R. Carcagno - MICE CC Testing at Fermilab 1

MICE Coupling Coil Testing at Fermilab

MICE Collaboration MeetingRuben CarcagnoMarch 15, 2012

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TD/T&IMICE CC Assembly

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First Coupling Coil has been delivered to LBNL

Parameter Value Coil Length (mm) 281 Coil Inner Radius (mm) 750.5 Coil Thickness (mm) 104 Number of Layers 96 No. Turns per Layer 166 Assembly O.D. (without cooling tubes, mm) 1860.00 Assembly O.D. Envelope (with cooling tubes protrusion, mm) 2025.64 Assembly Height (mm) 325 Assembly Weight (tons) 2.2 Maximum Design Current (A) 210 Self-Inductance (H) 596 Stored Energy at 210 Amps (MJ) 13 Coil Temperature Margin (K) 0.77

R. Carcagno - MICE CC Testing at Fermilab 3

TD/T&IMICE CC Assembly Preparation

• To be installed by LBNL:– Cooling Tubes– Coil Quench Protection system. Coil cannot be

tested without cold diodes and cold resistors!– Mechanical Supports– Heater to induce quench– Instrumentation (Temperature sensors, voltage

taps)

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TD/T&IFringe Magnetic Field at 210 A

• Peak Field: 7.5 T• 600 Gauss at 3m (~10 ft.)• 100 Gauss at 5 m (~16 ft.)• 5 Gauss at 15 m (~ 50 ft.)

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TD/T&ITest Cryostat

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• Built by Meyer Tool in 1997 for SMES, never used • Recently transferred from NHMFL/FSU to Fermilab for this use• Requires several modifications

11.8 ft.

10 ft.

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TD/T&I

Removing Background Coil at NHMFL

• Background coil was removed prior to shipping to Fermilab and it was disposed in Florida

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TD/T&ITop Plate

• Existing top Plate has sufficient penetrations for helium supply, return, power leads, instrumentation ports, etc.

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TD/T&ICryostat Modifications

• Background coil already removed

• The Helium Vessel and vacuum vessel cover will be removed

• A Dished Head will be installed to make the top plate transition to the vacuum vessel wall

• Mechanical support for coil assembly

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TD/T&IInsert

• Cold Mass will be supported from the top plate

• Lateral motion due to magnetic forces will be restrained by supports attached to a column bolted to the bottom of the cryostat

• Cold mass and column will be wrapped with MLI

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TD/T&I

Test Site: Central Helium Liquefier

• Locations considered: IB1, CDF, and CHL• CHL (South Annex) was recommended• Fermilab management directed AD and TD to proceed with CHL

location recommendation on 1/17/2012 and make it a high priority

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TD/T&ICHL Test Area

• Cryostat was already moved to CHL test area location• Preliminary vacuum vessel leak check in progress• Calculation of forces due to fringe magnetic field interaction with building ferromagnetic

elements in progress (V. Kashikhin)

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TD/T&IPlatform, Staging Area Concept

• May not have time to deploy for first MICE CC test• Alternative solutions considered: articulated boom, scissor lift

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TD/T&ICryogenic System

• A simple scheme is proposed based on supplying LHe to the test cryostat from a large CHL LHe dewar, and a heater to warm up all the return gas to room temperature

• The 10,000 Gallon LHe dewar will be refilled as needed by the CHL liquefier• Controlled cooldown is accomplished by mixing of room temperature He gas

with the LHe supply

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Test Cryostat P&ID CHL Cryo Distribution

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TD/T&IDAQ and Controls

• Based on proven technology used at the IB1 Magnet Test Facility• A similar Voltage Taps DAQ system was fabricated by TD and is ready for shipment

to support the MICE Spectrometer Solenoid testing at Wang NMR• Additional functions will include test stand cryo controls, power supply controls,

and DAQ of various sensors (temperature, pressure, level, etc)

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TD/T&IDAQ Block Diagram

• Quench Detection• Fast Loggers• Slow Scan• Personnel Interlocks• Equipment Interlocks• Power System Control• Cryo Controls• Data Archival• E-Log

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TD/T&ITest Operations

• Preliminary estimates indicate that it would take up to 2.5 hours to cryogenically recover from a quench (to be verified by LBNL thermal analysis)

• Given the high magnet inductance of 596 H, it would take ~ 4 hours to ramp to full current (210 A)

• We anticipate no more than one training quenches per day• A full thermal cycle is included after the coil has trained to verify

that the coil “remembers” its training• There could be several training quenches for this coil (50 or more?),

so we estimate a total test run duration of approximately 2 months• There will be a total of 4 Coupling Coils to be tested in this facility

(one for MTA, two for MICE, and one spare)

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TD/T&IProject Responsibilities

• The following organizations are involved in the MICE CC Test Stand project: the Accelerator Physics Center (APC), Technical Division (TD), Accelerator Division (TD), and Lawrence Berkeley National Lab (LBNL)

• Scope and deliverables for each organization has been agreed

• Detailed scope and interface documents exists between TD and AD

• Detailed scope and interface documents with LBNL are in progress

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TD/T&IFNAL/APC

• Fermilab’s Accelerator Physics Center (APC) sponsors this project, provides the funding, specifies the schedule and priorities, and facilitates coordination with Lawrence Berkeley National Lab and other institutions involved in the MICE experiment

• The first coil is intended to go to Fermilab’s Mucool Test Area (MTA)

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TD/T&ILBNL Responsibilities

• Specify test requirements and provide test run plan documentation

• Prepare the CC assembly and deliver it to Fermilab ready for testing and installation in the test cryostat, including:– Cooling tubes and manifold– Coil quench protection system (cold diodes and resistors)– Coil assembly mechanical support system– Temperature sensors, voltage taps, and heater to initiate a quench– Drawings and documentation

• Deliver a 300 A power supply and energy absorption system• LBNL is responsible for thermal and electrical analysis of the coil

assembly, and for the performance of the coil’s cooling system and the passive coil quench protection system

• Test Support3/15/2012

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TD/T&IFNAL/TD Responsibilities

• SMES cryostat modifications to accommodate the MICE CC assembly for conduction-cooled testing

• Current Leads and superconducting bus to coil• Test cryostat cryogenic system and controls up to the coil cooling tubes

supply and return connections– U-tubes, heater, valves, sensors, internal tubing, thermal intercepts, relief valves

• Not responsible for the coil conduction-cooled thermal performance (cooldown, steady state, quench recovery, warmup)

• Quench detection/protection for HTS leads and SC bus (NOT for the coil!)

• DAQ and Power Supply control systems• Coil assembly installation and removal• Test stand installation and commissioning• Test Stand Operational Support

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TD/T&IFNAL/AD Responsibilities

• Prepare CHL area for SMES cryostat installation• CHL Cryogenic Distribution System– Liquid Helium transfer line, bayonet can, ambient

temperature helium piping• CHL Liquefier operations support during the

test– Refill CHL LHe dewar as needed– Recover return ambient helium gas

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TD/T&I

Test Stand Technical Project Team

• Project Leader: Ruben Carcagno, TD-T&I• Lead Engineers:

– C. Sylvester, TD-T&I (Cryostat modifications, installation, and mechanical support)

– R. Rabehl, TD-T&I (Test Cryostat Cryo System)– B. Soyars, AD-Cryo (CHL Cryo Distribution System)– D. Orris, TD-T&I (Quench Detection, DAQ, controls)

• Department Heads:– Jay Theilacker, AD-Cryo– Ruben Carcagno, TD-T&I

• LBNL Technical Point of Contact: Steve Virostek• APC Management: Mark Palmer, Alan Bross, Steve Geer

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TD/T&I

Test Stand Project Risk Assessment

• This risk assessment does not include the MICE CC assembly, it is only for the test stand infrastructure• From Fermilab’s Engineering Manual:

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Risk ScoreEngineering Risk Element 1 3 4 5 6 7 8 9A Technology 3 X X X X X Off the shelf technology plus custom parts similar to previously manufactured partsB Environmental Impact 1 X X X X X X No environmental impactC Vendor Issues 2 X X Multiple vendor sources, standard but specialized partsD Resource Avaliability 4 X X Resources busy with other projects, multitasking, need to prioritizeE Quality Requiremnts 2 X X X X X Quality requirements can be met with existing infrastructure with modificationsF Safety 3 X X X X X X X X The project will require increased diligence due to its location and type of work. Includes FESHM reviewsG Manufacturing Complexity 2 X X X X Similar to previously manfufactured items, larger cryostat scale

Chapter score 7 13 13 13 12 10 3 4Chapter threshold 10 16 19 19 16 13 4 7

Project Risk ElementH Schedule 5 Schedule is critical for the MICE experimentI Interfaces 4 Complex interfaces: TD, AD, LBNLJ Experience/Capability 2 Dominated by experts participationK Regularory Requirements 1 Minor to no involvementL Project Funding 1 MAP will be the source of funding for this projectM Project Reporting Requirements 3 Regular reporting to Division Heads and MAP director will be requiredN Public Impact 1 The public will not be affectedO Project Cost 3 The project requires Divisional budget planning

Project score 20Project threshold 25

Chapter

• Engineering Chapter and Project threshold not exceeded: formal controls not required• Will follow good documentation practices and reviews• Most critical elements are schedule, complex interfaces, and resource availability

– Must keep scope to a minimum and make design choices consistent with a fast-track schedule

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TD/T&IPreliminary Cost Estimate

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• Direct Cost to setup test stand and test 1st coil: ~ $1M• Operating cost includes cost of He losses and Electricity• Cost of CHL initial helium charge not included (recoverable)• Operating CHL in “batch” mode would reduce operating cost

Direct M&S Direct Labor (SWF)

Total ($K)

Test Cryostat Prep $133 Vacuum System $47 Cryogenic System $81 Electronics $106 Test Operations (one coil) $146 Grand Total $514

Total (FTEs)

Total ($K)

Project Management 0.23 $32.8 Test Cryostat Prep 0.74 $77.0 Cryo Integration Design 0.28 $32.7 Cryo Integration Fabrication 0.29 $33.6 Commissioning 0.16 $22.1 DAQ Fabrication and Installation 1.17 $126.6 Documentation 0.37 $45.9 Test Operations (one coil) 0.79 $85.9 Grand Total 4.02 $456.6

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TD/T&IPreliminary Schedule

• Attempts to meet MICE urgent programmatic needs• Cryostat pacing item: dished head assembly (at least 14 weeks)• Needs at least six weeks to install coil after LBNL delivers to FNAL

– Coil must be delivered to Fermilab by end of April 2012 at the latest• Assumes availability of skilled resources (4 FTEs in 6 months!)• This schedule will be very tough to meet!

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TD/T&ISummary

• All elements are in place to proceed with a MICE CC Test Stand installation at CHL.

• Detailed design in progress, and procurement of long lead items started.

• No technical issues: technology well understood and based on prior experience

• Critical project elements: tight schedule, complex interfaces, and availability of skilled people– Must be given very high priority at LBNL, FNAL/AD, and FNAL/TD– Must make sure scope is kept to a minimum– Still, schedule is very optimistic!

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