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THE SUPER-FRS DIPOLE
PROJECT
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Super-FRS Dipôle « Vendor information meeting » | Lionel Quettier
CONTRIBUTION CEA/Irfu
CEA/Irfu contribution within the framework
of the"Cooperation Agreement on the French
contribution to the construction of the
international Facility for Antiproton and Ion
Research in Europe (FAIR) and on the
German contribution to the construction of the
SPIRAL2 Facility at GANIL”
2
CONTRIBUTION CEA/Irfu
•
CEA is responsible for the delivery of all 24 superferric SC-dipole magnets
– 3 WPs
–
–
–
–
Management
Review of the existing design of the magnet
Functional specification and conceptual drawings production
Follow-up of the project including the production
The information meeting organized today in related to WP1 only.
3
DIPOLES FOR THE SUPER-FRS
Branched dipole
Dipole Type
D2
Number of dipoles
Deflection angle
Bending radius
Effective length
Good field region
(horizontal with sagitta)
Good field region
(vertical)
Integral field quality
(relative)
3
11
12,5
2400
degree
m
mm
mm
mm
D3,
standard
18
9,75
12,5
2127
D3,
branch
3
9,75
12,5
2127
±190 ±29 ±190 ±23 ±190 ±23
±70
±70
±70
±3E-4
±3E-4
±3E-4
4
WP1
•
WP1 covers the following items:
– 3 long superferric dipoles with a bending radius of 11° (type D2 design)
– 21 short superferric dipoles with a bending radius of 9,75° (type D3 design)
• 18 short superferric
• 3 special short superferric dipoles, having in addition a straight beam exit (“branched design”)
– 1 spare cryostat including the cold mass for the long dipole
– 1 spare cryostat including the cold mass for the short dipole
•
The electrical circuit and the external instrumentation are not part of the work package.
•
The spare cryostats are included in the engineering work.
•
The three special dipoles require special study including open coils and special branching vacuum
chambers. Their realization requires yokes and coils from the serial production.
•
Each magnet must be equipped with an Hall probe (exact location to be determined by CEA).
•
The magnet testing is organized by GSI and realized by CERN. CEA/Saclay will participate to the
commissioning and to the magnetic measurements of the magnets.
5
PRODUCT BREAKDOWN STRUCTURE
Super-FRS Dipole Magnet
Cryogenics
distribution
Magnet
Electrical
circuit
MCS/MSS
Conductor
MCS
Coils
MSS
Cryostat
Internal
cryogenics
External
instrumentation
Yoke
FAIR/GSI
Current leads
Assembly
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PROJET ORGANISATION @ CEA
SuperFRS Dipoles Project
Irfu / SACM - SIS
QA/QC - Documentation
L. Vieillard / J. Munoz Garcia
Planification
J.D. Douarin
Design Analysis
Magnetic design
L. Quettier / C. Pes
Cooperation Agreement
“French contribution to the
SuperFRS components”
GSI-FAIR
M.Winkler
Project Manager
L. Quettier
GSI
H. Mueller
Technical and Scientific Advisor
C. Mayri
Fabrication
Testing
Technical specifications
and interfaces with GSI/CERN
L. Quettier / J. Munoz Garcia
Coordination
L. Quettier
GSI
P. Schnitzer
Cryogenic design and Vaccum
C. Mayri / W. Abdel Maksoud
Quench analysis
L. Quettier / F.P. Juster
Coordination with GSI/FAIR
for the call for tender
L. Quettier
Conductor
C. Berriaud
Design office
P. Manil
Mechanical design
Z.Sun/P. Graffin
Internal instrumentation
L. Quettier / J. Munoz Garcia
Testing at CERN
L. Quettier / J. Munoz Garcia
Industrial follow-up
V. Hennion
7
DESIGN EVALUATION
Design work started @ CEA in January 2014
Reviews of the design organized by FAIR/GSI (”normal design”)
• PDR hold July, 4th 2014
• FDR planned in November 2014
Review committee:
External reviewers:
Al Zeller (MSU)
Tom Taylor (CERN)
Luigi Serio (CERN)
GSI members
8
General design of the magnet
•
Superferric magnet – iron dominated - warm iron yoke and warm bore
•
The magnet is made of two SC coils with a trapezoidal shape
52,1mm x 48,8 mm cross-section
560 turns (28 x 20)
•
Wire in channel NbTi conductor (7,5km per coil is required)
1,93mm x1,17 mm
Copper/non copper ratio 9,9
55 filaments - 66µm diameter.
•
Vacuum impregnated
9
General design of the magnet
The two coils are integrated into a common stainless steel case (top and bottom covers are welded):
•
The common casing is used to withstand the magnetic forces acting on the coils
•
The casing is also used as helium reservoir.
10
General design of the magnet
•
The coil mass is integrated into a cryostat equipped with a thermal shield
•
The cold mass is supported by 14 tie rods (prototype version).
•
The cryostat shape is tailored to match the coil shape
and to keep an open space for the beam and the yoke.
11
General design of the magnet
•
•
•
A yoke installed around the cryostat is also contributing to the required magnetic field map
Yoke is made of thin sheets of steel
One air trim slot to improve field quality
Cross section of the lamination sheet
BH curve of iron
(low carbon steel)
12
Prototype magnet
A prototype was built by FAIR China Group
• Inst. of Plasma Physics, Hefei: cryostat and coil
• Inst. of Electrical Engineering, Beijing: conceptual design
• Inst. of Modern Physics, Lanzhou: yoke and tests
Visit to IMP Lanzhou of Irfu and GSI people
in April 2014 to review the prototype design and discuss
the testing results
13
Design of the prototype magnet
Prototype magnet specification
Design
Superferric H-type
Min / Max dipole field
0,15 T / 1,6 T
Bending angle
15°
Curvature radius
8,125 m
Effective path length
2,126
Useable horizontal aperture
±190 mm
Sagitta
70 mm
Total horizontal good field area
±225 mm
Useable vertical gap height
±70 mm
Vertical pole gap height
±85 mm
Integral field quality (relative)
Δ∫ Bdl/∫ Bdl
Yoke
±3x10-4
Courtesy IMP
Cold mass testing
14
Tests of the prototype @ IMP
Magnetic flux:
Bgap = 1.6 T @ I = 232 A
(design value: I = 230 A)
Required field quality:
DB/B = 310-4
(over 190 mm, 5 mm steps)
Measurement (cold test)
Courtesy IMP
-4
integral field homogeneity [10 ]
3
• field quality tests successful
• quench tests successful
• calculated: maximum hot spot ~100K,
maximum coil to ground voltage ~300V
• stored energy ≈ 400 kJ
• inductance ≈ 15 H
• heat load @ 4.2 K: 6.8-8.1 W (0-232A)
2
1
0
-1
1.6 T
1.3 T
0.8 T
0.16 T
-2
-3
-200
-100
0
100
radius shift [mm]
200
15
Required modifications
•
Motion of the cryostat observed during the tests
I = 278 A
I=0A
Courtesy IMP
16
Required modifications
•
Ensure the lack of physical interference
between two successive magnets
•
Modifications on the magnet/yoke will be required for the branched dipole not studied yet
•
The cryogenic interfaces must be modified for the testing @ CERN and for the local
cryogenics of the Super-FRS tunnel of FAIR
17
Magnet design
Conceptual design for version D3 (standard dipole - short version) – main parameters
Superconducting strands
NbTi
Dimension of conductor
1.432.23 mm2
Number of Sc filaments
55
Ratio of Cu and NbTi
10.7
RRR of Cu in core wire
133
Number of turns
28 x 20 turns
Operating current
230 A
Central field @ 230 A
1,6 T
Coil dimensions
1133 mm (medium length) x 2256 mm
Bending angle
9,75°
Curvature radius
12,5 m
Section size of coil
52.148.8 mm2
Coil (per coil)
155 kg
Coil casing
755 kg
Cold mass
1065 kg
Peak field on the conductor
@ 230 A
1,3 T
Thermal shield
155 kg
Inductance @ 230 A
18,3 H
Vacuum vessel
650 kg
Stored energy @ 230 A
484 kJ
Vacuum vessel assembly
1870 kg
540 A
Yoke
46 tons
Critical current density for
wire @ 5 T @4,2 K
Overall mass
47 tons
Length of conductor per coil
7,5 km
Ground insulation
requirements and tests
3 kV
18
Magnet design
Magnet operation:
•
The dipoles are DC magnets and will be submitted to 3 triangular cycles in a row (from 0 to
maximum field) with a cycle period of 240 s (ramp duration of 120s ). This requirement gives
the possibility to change the separation cuts in the Super-FRS in acceptable time period.
•
The three dipoles of one stage will be powered in series. A small power supply for small
adjustments is foreseen for each single magnet. Therefore two power cables have to be
connected to each current lead.
19
Magnet design
•
Different curvature radii
Good field region is +/- 190mm in the horizontal direction and +/- 70 mm in the vertical
direction.
Specification:
Integral field quality (relative)
Δ∫ Bdl/∫ Bdl
±3x10-4
20
Magnet design
•
End chamfer design (picture taken during the tests with a resistive coil)
Courtesy IMP
•
Prototype design was updated with faceted end chamfers shape:
– To take into account the new bending angle of 9,75° and 11°
– To keep the field integral homogeneity in the useful area from B=0,15T to B=1,6T
21
Magnet design
New mechanical design with reduced number of rigid cold to warm supports and transverse sliding guides
22
Magnet design
Studies performed by CEA (main results will be included in the design report that will be part of the
bidding package)
•
Mechanical design (calculations including gravity, cooldown, vacuum, and magnetic forces)
•
Quench analysis
•
Cryogenic design
•
Tolerance analysis:
– Influence on the field quality of the coil positioning
– Influence on the field quality of the pole geometry
– Tolerances analysis (coil and yoke) also performed to verify the mechanical forces (loss of the
symmetries)
23
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage 1: Setting of the coil casing on mounting supports.
Lower side
Upper side.
Studs supporting the coil casing.
24
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage 2: Integration of
the lower coil into the coil casing.
Lower Coil
Shim made of G10
Output electrical conductors.
25
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage 3: Tightening the coils used with joints.
integration of external faces
Clamping forces
Welding the outer faces
Welding the outer faces
26
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage4: Welding of the lower cover
Helium volume inside the vessel is 28 liters.
Lower cover
Output electrical conductors.
Studs supporting the coil casing.
27
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage5: Rotation of the assembly
Output electrical conductors.
Lower cover
Studs supporting the coil casing.
28
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage 6: Integration and setting of the upper coil.
Upper coil
Output electrical conductors.
Studs supporting the coil casing.
Shim made of G10
Passage for the connection
between the coils (helium and conductors)
29
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage 7: Tightening the coils used with joints.
integration of external faces.
Clamping forces
Welding the outer faces
Welding the outer faces
30
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage8: Welding of the upper cover and of the Helium tank
Helium tank
Output electrical conductors.
Top cover
Studs supporting the coil casing.
Implementation of accessories in the Helium tank.
31
SUPER FRS DIPOLE – ASSEMBLY SCENARIO
Stage9: Welding of the helium pipe.
Helium pipe
Mass of the coil casing = 755 Kg
Mass of the two coils = 310 Kg
Studs supporting the coil casing.
32
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage10: Assembly of the thermal shield.
Integration shims G10
The thickness of the thermal shield is 2 mm.
Integration shims G10
Studs supporting the thermal shield.
33
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 11: Temporary pads used to install the coil casing
34
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 12: Integration of the coil casing into the thermal shield.
Coils casing
Thermal shield
Studs supporting the coil casing.
Studs supporting the thermal shield.
35
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 13: Closure of the thermal shield
thermal shield covers
thermal shield
chimney
Sides
Studs supporting the
Thermal shield
Studs supporting the coils casing
Setting the screen relative to the coil casing
36
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 14: Cooling tubes spot welding
Mass of thermal shield = 155 Kg
Cooling
Flex clamp
37
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 15: Installation of the superinsulation outside the thermal shield.
Insulation thickness of 5 mm.
38
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 16: vacuum vessel assembly
vacuum vessel thickness of 8 mm.
Studs supporting the vacuum vessel
39
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 17: Integration of the thermal shield and the coil casing inside the vacuum vessel
Sling for handling
40
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 16: Bolting of interface pads for cold to warm supports.
Bolted flanges
Interface pads for cold to warm supports.
41
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 17:Installation and adjustment of the coils casing
depending on the vacuum vessel.
Mounting guiding system
Mounting and welding of warm support
42
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 18:.
welding of the cover
welding of the slot sets
Mass of vacuum vessel assembly = 1870 Kg
43
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 19: Installation of the chimney with its accessories
chimney
44
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 20: Mounting of the vacuum vessel in the lower yoke
vacuum vessel assembly
Lower YOKE
45
SFRS DIPOLE – SCENARIO ASSEMBLY
Stage 20: Mounting of upper yoke
upper yoke
Lower yoke
vacuum vessel assembly
46
Branched magnet design
Dipole Type
Number of dipoles
Deflection angle
Bending radius
Effective length
Good field region
(horizontal with sagitta)
Good field region
(vertical)
Integral field quality
(relative)
•
Same SC coils used for the standard D3 magnets
•
Modification of the coil case (not compatible with the new design)
•
Modification of the cryostat
•
Modification of the iron yoke
•
Dedicated vacuum chambers
degree
m
mm
mm
mm
D3,
standard
18
9,75
12,5
2127
D3,
branch
3
9,75
12,5
2127
±190 ±23 ±190 ±23
±70
±70
±3E-4
±3E-4
No detailed studies at this stage
47