Update on Q4DSM/IRFU/SACM

The HiLumi LHC Design Study (a sub-system of HL-LHC) is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

M. Segreti, J.M. Rifflet

3 July 2013

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

New porous cable insulation scheme (radial = 0.16 mm; azimuthal = 0.145 mm)

Classical MQ insulation thicknesses(radial = 0.13 mm; azimuthal = 0.110 mm)

3 blocks (7-5-2 conductors)HX hole at 101 mm of the magnet center

Inom = 16188 A; Collar µr = 1.003

3 blocks (8-4-2 conductors)HX hole at 95 mm from the magnet center

Inom = 16050 A; Collar µr = 1.003

Harmonics (Units)b3 b4 b5 b6 b10 b14 b18

0.06 0.15 -0.25 0.00 0.00 2.02 -0.27

Harmonics were not optimized after having added the collar

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

Thermo-mechanical properties

Due to the cable insulation creep after the collaring process, it is also assumed 20 % and 30 % losses of pre-stress in conductor blocks using the classic MQ and the new porous EI#4 insulation schemes, respectively

Materials Temp. Elastic Yield Ultimate IntegratedComponants Modulus Strength Strength Thermal Shrinkage

(K) E (GPa) (MPa) (MPa) a (mm/m)yus 130 S Nippon Steel 300 195 445 795

Collars 2 210 1023 1595 2.6316L Stainless Steel 300 205 275 596

Keys 2 210 666 1570 2.9Copper 300 124

Angular wedges 2 136 3.7Kapton Foils 300 2.5

inter-layer & inter-pole insulations 2 4 6.0 insulated NbTi conductor blocks 300 10.00

Coils with classic MQ insulated cable 2 15.00 4.9 insulated NbTi conductor blocks 300 4.50

Coils with MQ cable using EI#4 2 6.75 * 7.5 *

* For QM cable insulated with EI#4, it is assumed that: E 2K = 1.5 × E 300Kand α = 7.5 mm/m (very pessimist estimate)

Mechanical results with MQ cable using the classical MQ insulation

(Insulation thickness: radial = 0.13 mmazimuthal = 0.11 mm)

Coil azimuthal stress distribution (MPa)

After collaringθ max = - 104 MPaθ mean = - 67 MPa

At 2 Kθ max = - 52 MPaθ mean = - 40 MPa

At 110 % of Inom

θ max = - 63 MPaθ mean = - 41 MPa

Coil Von Mises stress distribution (MPa)

After collaringVM max = 93 MPa

At 2 KVM max = 51 MPa

At 110 % of Inom

VM max = 61 MPa

Coil displacement due to Lorentz forces at 110 % of Inom (µm)

Coil azimuthal displacementδθ max = 17 µm toward mid-plane

Coil radial displacementδr max = 27 µm toward outer radius

Mechanical results with MQ cable using the new porous EI#4 insulation

(Insulation thickness: radial = 0.16 mmazimuthal = 0.145 mm)

Coil azimuthal stress distribution (MPa)

After collaringθ max = - 132 MPaθ mean = - 84 MPa

At 2 Kθ max = - 63 MPaθ mean = - 48 MPa

At 110 % of Inom

θ max = - 72 MPaθ mean = - 49 MPa

Coil Von Mises stress distribution (MPa)

After collaringVM max = 118 MPa

At 2 KVM max = 62 MPa

At 110 % of Inom

VM max = 70 MPa

Coil displacement due to Lorentz forces at 110 % of Inom (µm)

Coil azimuthal displacementδθ max = 33 µm toward mid-plane

Coil radial displacementδr max = 42 µm toward outer radius

Summary of the main results at each stepQ4_90 mm aperture with MQ insulation Collaring Creep (20%) Cool down Energization

Max azimuthal stress/Max Von Mises stress -104/93 -83/74 -52/51 -63/61Average azimuthal stress -67 -53 -40 -41Min azimuthal stress on polar plan -10Average azimuthal stress on polar plan -12

Point A 27Point B 8Point C 18Point D -1

In collars 832 666 593 700In keys 227 181 174 203

Fx = 4.36 105 (N/m)Fy = -6.12 105 (N/m)

Stresses in coil (MPa)

Coil radial displacement due to Lorentz forces (µm)

Max von Mises stress (MPa)

Q4_90 mm aperture with EI#4 insulation Collaring Creep (30%) Cool down Energization

Max azimuthal stress/Max Von Mises stress -132/118 -93/83 -63/62 -72/70Average azimuthal stress -84 -59 -48 -49Min azimuthal stress on polar plan -10Average azimuthal stress on polar plan -18

Point A 42Point B 13Point C 20Point D -3

In collars 1329 932 897 1016In keys 355 249 253 284

Fx = 4.77 105 (N/m)Fy = -6.65 105 (N/m)

Stresses in coil (MPa)

Coil radial displacement due to Lorentz forces (µm)

Max von Mises stress (MPa)

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

geometric errors in the 24 blocks (inputs for the 500 ROXIE calculations)

Block1 Block2 Block3Radius xl 44.900 44.900 44.900(mm) xu 45.100 45.100 45.100

xs 45.000 45.000 45.000Positioning xl 0.0652 16.5160 30.9896angle (deg) xu 0.2828 16.7336 31.2072

xs 0.1740 16.6248 31.0984Inclination xl -0.7460 16.4063 27.1690angle (deg) xu 0.7460 17.8983 28.6610

xs 0.0000 17.1523 27.9150

rms of 100 µmBlock1 Block2 Block3Radius xl 44.990 44.990 44.990(mm) xu 45.010 45.010 45.010

xs 45.000 45.000 45.000Positioning xl 0.1631 16.6139 31.0875angle (deg) xu 0.1849 16.6357 31.1093

xs 0.1740 16.6248 31.0984Inclination xl -0.0746 17.0777 27.8404angle (deg) xu 0.0746 17.2269 27.9896

xs 0.0000 17.1523 27.9150

rms of 10 µm

We do also for rms of 10, 20, 30, 40 and 50 µm

For quadrupole magnet, the standard deviation of the normalized multipoles can be described by a power law σ(an,bn) = dαβn

d alpha beta[µm] [1/µm] [-]100 0.266380 0.64577850 0.266368 0.64577840 0.266323 0.64577830 0.266253 0.64577820 0.266325 0.64577810 0.266570 0.645778

Average 0.266370 0.645778

Random in the 24 blocks of one of the double 90 mm aperture, R ref = 30 mm, I = 16188 A, with symetric yoke, with 0.003 shrinkage, to compare with operating measurements

d alpha beta[µm] [1/µm] [-]100 0.298204 0.64397250 0.298206 0.64397240 0.298155 0.64397230 0.298083 0.64397220 0.298155 0.64397210 0.298330 0.643972

Average 0.298189 0.643972

Random in the 24 blocks of the single 90 mm aperture, R ref = 30 mm, I = 1000 A, without yoke, without shrinkage, to compare with warm measurements

Thanks to Qingjin Xu and Xiaorong Wang for their help!

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

Yoke hole diameter Hole vertical position Harmonics (Units)for HX (mm) from magnet center (mm) b3 b4 b5 b6 b10 b14 b18

60 * 95 0.06 0.15 -0.25 0.00 0.00 2.02 -0.2750 95 -1.26 0.15 -0.13 -0.04 0.00 2.02 -0.2740 95 -1.20 0.32 -0.05 -0.04 0.00 2.02 -0.2730 95 -1.28 0.16 -0.09 -0.04 0.00 2.02 -0.27

Yoke hole diameter Hole vertical position Harmonics (Units)for HX (mm) from center (mm) B3 b4 b5 b6 b10 b14 b18

80 110 0.28 0.34 -0.33 0.01 0.00 2.02 -0.2770 103 -0.01 0.23 -0.27 0.01 0.00 2.03 -0.27

60 * 95 0.06 0.15 -0.25 0.00 0.00 2.02 -0.2750 86 0.03 0.12 -0.26 0.00 0.00 2.02 -0.2740 76 0.10 0.05 -0.14 -0.01 0.00 2.02 -0.2730 66 -0.09 -0.04 -0.04 -0.02 0.00 2.02 -0.27

b3 can be minimized by adapting the vertical position of the HX hole without changing the position of the conductor blocks i.e. the coil geometry the final HX size can be decided later

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

Main goal of the coil end optimization :- The minimization of the mechanical stress on the

cable i.e. minimization of the strain energy due to the winding process

- The minimization of the integrated multipole coefficients along the coil end (this is harder to obtain with only one coil layer)

- To limit the peak-field as possible if localized in coil ends to improve quench performance

Use of ROXIE to design and to optimize the coil ends(3 D calculation and analysis take a lot of time)

integrated multipole coefficients along the coil return end

b6

b10

1. Magnetic designs (90 mm aperture with one layer of MQ cable) using:• the classical cable insulation• the new porous EI#4 insulation scheme

2. Mechanical comparison of results obtained with the two schemes of cable insulation

3. Random field error analysis

4. Effect on harmonics of heat exchanger position (in the iron yoke)

5. Coil end design & optimisation

6. Protection (brief results)

Case 1: results obtained without dump resistor and with 0.016s delay quench-heater

Results obtained from the protection software developped by P. Fazilleau

Case 2: results obtained with a 49 mΩ dump resistor and without quench-

heater

Results obtained from the protection software developped by P. Fazilleau

Case 3: results obtained with a 49 mΩ dump resistor and with 0.016s delay quench-heater

Results obtained from the protection software developped by P. Fazilleau