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

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

Documents

single bus

rd leak rate

rd bus bars

insulated corrector

rd program slide

voltage slide

lbnl jon zbasnik lbnl

bar leak rate of jacket