Dogleg Review 2-1-131 Dogleg Upgrade Tommy Hiatt Magnet Modifications.
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Transcript of Dogleg Review 2-1-131 Dogleg Upgrade Tommy Hiatt Magnet Modifications.
Dogleg Review 2-1-13 2
Outline
• Requirements
• Design Approach
• Mechanical Design
• Modeling
• Performance
• Schedule
• Summary
Dogleg Review 2-1-13 3
Modification Requirements
• Design modifications to dipoles so that the dogleg dipoles meet the specified BL requirements
• Constraints
–Use same type of power supply for each string
–Modifications compatible with existing stands
–Magnet deinstallation-modification-measurement-reinstallation must fit within UIM down (summer 2014)
• Dipoles affected
–Dog3 – 1 BX dipole
–Dog4 – 1 BX dipole and 2 BW dipoles
Dogleg Review 2-1-13 4
Design Approach
• Use similar approach as the 12 GeV dipoles
–Minimize Cost
–Reuse existing magnet cores
– Limit temperature rise in LCW to be consistent with 12 GeV Upgrade (<40C dT)
–Use lengthening shims or field shaping shims if needed on modified magnets
• Repurpose or procure steel to increase core length
• Minimize additional LCW consumption
• Remove / touch as few magnets as possible
Dogleg Review 2-1-13 5
Mechanical Design
• Dogleg dipoles have published field maps on a 300 A loop
– Dog1 will operate within that range at 167 A
• All other dipoles will be pushed to higher currents
– Some will meet the BL requirements by just pushing the current
• Dog2 – 318 A
• Dog5 – 365 A
• Dog6 – 389 A
• Dog7 – 414 A
• Dog8 – 396 A
• Dog9 – 413 A
–Others will need mechanical modification to achieve BL
• Dog3 BX – new coils
• Dog4 – new coils and more steel
Dogleg Review 2-1-13 6
Mechanical Design
• Modify Dog3 BX
– Use larger cross section coil (BZ conductor)
– No coil pocket mods necessary
– No lengthening steel added
• Modify Dog4 BWs
– Use larger cross section coil (BZ conductor)
– Modify coil pocket (remove steel)
– Add face shim to make up for part of the coil pocket mod.
– Add ~30 cm of lengthening steel
• Modify Dog4 BX
– Use larger cross section coil (BZ conductor)
– No coil pocket mods necessary
– Add ~60 cm of additional steel
Dogleg Review 2-1-13 7
Mechanical Design
• BX Modifications (1 in Dog3 and 1 in Dog4)
– Use larger cross section coils
– Dog3 – no lengthening steel
– Dog4 – ~60cm of additional steel
Dog 4 BX Modifications
Dogleg Review 2-1-13 8
Mechanical Design
• BW Modification (2 in Dog4)
– Use larger cross section coils
– Modify coil pocket
– Use face shim to make up for part of the coil pocket modification
Dog 3 BW Modifications
Dogleg Review 2-1-13 9
Mechanical Design• Mechanical changes result in
– 3 modified coil designs
• 2 for BX (with and without steel addition)
• 1 for BW
– 31 ft3 of additional steel required
• Lengthen 3 dipoles
– Decision point on steel acquisition options
• Option 1 – Obtain permission to use excess 12 GeV spare steel
– Billets were purchased as back up steel for catastrophic machining or handling of S/R and arc dipoles.
• 2 – 3m steel billets on hand• Dogleg upgrade will consume 2 billets
• 6 – 1m steel billets on hand• Dogleg upgrade will consume 2 billets
• Option 2 – Purchase the steel billets that we need (similar to 12 GeV) and machine (~$65k)
• Option 3 – Design for 1” plate laminates (something readily procure-able) and purchase plate
Dogleg Review 2-1-13 10
Modeling
• Linear extrapolations were done to calculate preliminary BL
• Tosca models were used to
– confirm saturation effects for Dog3 and Dog4
– dial in exact lengths of additional steel for Dog4
Dogleg Review 2-1-13 11
Modeling• Use TOSCA to confirm B0 at high currents
• Dog3 BX at 428.6 A, B0 = 8421G (1/4 symmetry, vert. and hor.)
• Dog 4 BW at 377.4 A, B0 = 7390 G (1/2 symmetry, horizontal only)
Scale is 0 - 18,000 G Scale is 10,000 - 18,000 G
Scale is 0 - 18,000 G Scale is 10,000 - 18,000 G
Dogleg Review 2-1-13 12
Performance
Dog CurrentB0
(linear) Total
VoltageTotal Flow
LCW Max dT
(A) (G) (V) (gpm) (C)
1 166.5 3277 27.2 1.5 16
2 317.7 6255 52 4.5 20
3 428.6 8437 47.2 14.8 12
4 377.4 7429 49.4 4 26
5 365.2 7117 – BY 7189 – BZ 52 3.8 27
6 388.9 7580 – BY 7656 – BZ 54.4 6 18
7 413.9 8068 – BY 8148 – BZ 58.4 6 21
8 395.9 7717 – BY 7794 – BZ 55.2 6 19
9 412.8 8046 – BY 8127 – BZ 58 6 21
Dogleg Review 2-1-13 13
Performance
• BL without modifications
Dog Dipole CurrentTosca
B0dL BL
Required BL
- - (A) (G) (cm) (G-cm) (G-cm)
3 BX 428.6 8421 0 842,098 837,196
4 BW 377.4 7390 0 371,145 588,806
4 BX 377.4 7419 0 741,899 1,177,612
Dogleg Review 2-1-13 14
Performance
• BL with modifications
Dog Dipole CurrentTosca
B0dL BL
Required BL
- - (A) (G) (cm) (G-cm) (G-cm)
3 BX 428.6 8421 0 842,098 837,196
4 BW 377.4 7390 29.72 588,849 588,806
4 BX 377.4 7419 58.74 1,177,691 1,177,612
Dogleg Review 2-1-13 15
Schedule
• Coils
– ~12 month lead time
–Complete detailed design and drawings by March 2013 (drop dead)
– PO finalized by end of April 2013 (drop dead)
–Ready for magnet assembly by May 2014
• Steel
–Decision of option path by Feb. 22, 2013 (drop dead)
–Complete detailed design drawings in next 12 months
–Ready for magnet assembly by May 2014
Dogleg Review 2-1-13 16
Summary
• Most dogleg dipoles meet BL requirements with current increase only
• Some dipoles will require lengthening steel and new coils
• Will need to purchase 3 families of coils
• Will need 30.6 ft3 of steel
• This work is understood and similar to recent work done for 12 GeV
Dogleg Review 2-1-13 20
backup• Machine Shop work
– 2 machinist at 1 week per dipole half
• 2 BW, 1 BX = 6 dipole halves
• 2 x 6 = 12 man-weeks (12*40*$55 = $26.4k)
• Refurb work
– 2 MT at 1 week per dipole
• 2 BW, 2 BX = 4 dipoles (4 * 2 * 1 * $1.3k = $10.4k)
• Installation
– Tooling Design 1 MD for 5 weeks = (1 * 5 * $1.3k = $6.5k)
– Tooling cost - $5k
– Ripout – 6 MT at 2 weeks each side (6 * 2 * 2 * $1.3 = $31.2k)
– Install – 6 MT at 4 weeks each side (6 * 4 * 2 * $1.3 = $62.4k)
– Vacuum – half of Install estimate = $31.2k
– Alignment – 2 MT for 2 week (2 * 2 * $1.3 = $5.2k)
– My estimate (above = $141k) ----- Neil’s estimate 209 man days = $95k