Jun 22, 2011 Replacement Solenoid

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Items for followup from previous meeting

  1. Questions to JLab

Tentative Agenda

  • 8:30 Meet in CC324. Tour of the Hall D experimental area.
    • Elton, Tim
  • 9:30 Tour of the test lab and ongoing testing of individual solenoid coils.
    • George, Elton
  • 10:30 CC324. Group Discussion/ Question & Answer session
    • George, Tim, Eugene, Elton, Johathan, Glenn
    • Ettore on the phone (not confirmed)
  • Lunch
  • 1:30 Closeout
    • Clarify any remaining questions
    • Assign task list for future work
  • 2:30 Discussions with Hall B personnel concerning toroid (not confirmed)

Minutes

Attending: Brad Smith, Alexey Radovinsky, Elton Smith, Glenn Young, Eugene Chudakov, George Biallas, Tim Whitlatch, Jonathan Creel

  1. Brad and Alexey were given tours of the experimental Hall D and the coil test in the Test Lab
  2. Discussions began with presentations by Alexey (magnetic and mechanical design) and Brad (conductor choices)
  3. Magnetic and mechanical design (Alexey)
    1. Used ANSYS 2D and Vector Fields 3D modeling
    2. Fringe fields 6m downstream is calculated at 230-250 G, exceeding the specification. No cladding was included to this point, but will be added and fields checked
    3. Three subcoils used to produce the field profile
    4. Calculated axial Lorenz forces on coils was 1.4 MN.
      • George will provide comparable forces on the existing coils
    5. Winding and mechanical supports were presented
  4. Project organization (Brad)
    • Brad will serve as project engineer and also responsible for conductor design and quench protection
    • Alexey responsible for field design and mechanical design
    • Cryogenic engineer will be added at the appropriate time
    • Mechanical designer provides support with Solid Works for drawings and integration
  5. Conductor options considered
    1. New SS cable and stabilizer
      • Possibly optimum, but cable cost ~ $180k, 5800 A capability
    2. Existing SSC cable soldered into copper stabilizer
      • Most likely the most practical option. 7500 A capability
    3. Existing SSC cable soldered into aluminum stabilizer (likely use 5083 Al)
      • Correction note from Brad: The 5083 aluminum alloy was mentioned as a candidate for the winding support mandrel in the cold mass. It is not the alloy used to stabilize the superconducting cable. That alloy is written about in many of the papers related to the LHC Atlas magnets. I don't know if it has a specific name. It has unique properties of high RRR (~500) and high strength and is capable of being co-extruded over the cable.
      • High premium cost for conductor compared to copper, and technically challenging.
    4. Require about 7600 m of conductor. Joints may be required and if so would be placed at the end of each layer.
    5. The CIC option has not yet been evaluated, but will be in time for July milestone.

Action Items

  1. Complete interface drawings with sign off. (Tim)
    • RevA has been issued and e-mail sent out with attachments. (6/29/11)
    • Also make available drawings of filler rings.
      • The Filler Ring Drawings are in a directory on the web: Filler Rings
      • The sub folders are:
      • The simple fillers: /D00000-04-02-2124_2125T
      • The remaining fillers: /GLUEX_Ring_Girders
    • Include estimate of Helium level (George)
      • The height above beam line of the Helium liquid to gas surface (in the exiting coil test) is: 139 inches
  2. Provide parameters of refrigerator and cryogenic system (Johnathan)
  3. Provide drawings of service cryo cans (both D and C types) (George)
    • The Cryo Can Assembly Drawings are in a directory on the web; CryoCans
    • The Cryo Can Drawings for Hall C with 5000A Leads that are welded into place on a magnet cryostat are in Subfolder: /HallC
    • The Cryo Can Drawings that utilize a flanged bellows-like outer connection with o-rings, 2000 A Leads and CF Flange connections for the LASS Solenoid Piping are in subfolder: /HallD
  4. Add cladding to model and repeat magnetic calculations to check fringe fields (Alexey)
    • Calculation was completed and shows that even with cladding, the fringe field at z=6 m, r=0.1 m is reduced from 227 G down to 177 G, still exceeding the 150 G limit.
  5. Send (draft) presentation to everyone (Alexey and Brad)
    • e-mail with draft presentations was sent out to the list.
  6. Consider options for inserting coil from upstream end. (JLab)
    • Preference is to have the chimney upstream (to minimize saturation downstream and have lower fields at current leads), but will weigh alternatives
    • Provide guidance on location following evaluation
  7. Provide estimate weight of coil (Brad)
    • Estimated weight of new coil is 23.4 metric tons (greater than crane limit). See Table 1 below.
  8. Provide table of lengths of SSC cable, so that splicing options can be studied (Elton)
    • e-mail with information sent out to list
  9. Get name of company that is extruding copper channel for conductor (Elton/Glenn)
    • The company with the Hall C contract (and the Hall B one via Wang NMR) is Freeport McMoRan. Please see general website, photo of open-pit mine, etc. The site where Paul Brindza and Steve Lassiter visit for the actual extrusions is:
      • Freeport McMoRan
      • Bayway Operations
      • 48-94 Bayway Ave.
      • Elizabeth NJ 07202
      • 908-558-4318 - phone
      • 908-351-9475 - fax
      • Bron Zienkiewicz - contact person
    • The other option for a company who would quote for the Hall C magnets is:
      • Swissmetal Industries Ltd.
      • Weidenstrasse 50
      • P.O. Box
      • CH - 4143 Dornach 1
      • Switzerland
      • +41 61 705 33 33 - phone
      • +41 61 705 34 51
      • contact@swissmetal.com, swismetal.com, danielle.walch@swissmetal.com - is the person who provided the quote to SigmaPhi, who is the magnet maker for the Hall C large dipole and two large quadrupoles. We have not had direct contact with Swissmetal. Their quoted extrusion tolerances are similar to those for Freeport McMoRan.
  10. Provide information regarding the nitronic rods (non-magnetic stainless) as an option for tensioning supports (Tim)
  11. Specify guidelines (requirements) for burnout-proof leads (George?)
  12. (Added while writing minutes) Provide forces on existing coils for comparison with new coil (George)
  13. (Added while writing minutes) Provide quench protection circuit for existing coil , including voltage delays and thresholds (George)
  14. (Tim remembered this item 7/11/11) Investigate possibility of coil installation from the upstream end
    • We have looked over the 3D model and space requirements for installing the replacement solenoid from the upstream end. I looks like it is definitely possible to do.


Table 1: Estimated weight of new coil
Part Material Weight (kg)
Cryostat SS 15878
Rad. Shield Copper 467
Mandrel Al 1807
Spacers Al 426
Coils dens=7 t/m3 4828
Total 23407
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