LARP LQX and MQX Cold Mass Testing at Fermilab

Overview and Required Test Stand Upgrades

Cosmore D. Sylvester

QXF Cold Mass Test Program

• To satisfy the Functional Requirements our plan is to:– Implement required upgrades (Cryo, Mech, Power & DAQ)– Test Prototype LQXF cold masses (4.8 m) on the Upgraded

Test Stand (starting in Nov. 2015)– Test Production MQXF cold masses (20 total) on the

Upgraded Stand (starting in Nov. 2018)– Complete the Production testing by “early 2021”

Overview of Existing Test Stand

• Magnet Support Stand outfitted with utilities (compressed air, LCW, cryogens, turbo pump, etc.)

• 30kA DC Power Supply (30V)• 3 ea 15kA Vapor cooled Power Leads • ASME Code Stamped Feedbox with

helium vessel with interconnect features for LHC IR Quad Magnet Interfaces at the Lead and Return End

• Return End Can with additional Strain Gage Instrumentation readouts

• Warm Finger (60mm OD and 45mm ID) and Quench Antenna array

• Magnetic Meas. Probes (43mm OD) Translation and Drive Systems

• Rotating Probes for Integral and z-scan Measurements of the Cold mass

• Interfaces for SSW Measurements

Existing Test Stand (for LHC IR Quads)

After a magnet is installed on the test stand and aligned to the Feedbox:• Solder Power connections and insulate• Connect Instrumentation• Connect Piping and Perform Leak check of piping

connections• Insulate interconnects, add shield section and its

insulation• Close up interconnects and evacuate cryostat• Perform pre-cooldown electrical checkout• Cooldown• Test• Warm up and disassemble

Mechanical Upgrade Items

• Replace existing 15kA power leads with 30kA Lead assembly and LTS section; if final plan is to test two cold masses in a single cryostat – 3 leads are required

• Design and build a Warm Finger (WF) assembly with embedded Quench Antenna (QA) System and other Instrumentation (RTDs, Heaters)

• Design and build Magnetic Measurement Probe for 150 mm aperture magnet; preliminary sizing indicate a probe diameter of 100mm

• Modify the Return End (RE) Can to facilitate 150 mm aperture WF Assembly• Refurbish and commission the Magnetic Measurement Table with Probe

Translation System• Design and fabricate miscellaneous tooling and fixtures• Purchase and Install Vacuum Pump Cart for Insulating Vacuum Pumpdown• Design and build an Adapter Box to accommodate the interfaces between

the existing Feedbox and the LQXF/MQXF magnets.

Feedbox Lambda Plate Instrumentation

• Differential Pressure transducers• LTS Bus feedthrough• Liquid Level Sensors• Potted Instrumentation feedthrough• Instrumentation Connector

Terminations• Current Limiting Resistors• Check Valves• Lambda Plate tie-down rods

WF and Imbedded QA Assembly for LHC IR Quads

• Design and purchase multipole winding patterns on Kapton substrate• Install QA windings at preferred/optimized locations (center and ends) plus heaters

and RTDs• Terminate above elements to room temperature connectors• Design and build the WF assembly

Return End Can

• Disassemble and machine larger penetration to accommodate the WF and 100mm diameter measurement probe

• Reassemble unit and helium Leak check

Re-Usable Cryostat

• The plan is to use a re-usable cryostat to test all cold masses– Design and build a re-usable cryostats with:

• Vacuum Vessel• LN2 cooled Thermal shield and multilayer insulation (MLI)• Heat exchanger assembly• Magnet supports/suspension

– May need to purchase 2 cryostats to satisfy the magnet throughput

Power and Data Acquisition System

• Power System – 30kAmps vapor cooled leads– 1500 MCM cables– Stabilized LTS power bus

• Data Acquisition System– Plan to use existing system which

was used to test the IR quads with updated electronics and Instrumentation• Current Receivers• Isolation Amplifiers• Quench Management System• Slow Scan System• Replace, Repair, Calibrate

Instrumentation• Cabling and Connectors

Conceptual Layout for the Double Cold Mass w/WF and Probe Insertion from the RE

• For a long cryostat option will need to insert probe and warm finger from RE

• This is to avoid making modifications to the ASME Code Stamped vessel in the Feedbox

• Stop the probe shaft in the Interconnect region at Lead end

• Insert probe driveshaft for Feedbox end connect shaft sections at the lead end interconnect.

Cryogenicsby

Roger Rabehl

Test Stand Upgrade Cost (Labor plus M&S)

Description Engineer (m-wks)

Designer (m-wks)

Technician

(m-wks) M&S ($K)Project 12Cryogenic System 22.2 7 24 $99Feed Can 14 25.4 18 $161

Magnetic Meas. System 14 8.4 46 $68

Power System 2.5 1.5 $11

Quench Protection, DAQ upgrades 15 35 $134

Vacuum System $21Acceptance Test 9.5 12.5 $8Grand Total 89.2 40.8 137 501

Fully Loaded, no contingency ($) $1,854,540

Operations Cost - Prototypes

Description Engineer (p-wks) Labor (p-wks) M&S ($K)

Prototype (single cold mass) 5 32 $60

Fully loaded, no contingency ($) $230,768

Prototype (double cold mass) 9 48 $120

Fully loaded, no contingency ($) $338,886

Operations Cost - Single MQX Cold Mass

Description Engineer (p-wks) Labor (p-wks) M&S ($K)

Single cold mass option unit test 2.5 16 30

1st production 3.8 24 $45

2nd production 3.1 20 $37.5

Production 3-20 45 288 $540

TOTAL single cold mass (20 tests) 51.9 332 $622.5

Fully Loaded, no contingency ($) $2,394,218

Operations Cost – Double MQX Cold Mass

Description Engineer (p-wks) Labor (p-wks) M&S ($K)

Double cold mass option unit test 4.5 24 $60

1st production 6.8 36 $90

2nd production 5.6 30 $75

Production 3-10 36 192 $480

TOTAL doble cold mass (10 tests) 48.4 258 $645

Fully Loaded, no contingency ($) $2,104,506

Fixed and Operating (Variable) CostDescription Single Cold Mass Double Cold Mass

Fixed Cost QTY QTY

Test Stand Upgrade $1,854,540 $1,854,540

Re-Usable Cryostat 1 $986,297 $1,086,535

Total Fixed Cost $2,840,837 $2,941,075

Operating Cost

Cryostating Prototype 4 $578,854 $TBD

Prototype Test4 $923,072 $TBD

Cryostating Production 20 $2,894,272 10 $1,915,328

Production Test20 $2,394,218 10 $2,104,506

Total Operating Cost $6,790,416 $4,741,786

GRAND TOTAL $9,631,253 $7,682,866

Schedule to Prepare Test Stand

ID Task Name Duration Start Finish Predecessors

1 Stand Preparations 369 days Tue 4/1/14 Fri 8/28/152 Stand Disassembly 10 days Fri 10/10/14 Thu 10/23/143 Design and Fabricate Mechanical

Components360 days Mon 4/7/14 Fri 8/21/15

4 Assemble and Install Instrumentation120 days Thu 5/1/14 Wed 10/15/145 Valve and Instrument List 25 days Mon 7/14/14 Fri 8/15/146 Design and Fabricate an Interface Box80 days Mon 8/18/14 Fri 12/5/14 57 Vacuum System refurbishment 60 days Mon 12/8/14 Fri 2/27/15 68 Helium Temperature Control (HX

configuration) 25 days Mon 3/2/15 Fri 4/3/15 7

9 Quench Line Recovery Engineering and fabrication

25 days Mon 4/6/15 Fri 5/8/15 8

10 Cryogenic Controls 10 days Mon 5/11/15 Fri 5/22/15 911 Design and Fabricate re-usable Cryostat360 days Tue 4/1/14 Mon 8/17/1512 Perform Electrical Checkout of Stand 10 days Fri 6/5/15 Thu 6/18/1513 Develop Safety Documentation 60 days Mon 3/16/15 Fri 6/5/1514 Submit Safety Documentation to

Review Panel0 days Fri 6/5/15 Fri 6/5/15 13

15 Complete Cryogenic Safety review 0 days Mon 7/13/15 Mon 7/13/15 1616 Receive Recommendation to

operate (from Safety Panel)0 days Mon 7/13/15 Mon 7/13/15

17 Receive Operational Readiness Clearance (ORC)

0 days Mon 8/3/15 Mon 8/3/15

18 Acceptance test and Commissioning 10 days Mon 8/17/15 Fri 8/28/15

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Schedule for LQXF (prototypes) Testing

Schedule for MQXF TestingID Task Name Duration Start Finish

1 MQXF Production Testing 630 days Mon 10/1/18 Fri 3/19/212 Assemble MQXF01 30 days Mon 10/1/18 Fri 11/9/183 Deliver to Test Stand 0 days Fri 11/9/18 Fri 11/9/184 Test MQXF01 30 days Mon 11/12/18Fri 12/28/185 Assemble MQXF02 30 days Mon 11/12/18Fri 12/28/186 Deliver to Test Stand 0 days Fri 12/28/18 Fri 12/28/187 Test MQXF02 30 days Mon 12/31/18Fri 2/8/198 Assemble MQXF03 30 days Mon 12/31/18Fri 2/8/199 Deliver to Test Stand 0 days Fri 2/8/19 Fri 2/8/19

10 Test MQXF03 30 days Mon 2/11/19 Fri 3/22/1911 Assemble MQXF04 30 days Mon 2/11/19 Fri 3/22/1912 Deliver to Test Stand 0 days Fri 3/22/19 Fri 3/22/1913 Test MQXF04 30 days Mon 3/25/19 Fri 5/3/1914 Assemble MQXF05 30 days Mon 3/25/19 Fri 5/3/1915 Deliver to Test Stand 0 days Fri 5/3/19 Fri 5/3/1916 Test MQXF05 30 days Mon 5/6/19 Fri 6/14/1917 Assemble MQXF06 30 days Mon 5/6/19 Fri 6/14/1918 Deliver to Test Stand 0 days Fri 6/14/19 Fri 6/14/1919 Test MQXF06 30 days Mon 6/17/19 Fri 7/26/1920 Assemble MQXF07 30 days Mon 6/17/19 Fri 7/26/1921 Deliver to Test Stand 0 days Fri 7/26/19 Fri 7/26/1922 Test MQXF07 30 days Mon 7/29/19 Fri 9/6/1923 Assemble MQXF08 30 days Mon 7/29/19 Fri 9/6/1924 Deliver to Test Stand 0 days Fri 9/6/19 Fri 9/6/1925 Test MQXF08 30 days Mon 9/9/19 Fri 10/18/1926 Assemble MQXF09 30 days Mon 9/9/19 Fri 10/18/1927 Deliver to Test Stand 0 days Fri 10/18/19 Fri 10/18/1928 Test MQXF09 30 days Mon 10/21/19Tue 12/3/1929 Assemble MQXF10 30 days Mon 10/21/19Tue 12/3/1930 Deliver to Test Stand 0 days Tue 12/3/19 Tue 12/3/1931 Test MQXF10 30 days Wed 12/4/19 Mon 1/20/2032 Assemble MQXF11 30 days Wed 12/4/19 Mon 1/20/2033 Deliver to Test Stand 0 days Mon 1/20/20 Mon 1/20/2034 Test MQXF11 30 days Tue 1/21/20 Mon 3/2/2035 Assemble MQXF12 30 days Tue 1/21/20 Mon 3/2/2036 Deliver to Test Stand 0 days Mon 3/2/20 Mon 3/2/2037 Test MQXF12 30 days Tue 3/3/20 Mon 4/13/2038 Assemble MQXF13 30 days Tue 3/3/20 Mon 4/13/2039 Deliver to Test Stand 0 days Mon 4/13/20 Mon 4/13/2040 Test MQXF13 30 days Tue 4/14/20 Mon 5/25/2041 Assemble MQXF14 30 days Tue 4/14/20 Mon 5/25/2042 Deliver to Test Stand 0 days Mon 5/25/20 Mon 5/25/2043 Test MQXF14 30 days Tue 5/26/20 Mon 7/6/2044 Assemble MQXF15 30 days Tue 5/26/20 Mon 7/6/2045 Deliver to Test Stand 0 days Mon 7/6/20 Mon 7/6/2046 Test MQXF15 30 days Tue 7/7/20 Mon 8/17/2047 Assemble MQXF16 30 days Tue 7/7/20 Mon 8/17/2048 Deliver to Test Stand 0 days Mon 8/17/20 Mon 8/17/2049 Test MQXF16 30 days Tue 8/18/20 Mon 9/28/2050 Assemble MQXF17 30 days Tue 8/18/20 Mon 9/28/2051 Deliver to Test Stand 0 days Mon 9/28/20 Mon 9/28/2052 Test MQXF17 30 days Tue 9/29/20 Mon 11/9/2053 Assemble MQXF18 30 days Tue 9/29/20 Mon 11/9/2054 Deliver to Test Stand 0 days Mon 11/9/20 Mon 11/9/2055 Test MQXF18 30 days Tue 11/10/20 Wed 12/23/2056 Assemble MQXF19 30 days Tue 11/10/20 Wed 12/23/2057 Deliver to Test Stand 0 days Wed 12/23/20Wed 12/23/2058 Test MQXF19 30 days Mon 12/28/20Fri 2/5/2159 Assemble MQXF20 30 days Mon 12/28/20Fri 2/5/2160 Deliver to Test Stand 0 days Fri 2/5/21 Fri 2/5/2161 Test MQXF20 30 days Mon 2/8/21 Fri 3/19/2162 Complete MQXF Testing 0 days Fri 2/5/21 Fri 2/5/21

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