Dogleg Review 2-1-131 Dogleg Upgrade Tommy Hiatt Magnet Modifications

Dogleg Review 2-1-13 1

Dogleg Upgrade

Tommy HiattMagnet Modifications


Outline

• Requirements

• Design Approach

• Mechanical Design

• Modeling

• Performance

• Schedule

• Summary


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


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


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


Mechanical Design

• Modify Dog3 BX

– Use larger cross section coil (BZ conductor)

– No coil pocket mods necessary

– No lengthening steel added

• Modify Dog4 BWs


– 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


– No coil pocket mods necessary

– Add ~60 cm of additional steel


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


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


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


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


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


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


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


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


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


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


Questions?


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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

Documents

Dogleg Review 2-1-131 Dogleg Upgrade Tommy Hiatt Magnet Modifications