24 Oct 2002 RFP Review1 DFBX Fabrication Activity at LBNL Jon Zbasnik LBNL

24 Oct 2002 RFP Review 1

DFBX Fabrication Activity at LBNL

Jon ZbasnikLBNL

Brookhaven - Fermilab - BerkeleyUS LHC ACCELERATOR PROJ ECT


Contents of Presentation

• Present the Items to be fabricated at LBNL– Bus Duct Assemblies

– Beam Tube Assemblies

– Instrumentation Duct Assemblies

• For each Item will address– Requirements

– Readiness Summary

– Fabrication/Acceptance Outline


Items to be fabricated at LBNL

• Bus Duct Assemblies– 8 each MQX, LBNL Dwg 25M857

– 4 each MBX1, LBNL Dwg 25M859

• Beam Tube Assemblies– 4 span Q3 to cold D1, LBNL Dwg 25I855

– 4 span Q3 to CERN Cold to Warm Transition

• Instrumentation Bus assemblies– 8 each MQX2 (100 wires), LBNL Dwg. 25I301

– 4 each MBX2 (22 wires), LBNL Dwg. 25I219


Bus Duct Requirements (1)

• Current Rating for MQX1– 4 each 7500 A busses

– 24 each “600 A” busses

• Current Rating for MBX1– 2 each 7500 A busses

• Voltage Rating– 7500 A busses 1500 Vdc in STP helium, 5 kV in air

– 600 A busses 600 Vdc in STP helium, 2.5 kV in air

– Voltage is applied to single bus with all others at ground

– Leakage current less than 20 x 10-6 A after 1 min at voltage


Bus Duct Requirements (2)

• Leak Rate across Lambda Plug– Less than 0.1 atm cc/sec (helium) at room temperature

– measured at a pressure differential of 0.7 atm or more

• 20 bar pressure rating on magnet side

• 3.5 bar pressure rating on DFBX side

• Operational Requirements– Leak Rate satisfied after 50 thermal cycles (verified in R&D)

– Leak Rate satisfied after 25 pressure pulses to 20 bar (verified in R&D)

– Bus bars must be stable and safe against quenching• Use FNAL-developed main quadrupole busses

• Use CERN corrector bus wire, also used by FNAL in the inner triplets


MQX1 Bus Duct Assembly

• Configuration delivered to Vendor is shown– Protective Pipe (yellow) over DFBX Conductors

• O-ring seal to lambda flange

• Pumping/Test Port

– Orange Piping Connects to Q3

– Helicoflex seal on Stub

– Endcap on bellows• Bellows restraint

• Pumping/Test Port

• Tooling Ball Feature


Bus Assembly Fabrication Readiness

• Lambda Plug R&D (with short conductors) is complete– R&D Plugs meet requirements

– Design is finalized and verified

– Plug potting process is finalized and gives stable results

– Closeout and installation welding was simulated

– Approved in 4 Sept 2002 review at LBNL

• Preliminary fabrication plan is outlined

• Development of fixtures to handle long conductors will start in November

• Final detail design is underway

• Fabrication start is dependent on insulated corrector bus


Lambda Plug R&D Results

• Notes:• a. An excessive amount (1000 g) of epoxy was mixed

and the exothermic heat generated caused the epoxy to harden before the plug was filled.

• b. No change in leak rate due to welding.• c. We have evidence that the leak rate increased upon

welding. We will check this carefully in PG-6d.• d.Thermal cycling is done by plunging the assembly

into a bath of LN2 , held for 1 hr, then pulled out and warmed in air for 1 hour, etc.

• e. Breakdown is not between nearest neighbors, so it

may be due to the test setup. We are checking this.

Test Sequence PG-6a PG-6b PG-6c PG-6dIn-Process Testing All okay Incomplete

step 2 potting aAll okay All okay

Leak rate after pottingin housing

Plug wasnot used

<1 x 10-10

atm cc/s

Leak Rate after 2thermal cycles

<1 x 10-10

atm cc/s<1 x 10-10

atm cc/s

Leak Rate afterwelding

.035atm cc/s b

.069atm cc/s c

7 x 10-10

atm cc/s

50 thermal cyclesd done done done

Post-thermal cyclingleakage

.035atm cc/s

0.10atm cc/s

3.6 x 10-3

atm cc/s

R.T. Pressure Test to420 psig (29 bar)

Passed,not

deformed

Passed, notdeformed

Passed, notdeformed

Post-pressure testleakage

.035atm cc/s

0.1atm cc/s

7.5 x 10-3

atm cc/s

Cold Pressure Test to420 psig

Passed,not

deformed

Passed, notdeformed

Passed, notdeformed

25 quench pressurepulses

Not done Passed Passed

Post-pressure testleakage

.025atm cc/s

.069atm cc/s

6.1 x 10-3

atm cc/s

R.T. Pressure testDFBX side to 80 psig


Cold Pressure testDFBX side to 80 psig


7500 A HiPot to 5 kV Ok to 5kV in air

600 A HiPot to 2.5 kV 22 ok to2.5 kV in

aire


Bus Duct Fabrication Plan (1)

• Outline is presented in the review’s URL

• Potting of long conductors into the stainless steel flange will be done by Supercon techs– They developed the process details

– They demonstrated that the process was stable in the R&D program

7500 A Busses

Corrector Busses Stainless Steel Housing


Bus Duct Fabrication Plan (2)

• The Bus Duct will be completed by Techs in the B 77 area– They have performed all welding in the successful R&D program

– They have performed all leak and pressure testing in the R&D program

– Performed hipot testing for other programs

• Detailed procedures and fixtures to be worked out in Nov/Dec– We anticipate that only orbital welds will be needed


Bus Duct Acceptance Testing

• Thermally cycle bus duct 2 to 5 times to LN temp

• Pressure Test magnet side to 370 psig ( warm & cold)

• leak rate through lambda plug less than 0.1 atm cc/sec (helium) – (both directions)

• Leak check magnet piping, – leak rate to be less than 1 x 10-9 std cc/sec (helium)

• Hipot test– 5 kV dc (air), with less than 20 microamps leakage after 1 minute

– 2 kV dc (helium on magnet side), with less than 20 microamps leakage

• Dimensions are within tolerance

• Conductors are properly labeled


Bus Duct Production Schedule

• Supply of Corrector Bus is on Critical Path

• Other parts are readily available– Cable conductors are at FNAL

– Bellows on hand at FNAL

– G-10CR Insulator Blocks are machined

– Weldneck flanges are on hand, 2 more need to be ordered

– Elbows are standard, some on hand

– Pipe sections readily available

– Helicoflex seals and clamps need to be ordered

• LBNL Manpower is available to do the job


Beam Tube Requirements

• Bore to be cleaned per LBNL UHV Cleaning Spec

• Cooling jacket around the bore to keep the temp less than 3 K

• Bore tube inner diameter greater than 74 mm

• Design Pressure of Cooling Jacket 20 bar

• Design Pressure of Bore Tube 5 bar

• Leak rate of Jacket to Insulation Vacuum < 1 x 10-9 std cc/sec

• Leak rate to Bore Tube < 1 x 10-10 std cc/sec with the Jacket at 25 bar Helium Pressure


Beam Tube Fabrication Readiness

• No R&D needed

• Final Design is Complete

• Preliminary Fabrication Plan Outlined (see Review URL)

• Acceptance Tests Outlined

• 316LN Bore tubes to be delivered by CERN via BNL


Beam Tube Fabrication/Acceptance Plan

• All operations to be done in B 77 Area

• Fabrication Steps outlined in Review URL

• No show stoppers seen

• Acceptance Testing– 2 to 5 thermal cycles of weld regions

– Pressure test Jacket to 370 psig

– Pressure test Bore to 75 psig

– Jacket Leak Rate < 1 x 10-9 std cc/sec (helium)

– Bore Tube Leak Rate < 1 x 10-10 std cc/sec (helium) with Jacket at 370 psig

– Dimensions within tolerance

• Shipped to DFBX Vendor under 3 psig N2 Pressure


Instrumentation Duct Requirements

• Provide wires for magnet cold mass instrumentation– MQX2 requires 100 good wires

• 32 each 30 AWG for low voltage sensors, 600 V dc rating

• 36 each 26 AWG for voltage taps, 5 kV dc rating

• 32 each 18 AWG for heaters, 5 kV dc rating

– MBX2 requires 22 good wires• 8 each 30 AWG for low voltage sensors, 600 V dc rating

• 6 each 26 AWG for voltage taps, 5 kV dc rating

• 8 each 18 AWG for heaters, 5 kV dc rating

• Low heat leak to Superfluid bath

• Pressure rating of 20 bar

• Leak rate to insulation vacuum < 1 x 10-9 std cc/sec

• Provide for thermal contraction of about 30 mm


Instrumentation Duct Fabrication Readiness

• Final Design is complete

• Development work is being done by FNAL

• Strawman fabrication steps are outlined in Review URL

• Work to be done in the B 77 area


Instrumentation Duct Acceptance

• Dimensions within tolerance

• Welds thermal shocked to LN 2 to 5 times

• Pressure tested to 370 psig

• Leak tight to < 1 x 10-9 stc cc/sec

• Suitable number of wires are installed– Give proper void fraction inside the conduit

– For MQX2, the Hypertronics connector on the magnet side is loaded

– Stripped ends on the magnet side of MBX2

– Continuity check passed

– Hipot test passed

– Wires on DFBX side are labeled per wiring diagrams


Conclusions

• We have completed the R&D on the Lambda Plug and are ready to commence work on incorporating this in Bus Duct Assemblies for the DFBX

• Schedule may be impacted by delivery of insulated corrector bus - we can use assistance from the USLHC-PMO in getting the bus delivered in Dec 2002

• Beam Tube Fabrication is ready to begin

• Instrumentation Bus can commence after FNAL has completed the necessary development work

• We expect to deliver the LBNL Items to the DFBX Vendor 2 months before they are needed

Documents

24 Oct 2002 RFP Review1 DFBX Fabrication Activity at LBNL Jon Zbasnik LBNL