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MECO Magnet Vendor Briefing at MT18

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Title: MECO Magnet Vendor Briefing at MT18


1
MECO Magnet Vendor Briefing at MT-18
October 23, 2003 Bradford A. Smith, MIT-PSFC MECO
Magnet Subsystem Manager
2
Outline of Topics
  • Conceptual design overview
  • A few words about procurement
  • Draft SOW overview
  • Magnet Work Breakdown Structure (WBS)

3
Conceptual Design Status
  • MIT-PSFC completed in Feb02 a conceptual design
    for the magnet system with a successful final
    review by a national review committee.
  • Conceptual design effort also included a detailed
    cost and schedule estimate for final design and
    fabrication
  • CDR Chapters

1. Introduction and summary 2. Interfaces 3.
Field specs and field matching 4. Conductor
design 5. Insulation design 6. Joint design 7.
Current lead and bus bar design 8. Quench
detection system 9. Quench protection system
10. Power supplies, dump resistors and
switches 11. Structural design criteria 12. PS
system stress analysis 13. TS system stress
analysis 14. DS system stress analysis 15.
Cryogenics system design 16. Magnet assembly 17.
Magnet installation
Available http//meco.ps.uci.edu/MIT_MECO_CDR.pd
f
4
System Overview
29,000 kg 28,000 kg
53,000 kg
53,000 kg
5
Magnet Interfaces
  • Current magnet interface information is available
    by WBS at
  • http//meco.ps.uci.edu/ref_design/ref_design.html

6
Field Requirements
  • Magnetic field varies more or less monotonically
    from 5 T at the high field end of the PS to 1 T
    at the low field end of the DS.
  • Field matching is required over a curvilinear
    cylindrical volume around the magnet axes as
    defined by a detailed specification.

Field specification characteristics
7
Field Solution Method
  • Postulate a set of n coils, coil builds and
    ampere-turns that might meet the field
    requirements.
  • Calculate fields at n points and influence
    coefficients for each coil at each point.
  • Calculate the field contributed by the iron.
  • Compare the field at n points against the field
    required by the specification.
  • Invert the influence coefficient matrix to obtain
    a corrected set of ampere-turns for each coil.
  • Check the field against the spec along three
    paths.
  • Iterate as required.
  • Final iteration and field calculation done with
    actual conductors, NI and builds

Field specification paths
8
Field Solution
  • A system of 94 solenoids, some with generally
    similar axial extent, but generally different
    radial builds meet the field requirement.
  • Coils are powered in 6 sets
  • PS 3500 A
  • TS13u 1500 A
  • TS2 4000 A
  • TS3d5 1500 A
  • TS4 4000 A
  • DS 4000 A
  • Conductor placement tolerance study indicated
    maximum current limits for TS and DS coils.
  • TS Straight sections 1500 A
  • TS Bends 4000 A
  • DS 4000 A

9
Conductors 1
  • MECO has permission to draw from existing
    inventories of SSC inner and outer cable
  • Conceptual design focused on and succeeded in
    achieving a design with acceptable margins using
    SSC cables

10
Conductors 2
  • Design guidelines
  • Fraction of critical ? 0.65 (will be revised to
    ? 0.4), and
  • Temperature Margin ? 1.5 K
  • SSC cables will be soldered into half-hard copper
    channels to meet protection guidelines (Max V 2
    kV, Max T 150 K).
  • PS is subject to nuclear heat load

Coil boundary (1st PS coil)
He
He
Contours of constant temperature margin in high
field PS coil
11
Conductors 3
PS 3500 A
  • Current limited by nuclear heating and
    temperature margin
  • 41 km of SSC Inner Cable (includes 25 overage)
  • fc 0.31
  • Bmax 5.9 T

TS 1500 4000 A
  • Current limited by conductor placement tolerances
  • 30 km of SSC Outer Cable (includes 25 overage)
  • fc 0.12, 0.28 respectively
  • Bmax 3.5, 2.8 T, respectively

DS 4000 A
  • Current limited by conductor placement tolerances
  • 30 km of SSC Outer Cable (includes 25 overage)
  • fc 0.26
  • Bmax 2.03 T

12
Electrical Joints
  • Joints are lap solder joints
  • Joints must meet the same margin requirements as
    the conductor
  • Fraction of critical current ? 0.65 (? 0.4
    when updated)
  • Temperature Margin ? 1.5 K
  • Conceptual design showed these margins can be
    achieved with the proper choice of solders and
    overlap lengths
  • Channel solder 60Sn-40Pb
  • Hands solder 44In-42Sn-14Cd (Indalloy 8)
  • Overlap length 2 cable twist pitches (19 cm)

13
Insulation
  • Turn ground insulation is epoxy impregnated
  • Turn insulation
  • 1-mil, half-lapped Kapton 3 mil, half-lapped
    fiberglass (S-glass in PS)
  • Voltage stress is about 10 V/mil on dump, max.
    for combined thickness
  • Ground insulation
  • Turn insulation plus 40 mil (1 mm) of fiberglass
    (S-glass in PS)
  • Voltage stress is about 40 V/mil on dump
  • PS Insulation must be designed to withstand
    nominal 30 Mrad
  • Radiation level is not significant for insulation
    compressive or shear strength.
  • Gas evolution deserves to be minimized.
  • Industrial study by Cryogenic Materials, Inc.
    recommended an epoxy system with the following
    components and cure
  • DGEBF resin, 90 ppw, Vatico (Ciba Geigy) GY282
  • PPGDGE toughener, 10 ppw, Dow Chemical DER 732
  • DETD hardener, 26 ppw, Vantico (Ciba Geigy)
    HY5200
  • Gel at 90 C for 15 hours
  • Cure at 130 C for 15 hours

14
Quench Detection and Protection
  • Because all coil inductances are generally not
    alike, a digital quench detection system is
    proposed.
  • Each coil and coil-coil joint is voltage tapped.
  • In addition, all coil currents are monitored and
    dI/dt values are calculated.
  • System calibration is performed at installation
    during charge and discharge.
  • External dump minimizes helium loss and recovery
    times
  • MIT quench code (SOLQUENCH) has been run on the
    highest field coils in each of the PS, TS and DS
    temperature distributions are output to ANSYS for
    structural analysis.
  • Maximum hot spot temperature and maximum voltage
    requirements are met, while stresses and
    temperatures remain below allowables.

15
Structural Design and Criteria
Overview
  • MECO magnet system is divided into 4 magnet
    assemblies, each with its own cryostat PS, TSu,
    TSd, and DS.
  • Division is based on shipping limitations and
    natural boundaries formed by each magnets
    function.
  • Loads between assemblies are reacted through
    their respective cold mass supports to the
    facility foundation.
  • Any or all coil groups may be energized
  • Warm bores may be at atmosphere or vacuum

Design criteria
  • Combination of fusion and ASME criteria are used
    for guidance in coil structural design.
  • Fusion criteria allow primary membrane stress to
    be based on the lesser of 2/3 Yield (Sy) or ½
    Ultimate (Su) when coils are supported by cases.
  • Otherwise ASME code criteria are used
  • Bases primary stress on 1/3 Su
  • Bending discontinuity and secondary stresses
  • Bolting and column buckling guidance is taken
    from AISC
  • Sy and Su are taken at the loaded temperature

16
Coil Structures
  • Production Solenoid (epoxy impregnated coils,
    bath cooled)
  • Outer Al shells provide hoop load support
  • Spherical-end rods take TS attractive loads
  • He can designed for 5 atm (quench)
  • Transport Solenoid (epoxy impregnated,
    conduction cooled)
  • Coils are wound outside H-shaped SS mandrels
  • Horizontal V formed by spherical-end-rod pair
    restricts horizontal motion at Be window
  • Mid-span rod reacts centering load and is
    designed for tension only
  • Vertical V spans proton beam port, provides
    lateral restraint and assists with gravity load
  • Detector Solenoid (epoxy impregnated, conduction
    cooled)
  • Uses spherical-end rods and H-shaped SS mandrels
    like TS

17
Cryostats and Cryogenics
All cryostats have stainless steel vacuum shells
and LN2-cooled thermal radiation shields.
  • Production solenoid
  • Natural convection/force-cooled with 6700 liter
    LHe volume to safely remove 192 W of nuclear heat
    load at 4.5 K
  • 25 cm diameter quench vent stack keeps quench
    pressure below 5 atmospheres
  • Transport and detector solenoids
  • Lack of nuclear heat load enables conduction
    cooling
  • Inner and outer copper shells intercept radiation
    heat load and take it to He-traced copper heat
    sinks at the top of each coil

18
Cryogenic Heat Loads
Supports

8.0


Valves

2.99



Vacuum separators

0.86


Therma
l radiation from 80 K

3.28


High energy radiation

192


Conductor electrical joints (qty 10)

1.24


Current leads


11.2
PS dewar


1.3
GRAND TOTALS

269.31

61.8
19
Cryogenic Flow Diagram
  • Current plan is to purchase a new
    refrigerator/liquefier to a spec developed by the
    magnet Vendor.
  • System is designed to be flexible and accommodate
    all modes of operation

20
Conclusions on Conceptual Design
  • Feasibility has been demonstrated.
  • Review (February 2002) was successful.
  • Led to further specific industrial studies that
    have been completed to reduce risk.
  • Insulation study
  • Refrigerator/liquefier study
  • Winding and impregnation approach
  • Magnet Tech Spec and SOW for procurement is being
    drafted.
  • Safety review studies have been initiated at BNL.
  • Results from Conceptual Design, Industrial and
    Safety Studies will be integrated into the Magnet
    Technical Specification and SOW for Final Design,
    Manufacturing, Installation and Commissioning.

21
A Few Words about Procurement
  • Draft RFP
  • Based on draft technical and interface
    requirements.
  • Will be used to initiate response from industry
  • Contracting terms
  • Need for clarification
  • Final RFP
  • Based on final technical and interface
    requirements
  • Clarified technical and contractual requirements.

22
Draft SOW - Overview
  • Items furnished by MECO project
  • SSC cable
  • General Responsibilities of the Vendor
  • Deliverables with the proposal
  • Final design
  • Fabrication
  • Installation
  • Acceptance test
  • Reporting

23
General Responsibilities of the Vendor
  • The Vendor shall, unless otherwise noted, furnish
    all labor, materials, equipment and facilities to
    design, fabricate, assemble, install and test the
    MECO magnet system in accordance with the
    SOW/spec document.
  • Magnet system conductor, coils, cold structure,
    cryostats, cold-to-warm and warm supports, PS and
    DS iron returns, bus and leads, control dewars,
    power supplies, quench detection and protection
    systems, cryogenic valves and piping, cryostat
    vacuum equipment, instrumentation and controls
  • Installation/acceptance test site Brookhaven
    National Laboratory
  • The Vendor shall supply all documentation
    required in the specification.

24
Preliminary Magnet WBS
25
PS Magnet WBS (Lower Level Sample)
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