HINS Linac Focusing Channel

1
HINS Linac Focusing Channel

• CH Section Solenoid
• Preparations to Production

2
Production Scope

• Four types of cryostats by length
• Two types of cryostats by number of leads (with
  or without correctors)
• With spares
• type 1 -- 6
• type 1C -- 3
• type 2C -- 5
• type 3 -- 5
• type 4 -- 3
• type 4C -- 3
• Totally 25 plus two spare cold masses

3
Strand Availability

• We are expecting 17 km of 0.8 mm strand from
  Oxford in the end of April.
• The total need of strand for this part of the
  front end is 0.6 km x 30 18 km.
• Two cold masses have been already built and we
  still have some strand to build another four
  solenoids.
• 0.6 mm strand for bucking coils is readily
  available from Oxford and is not going to be a
  restricting factor.

4
Stages of fabrication

• - coil winding
• - coil impregnation
• - cold mass assembly
• - cold mass testing
• - cryostat assembly
• - final assembly testing

5
Production Pre-Requisites

• Fabricate and test cold masses for pre-production
  solenoids two with correction dipoles and two
  w/o correctors
• Add LHe vessels to some of the tested solenoids
  and test the cold masses with LHe vessels
• Make final corrections to the cold mass drawings
• Assemble existing and tested cold masses (with
  LHe vessels) into a cryostat. Test the assemblies
  using a devoted test stand (to be organized).

6
Part Procurement

• Allow 2 month for parts to start arriving
  after an order has been placed. Procurement of
  some critical parts can be expedited. Help of the
  IB-2 production group can be useful to follow
  orders.
• With some attention to the issue, winding can
  start in July

7
Fabrication time
8
Time Saving Options

• Wind coils in batches
• Impregnate and cure several coils in one cycle
  (several sets of winding tooling is needed)
• Test several solenoids in one cooling cycle
• Assemble solenoids in batches
• Make job in parallel, not in series

9
Needed Resources

• 1. Fabrication teem should consist of three
  experienced technicians working under T.Ws
  supervision
• - winding (qualification of Pat Sanches or
  Chuck Pribyl)
• - impregnation (Dave Burk or Juniar Jones)
• - assembly (Dan Assel, Bill Robatzek)

Expected average output 1 cold mass per week
10
Needed Resources (cont)

• 2. Access to stand 3 with some setup help
  provided as needed by Charlie and Fred (1 day a
  week or so)
• 3. A person from test department to make cold
  mass and assembled solenoid tests (1 day a week
  or so)
• 4. A stand for testing solenoids assembled in
  cryostats must be set.

11
Sample production schedule
After a 6-week delay we can have one system per
week of output
12
Costs

• Cryostats 27K x 25 675 K
• Cold masses 7K x 40 280 K
• Assembly tooling 20K
• LHe (if in Dewars) 2K x 2 x 20 80K (cold
  mass)
• LHe cost if in Duars 2K x 40 80K (assembled
  system)
• Personnel salary 300K
• Total 1.4M

13
Other production options

• Winding and impregnation by a vendor, testing and
  the final assembly at TD
• Cold mass fabrication and testing by a vendor,
  final assembly and testing at TD
• Focusing solenoid fabrication and testing by a
  vendor, retesting at TD
• Focusing Solenoids and Power System outsourced to
  a vendor

14
Power and Protection

• Option 1
• Each current circuit is powered by its own
  power supply.
• Typical size of one 6 V, 300 A power supply is
  400 x 400 x 100 mm3. Installation power is 2 kW.
  One rack can hold 5 power supplies (cooling
  problem). We need 35 channels for the CH section,
  so we need a space for 7 racks. Many 500 A cables
  must go from each rack.
• Control panel must be in the control room, so
  additional cabling is needed.

15
Power and Protection

• Option 2
• Two centralized 6 V, 6 kA power supplies plus
  6kA Al buses. Locally installed transistor
  regulators provide current for each current
  circuit. The regulators are controlled from one
  low-power rack in the control room (35 channels
  6 blocks by 6 channels each).
• The number of identical regulators makes it
  easy to design and cheap to fabricate. The system
  can be duplicated for solenoids in the s/c
  sections of the linac.

16
Current Regulator
17
Proposed Action Items

• Attempt to find vendors that can make solenoids
  or cold masses
• Understand options for powering the solenoids
  (B. Webber and ADs Electrical Department)
• Try to assign a priority to the job so that the
  needed resources could be found
• Continue with the pre-production program