SHMS Magnet Standardized Design &

Systems Approach • Superconductors and Stability• Energy Margin, Hot Spot and Final Temp.

HBQ1'Q2Q3D

SHMS Space Assignment

HB Q1' Q23 Dipole

SHMS Magnet Family Album

Horizontal Bend Q1' Quad

Q23 Quads Dipole

Cosine (Θ)5,05060 cm4.7 TDip

Cosine (2Θ)4,50060 cm13.1 T/mQ23

JLAB Q1'Cold Iron

18,10040 cm9.1 T/mQ1'

“C” TypeSuper Ferric

25,00018 x 272.95 THB

DesignJ A/cm^2ApertureBo/Go

SHMS Magnet Designs

140 t18.11.814500Dip

60 t9.870.7665053Q23

18 t0.6280.1243187Q1'

3.5 t0.2500.2544439HB

Wt.E (MJ)L (H)I (A)

SHMS Magnets Energy & weight

SHMS Q23 and Dipole Design

• Cosine ( Θ )and Cosine (2 Θ) designs selected for SHMS Dipole and Q23 Quads

• These magnet types produce excellent fields efficiently and there is an enormous global design basis.

• The fields produced are VERY linear and thus excellent spectrometer magnets

• Super Ferric designs cannot compete in the required field range

SHMS Dipole Design Example(Q23 similar)

Flange for JLAB Standard Cryo Control reservoir

3 Dbl Pancake Cosine Θ coils

Shrink Fit Coil CollarBath cooled coil

60 cm warm bore

Warm Iron Yoke

SHMS HB and Q1' Design

• Q1' must be an overall elipticaly shaped magnet and superconducting to reach the required 9 T/M gradient and get to the required 5 degree scattering angle in house design fits the bill!

• Q1' is an ideal quad geometry and is derived from a conformal map of a window frame dipole! L. Harwood

• HB must bend 12 Gev particles by 3 degrees & reach 5 degree scattering angle & full SHMS acceptance with minimal field on electron beam – compact “C” magnet & SC

• Super Ferric Designs were selected to meet the very tight space constraints and tight stray field on the exiting electron beam requirements

Conformal Map Generation of Cold Iron Quads (SHMS Q1’ & HMS Q1 Q2 Q3)

Classic Window Frame DipoleIdeal Hyperbolic Quad

Apply 1/ξ Transform

HMS Q1- SHMS Prototype!

Q1 Cold Iron quad section

40 cm warm bore

Cold Laminated Yoke

Flange for JLAB CryoControl Reservoir

Bath cooled coil

Q1' Coil is conformal mapof window frame coil

SHMS HB vertical sectionFlange for JLAB Cryo Control Reservoir

Notch for exit beam pipe

Notch for HMS Q1' clearance

Cold “C” Yoke

Window Frame coil

Warm bore (18 x 27 cm)

SHMS HB Coil Cooling Options

Potted Copper Fin option Compact He vessel Option

JLAB Design Tools

• TOSCA 3D PC version for Magnetostatics• 3D CAD UG/SDRC Ideas• FEA UG/SDRC Ideas• New Tools coming to JLAB this month!• 3D Quench from Vector Fields (VF)• Elektra- quench back, eddy currents (VF)• ROXIE- Cosine coil optimization- CERN

SHMS Magnet Design Team

• Paul Brindza 40 % (present time to SHMS)• Steve Lassiter 40 %• Mike Fowler 40 %• Contract Designer (Vacant as of 8/31) 100%• Term Designer (search underway) 100%

• The above named folks were the core of the HMS design team (3 other HMS team members are still at JLAB)

SCOPE of Magnet Presentations

• The SHMS Current Design was Frozen in June 2006• The HB Magnet Design was frozen end of July 2006• Today you will hear & see a lot of magneto- statics &

cold mass related work at a conceptual level.• What you won’t see & hear : Detailed 3D CAD Drawings,

cryostats, cryogenics, cooling systems, cool down & analysis, magnet heat loads, Pressure Vessel Analysis, 3D quench analysis,safety systems, Failure Effects Analysis, Tooling,…….

• We will present the JLAB/ Hall C standardized approach to the design of these systems.

How we Integrate Safety into the SHMS Magnet Conceptual Design

• SHMS Magnet designs were selected based on a rich engineering data base (no inventions)

• Superconductor selection for large margins• Cryo stable designs & bath cooling if possible• Design clamped coils too! (belts & suspenders)• Design for low Quench Hot Spot Temperature• Design for low operating voltages• Burnout proof current leads• Use of proven standardized systems• Initial sizing- low stress high buckling pressure

Standardized Systems Approach toSHMS Magnet Design

ALL SHMS Magnets will use these!

• JLAB Cryogenic Control Reservoir• JLAB/FNAL valves, actuators, bayonets• Burnout proof current leads (AMI/JLAB)• Hall C Standard Magnet control system• Standardized Instrumentation• JLAB Cool Down System• DC power system (JLAB/Danfysik)• Quench detection (Danfysik)• Yoke Iron (JLAB Furnished)• Common Superconductor

JLAB Standard CryoControl-ReservoirUsed in all HMS Magnets, G0 and Septums

Standard Commercial Cryogenic Components

• Require CODED Anderson-Greenwood Relief valve for LHE & LN2

• Require Fike Rupture Disc for LHE & LN2• Require Low pressure parallel plate relief

for Vacuum spaces• Require AMI Liquid Level for LHE & LN2• Require PT100 for LN2 temp• Require Carbon-Glass for LHE temp

Standard Commercial Cryogenic Components

• Require LeyBold Heraus Combi Gauge Vacuum (Convectron and Cold Cathode)

• Require MKS He Lead Flow meter• Require MKS pressure readouts• Require Micro Measurements Strain

gauges(CEA-06-125UT-350-P2)

PIX of Burnout proof VCL’s

Development of Burnout Proof Current Leads for SHMS Magnets

• AMI/JLAB 5000 AMP burnout proof re-optimized vapor cooled current lead (1.63 L/Hr/KA)

• 5 KA lead pair designed, built and tested by AMI• 5000 A DC No Cooling for 11.3 minutes Safe• 3700 A DC No Cooling Safe forever• 33 minute (2.5 A/sec)slow dump no cooling safe• We required a safe 15 Minute slow dump

non cooled discharge!

No burnout VCL 5 KA no coolant 11 min. test results

Figure 7Tempertaure Profile - 5000 Amp Current Lead

0

50

100

150

200

250

300

350

0 5 10 15 20 25 30

Sensor Location on Lead (inches, cold end to warm end)

Tem

pera

ture

(K)

Full Flow, 4900 AmpsNo FLow, 4900 Amps, 100 SecondsNo Flow, 4900 Amps, 200 SecondsNo Flow, 4900 Amps, 300 SecondsNo Flow, 4900 Amps, 400 SecondsNo FLow, 4900 Amps, 500 SecondsNo Flow, 4900 Amps, 600 SecondsNo Flow, 4900 Amps, 680 seconds

No burnout VCL discharge test results

Figure 9Temperature Profiles vs. Time for Decreasing Current

0

50

100

150

200

250

300

0 500 1000 1500 2000 2500 3000

Time (seconds)

Tem

pera

ture

(K)

Sensor 1Sensor 2Sensor 3Sensor 4Sensor 5

JLAB Standard Cool Down SystemUsed in Halls C, A and D & G0

Standard Hall C/D Magnet controls

• New system hardware and software custom designed for HMS and Hall D Solenoid by Hall C staff

• PLC based (dual redundant systems)• PLC and most electronics in counting house• Only RAD hard components and magnets left in

Hall C• System is operational and has NEVER crashed!• Presentation by S. Lassiter in PM

JLAB/Hall C & D Standard DC System

• Danfysik System 8000 - JLAB Features• Standard DC for HMS, Hall D, ClAS Torus

& HRS Q1’s Required for SHMS• Bulk purchase by JLAB ( 10 V, 5KA)• Integral NMR stabilization, polarity switch,

energy dump & Quench Detection• JLAB standard control panel• Compatible with standard Hall C magnet

controls

JLAB/Hall C & D Standard DC System

• Compatible with JLAB spare parts and staff expertise

• Stability at 1E-6 level in regulation mode• Stability is ~ 10 nano Tesla with NMR• Absolute Precision better than 1E-4 • Transistor final stage regulation• PARD better than 1E-5• “I have the simplest of tastes- I am always satisfied by the very best” – O. Wilde

JLAB/Hall C&D Standard DC systemSystem 8000 Integrated DC Power Supply

SHMS Magnets Standard DC System

JLAB/Hall C & D Standard 4 dual Channel QD board

• Range and sensitivity easily customizable• Detection range ~ 5 milliVolts - 1 volt +• Can be integrated into Danfysik System

8000 DC power supply

SHMS Magnet Iron

• Q1' and HB will use cold iron supplied and integrated by the magnet builder

• Q23’s and Dipole will use warm yoke iron supplied by JLAB ( HMS & HRS^2)

• Yoke steel 1006, 200 tons total• Bulk purchase by JLAB for best value• Steel will be cast, forged and machined• World vendor base

Conclusions on Standard Systems

• SHMS SC magnet designs will utilize standardized & tested systems & components

• Use of Standardized Tested Systems will result in safer magnets!

• Standardized magnet system components will lead to sensible higher quality magnet solutions that are easier to operate and maintain

• Standardized components (procured in bulk by JLAB) will save money & time

SHMS Magnets Superconductors

• All Magnets will use JLAB furnished and tested Superconductor

• SSC outer 36 strand Rutherford cable• HB and Q1' use the outer cable alone

flattened to remove the key stone shape• Q23 and Dip will use use a composite

stabilized conductor• Stabilized conductor is a 36 strand cable

wave soldered to a Copper extrusion

SHMS Q23 & Dipole Composite SC drawing

De- Keystoned SSC Outer Conductorfor SHMS HB and Q1'

11.68 mm

Mid-thickness1.156 mm

Keystone Angle1.01°

11.68 mm

1.1 mm

(De-Keystoned )

Note: We plan to flatten ~ 90 % of cable width to avoid degradation

SHMS Dipole with actual size conductor trial layout

Shrink Fit Force Collar

Titanium Key

Wedge Spacer

Composite StabilizedSuperconductor 3 DBL Pancake Cos Θ Coils

SSC Outer Cable Tests

• 12 samples of SSC outer cable tested at BNL• Test Conditions ~ SHMS Magnets• Field Range B ( 6T, 7T, 8T)• Current 0 < I < 11,000• Tests at 4.2 K• Results compare favorably to nominal short

sample curve Ic=31532(1-B/15)^2.315 L. Dresner

• Typical Ic twice (or thrice) Io at constant B

Ic measurements at 6T,7T and 8T

0

2000

4000

6000

8000

10000

12000

0 2 4 6 8 10 12 14

Test Number

Ic a

mps

Series1

Series2

Series3

Series4

SSC Outer Cable Measurements at 4.2 K

Cable Tests, Nominal SSC Outer Short Sample Curve & SHMS Dipole Peak Field Load line

Ic, Dipole Peak Field Load Line and Average of measurements

0

5000

10000

15000

20000

25000

0 2 4 6 8 10 12

B Tesla

Ic A

mps f it @ 4.4 K

Ic Ave at 4.4K

SHMS dipole

SHMS Dipole and Quad magnets stability and load lines

0

5000

10000

15000

20000

25000

0 2 4 6 8 10 12

B tesla

Cur

rent

am

ps

f it at 6.623 K

fit at 6.778 K

fit @ 4.4 K

SHMS dipole

SHMS quad

SHMS Dipole and Q23 temp margins

Temp Margin for HB and Q1

0

5000

10000

15000

20000

25000

0 1 2 3 4 5 6 7 8 9

Bmax in coil Tesla

Cur

rent

Am

ps

f it @ 4.4 K

SHMS Q1 Quad

SHMS H bend

Q1 at 8.304

HB at 7.746

SHMS Q1' and HB Temp margins

SHMS Operating Margins on Peak Field Load Line

0.5281.681552 (1.35)2.34Dip

0.4801.431217 (1.24)2.18Q23

0.2133.924659 (1.46)3.86Q1'

0.088 2.913408 (1.77)3.31 HB

EnergyJ/M

FieldT

Current RatioA Ic/Io

TempK

4500

5053

3188

4439

Io Amps

0.656.785.894.50CompDip

0.886.625.875.05CompQ23

1.328.302.7814.6CableQ1'

3.367.753.7925.2CableHB

AlphaTcKelvin

BmTesla

Jo kA/cm^2

Cond

Cryostability in SHMS Magnets

Energy Margin, Hot Spot, dump voltage and final temperature

• Available Conductor Enthalpy per meter between operating Temp and Critical temp is the Energy Margin.

• The final conductor temperature during a quench induced magnet discharge at the point of origin is the Adiabatic Hot Spot Temp.

• The Optimal Dump Voltage can be determined by limiting simultaneously the Hot Spot Temp and the Maximum Dump Voltage

• The Final Average Coil Temperature during an unprotected quench can be calculated from the Conductor Enthalpy

Energy Margin/Meter

• Conductor Energy Margin• E/L= Sum(Ai*Rhoi*Cpi)@Tc –

Sum(…)@4.44K• Sum is over all materials in

conductor Cu, Nb, Ti, Sn, Pb• Energy Margin per meter is

one measure of conductor stability and is the energy required to raise one meter to the critical Temp.

• Adiabatic approximation ignores Helium and conduction

.5286.78CompDip

.4806.62CompQ23

.2138.30CableQ1'

.0887.75CableHB

E/MJ/M

TcK

Cond.

SHMS Magnets Adiabatic Hot Spot TempAmps Squared Seconds Vs Dump Voltage

4.29E85.36E87.15E81.07E92.15E9Dip

2.76E83.45E84.60E86.91E81.38E9Q23

5.71E67.13E69.51E61.43E72.85E7Q1'

3.06E63.83E65.11E67.66E61.53E7HB

500 V400 V300 V200 V100 V

SHMS Magnets Adiabatic Hot Spot Temp Vs Dump Voltage

35 K39 K47 K69 K255 KDip

28 K31 K36 K46 K100 KQ23

41 K47 K59 K97 K501 KQ1'

30 K33 K39 K50 K110 KHB

500 V400 V300 V200 V100 V

SHMS Magnets Final Average Temp if one coil Absorbs all the Energy

78 K529318.3538.0472Dip

69 K50629.786.0322Q23

126 K16200.5545.080Q1'

113 K20870.2502.491HB

Final Temp

Energy/meter

EnergyLengthTurnsPer coil

Conclusions on SHMS Conductors

• SSC cable is a good match to the SHMS magnet requirements & saves time & money

• All SHMS Magnets have large margins• Dipole and Q23 will be cryostaticaly stable• SHMS Q1' with SSC cable will be more

stable than HMS Q1 MQE ~.060 J/M

• HB stability - TBD