Thomas Jefferson National Accelerator Facility Pg. 1 SHMS Status Hall C Users Feb. 2014 Paul...

Thomas Jefferson National Accelerator FacilityPg. 1

SHMS Status Hall C Users Feb. 2014

Paul Brindza


SHMS Construction Feb 13, 2014


SHMS Outline

• HB magnet construction• Q1 magnet construction• Dipole magnet construction• Q2Q3 magnet• JLAB magnet components• Hall C Infrastructure


HB Construction

• Coils complete and LHE tested• Helium vessel assembly underway

– Helium vessel backbone complete– Coil 1 installed, shimmed and welded in– Coil 2 installed, shimming underway

• LN2 shield sub-assemblies underway• Warm Yoke complete• Vacuum vessel components complete• Assembly of helium, vessel around coils has taken

longer than expected- current ETA is April 2014• Delivery to JLAB – August 2014• Monthly visits by JLAB to MSU to keep up pressure


Status of HB Manufacturing

First coil inserted in helium vessel (covered by middle plate)

Thermal shield test-fit onto Helium vessel.


Top vessel view in vertical position

Wiring from bottom through conduit to top, 5 mil kapton sheet between coil ends and retainers.

HB Helium Vessel



Hi-pot test at 1500+ V with back plate clamped

Lead out insulated



Back plate tack welded

Vessel repositioned for bottom coil shimming (bottom coil up)


HB Schedule


Bore of Q1 Magnet


Q1 Magnet Status

• Coils- complete and tested• Yoke- complete• Cold mass assembled and tested• Warm field mapping complete• Cryostat Components(Helium, LN2, Vacuum) complete• Helium vessel assembly around cold mass underway• LN2 shield and Vacuum vessel assembly TBD• Factory testing• Delivery to JLAB – July 2014


Yoke Containment Shells


Q1 He Vessel


Q1 LN2 Shield


Q1 OVC Vessel


Q1 Schedule


Q1 Magnet - Summary• Construction well-advanced.• Schedule risk being carefully monitored.

–60% of sub-contract is complete.–Good performance for the last 8 months.–Using incentives to advance delivery date.

• No known technical risks:–Typical manufacturing tasks and workmanship

remain.–QA and vendor oversight processes in place.


Dipole Q2Q3 Highlights Oct 2013- Feb 2014

• Site visits @ SigmaPhi Oct ,Nov ,Dec, Jan, Feb…..

near continuous presence by JLAB engineers• Q2Q3 FDR complete with punch list Oct 2013• Production Consolidation Equipment Operational• Dipole Prototype VPI completed Dec 13• Second winding station complete• Second source of coil spacers

delivering ~ 1 layer per week( see the video)• Conductor properties 300K and 4 K results including

shear measurements exceed requirements


Production Coil winding


Production coil 1st segment and spacer installed


Dipole Construction Underway

• First dipole production coil winding started Feb 17• First segment (25 turns) and spacer installed today• Second dipole production coil wind start March 12• Dipole cryostat at Chastigny and ASME overlay at

APAVE proceeding well• 4 K measurements of conductor compression

modulus excellent results 148MPA @ 4 K• 300 K improved measurements with extensometer

demonstrate that the initial “soft strain” was a measurement artifact. This makes the coil preload much easier and reduces the interference required.

• Shear measurements in reasonable agreement with JLAB/Hall B/Torus


Prototype Coil Results

• Winding– Techs, equipment and winding went well– late delivery of spacers caused delays

resolved with the second source– Coil Resistance and ringing tests results all OK– Equipment is sensitive to single shorted turn

• VPI– Equipment worked OK except for mold leaks which

allowed air intrusion causing some voids. Leaks were found and cause (rusty mandrel)eliminated.

– Mold release on coil spacers worked as planned– VPI process improvements to preclude a repeat

• Confidence high so proceed to production!!!!


Prototype in VPI Mold


24

Dipole prototype coil


25

VPI improvement

Objective N°1: Improve the impregnation qualityModifications implemented:1. Replace G10 sheet 0.2 mm by fiber glass cloth for easier resin flow2. Increase the number of holes in the G10 sheet (0.3 mm thickness)3. Sand blast mold for better vacuum seal 4. Tilt the mould (20-30°) to favor the resin flow in between the conductors5. Install the resin mixer above the mold to trap the air bubbles inside the

feed pipes6. Keep more pressure above the resin inside the malaxer to slow down the

impregnation7. Sequential injection8. Increase the curing duration to about 30h (cold point at 120°C hot point

at 135°C)Objective N°2: Make the resin less sensitive to crackingModifications Implemented:9. Improve the injection geometry: larger draft (30 degrees tilt)10.Add flexibilizer to the resin


Conductor testing

• Compressive stress strain results demonstrate that ALL dipole conductors have near identical properties- no need to sort conductor

• 300 K results from UBS lab using an extensometer demonstrate that the initial “soft strain” is a measurement artifact arising from surface defects and using platen travel- more good news!

• 4 K results demonstrate average compressive yield at 148 MPA as compared to 100 MPA stress levels at 11 Gev - adequate margin at operating current.

• Shear results to date indicate adequate margin. More measurements planned. Good agreement with JLAB measurements.


Compression results @ 300K


Test Instron at UBS with LVDT’s and Extensometer


4 K Conductor compression results from CEA/Saclay

Youngs Modulus(Gpa) Yield (MPA)

original 12 55

300K 21 110

77K 29 120

4K 22 148


Production consolidation equipment30 meters per hour


Production winding lines at SigmaPhi


Prototype in production oven


Dipole Schedule


Summary- SigmaPhi Magnets

• Production coil winding – coil 1 started Feb 17 – coil 2 March 12

• Coil spacer delivery solved by second source

delivery now one set per week• First double layer of production coils 1 and 2 will be

separately impregnated to verify VPI.• Dipole conductor mechanical property measurements

excellent results confirm adequate margins• Dipole delivery June 2015• Q2Q3 delivery Aug/Oct 2015


Magnet Components by JLAB

• HB/Q1/Q2/Q3/Dipole Conductor• Cryogenic Control Reservoir (5 magnets)

• Warm Yoke Steel (3 magnets); Q1 cold yoke by SMI; HB by MSU

• DC Power Systems (5 magnets)

• Instrument and Controls (5 magnets)

• Stands and Mounts (5 magnets)


Magnet Components by JlAB-complete

Contract Vendor Cost K$

Delivery Status Installationassembly

DC System Danfysik 922 Jan/Apr 2013 Complete March 2014

CryoReservoir Meyer Tool 1,067 Jan 2012 Complete At mag vendors

Current Leads AMI 94 Feb 2010 Complete At mag vendors

Controls &Software

JLAB 1,009 Oct 2013 CompleteTesting Underway

April 2014

Yoke Castings Ningbo-Jansen

1,298 Oct 2012 Complete NA

Yoke Machining

Craft Machine

125 June 2013 Complete April 2014

SC Cable SSC surplus

NA NA Complete NA

SC Cable Testing

BNL 91 Nov 2007 Complete NA

Copper Channel

FMM 266 Feb 2012 Complete NA

Redraw Channel

FMM 15 Feb 2012 Complete NA

Wave solder AES 284 Oct 2012 Complete At mag vendors

Magnet supports

Various 154 Oct 2012 Complete Installed


SHMS Cryo System

• Re-use G0 transfer line- Mods by Hall C Complete• Re-use G0 flex gas return lines- Ready to install• New flex cryo-line support – Installation March 2014• New SHMS transfer line- Installed Feb 2014• New U-tubes,L-tubes magnet connections complete,

delivered and tested at JLAB• Warm gas return system manifolds- complete• Warm gas return system- installation underway


SHMS Installation

• Rails and mounts complete• Steel Structure complete• Shield House concrete – last pour Friday Feb 14, 2014• Equipment deck 99% complete• Magnet stands installed• SHMS transfer line installed• Target access platform contracted• Shield house interior shielding contracted• Shield house raised floor- bids in-award soon• Electrical and LCW installation underway


SHMS Summary

• All magnets in production• Delivery of last magnet (Q3) still very tight• Issues with conductor properties resolved• JLAB magnet components all complete and delivered

or installed or awaiting installation• SHMS Cryo system all components on site and tested

transfer line installed• SHMS assembly in Hall C proceeding very well• First magnet delivery July 2014 and we will be ready


Happy Days!!!

Thomas Jefferson National Accelerator Facility Pg. 1 SHMS Status Hall C Users Feb. 2014 Paul...

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