davide tommasini status and prospects of the ps magnet consolidation program atop days march 4 th...

Davide Tommasini Status and prospects of the PS magnet consolidation program ATOP Days March 4th – 6th 2009

Status and prospects of PS magnets programs consolidation program

Davide Tommasini

Consolidation program of the PS main units : description status of Phase I consolidation findings proposed next steps

Documentation Overview of the spare magnet situation for the LHC first injectors chain Conclusions

with contributions by D.Bodart, A.Newborough, T.Zickler


Supporting Recent Documentation

http://indico.cern.ch/conferenceDisplay.py?confId=52221


Price breakdown for Phase I of the consolidation of the first half of the PS Price breakdown for Phase I of the consolidation of the first half of the PS Main magnets 2003-2006:Main magnets 2003-2006:

KCHFKCHF

Aluminium conductor for coilsAluminium conductor for coils 650650

Coil fabricationCoil fabrication 3,6763,676

Pole Face WindingsPole Face Windings 3,4803,480

Bus-barsBus-bars 506506

Magnet workshopMagnet workshop 426426

PS Inflector (to allow ISOLDE operation in 2005)PS Inflector (to allow ISOLDE operation in 2005) 200200

Engineer for magnet design & fabrication for AT-MEL (consultant)Engineer for magnet design & fabrication for AT-MEL (consultant) 200200

Industrial Support for magnet refurbishment for AT-MELIndustrial Support for magnet refurbishment for AT-MEL 400400

Industrial Support for magnet transport PS Industrial Support for magnet transport PS workshop for ST-HM workshop for ST-HM 150150

Industrial Support , new chambers & autom. Welding machine for AT-VACIndustrial Support , new chambers & autom. Welding machine for AT-VAC 593593

SurveySurvey 9090

ContingencyContingency 5050

Overall EstimateOverall Estimate 10,34110,341

PS Main Magnet Consolidation W. Kalbreier, T. Zickler AT-MEL AC Meeting 26-6-2003

Original cost estimate : Phase I


PS Main Magnet Consolidation W. Kalbreier, T. Zickler AT-MEL AC Meeting 26-6-2003

Price breakdown for Phase II of the consolidation of the second half of the Price breakdown for Phase II of the consolidation of the second half of the PS Main magnets 2006-2013:PS Main magnets 2006-2013:

KCHFKCHF

Aluminium conductor for coilsAluminium conductor for coils 650650

Coil fabricationCoil fabrication 3,6763,676

Pole Face WindingsPole Face Windings 3,4803,480

Bus-barsBus-bars 386386

Magnet workshopMagnet workshop 00

PS Inflector (to allow ISOLDE operation in 2005)PS Inflector (to allow ISOLDE operation in 2005) 00

Engineer for magnet design & fabrication for AT-MEL (consultant)Engineer for magnet design & fabrication for AT-MEL (consultant) 00

Industrial Support for magnet refurbishment for AT-MELIndustrial Support for magnet refurbishment for AT-MEL 400400

Industrial Support for magnet transport PS Industrial Support for magnet transport PS workshop for ST-HM workshop for ST-HM 150150

Industrial Support , new chambers etc for AT-VACIndustrial Support , new chambers etc for AT-VAC 443443

SurveySurvey 9090

ContingencyContingency 5050

Overall EstimateOverall Estimate 9,3259,325

Original cost estimate : Phase II


Status of Phase I consolidation

we have 1 spare magnet + one set of components per magnet type three consecutive failure on each magnet type can be covered

51 installed units + 4 spare units refurbished


Description / 1

100 + 1 main magnets operating since 1959 : 50 years !Magnet

TypeCoil Type Description N° Installed

R ABCD Return yoke outside D-F 35

S ABCD Return yoke outside F-D 15

T EFGH Return yoke inside D-F 35

U EFGH Return yoke inside D-F 15

4 types of Pole Face Windings

Figure of 8 windings


Findings in 50 years of operation

loose laminations since 1970 fasteners + spacers added in ‘77-’79damaged fastener during the shutdown 2002/2003 on MU 31coil insulation to ground damaged on most units but still effectivefirst coil insulation failure in 1999 in MU7 (short circuit to thermal interlock copper plate)HV test in 2002/2003 shutdown two failures : in MU6 and in MU19 same 2002/2003 shutdown a water leak provoked a short circuit on MU 20 bus barsevere degradation (aging) of PFW cables and of their internal contactsrepair loose laminations with LHC cycle not effective but with shims to Fo8 (to be confirmed)

MU6

MU19

MU31 MU1Loose

laminations

Loose laminations

Ground insulation

PFW connection


Findings : in summary

insulation between main coil turns : never failed failure of insulation to ground of main coils : it happened three times in general dielectric insulation coils-to-ground appears very reliable

this was equally true before and after Phase I

degradation of PFW insulation and connections (though few failures) problem of loose laminations still affects several units recent failure Fo8 connection : bad tightening of a refurbished unit shutdown preventive (in particular thermal and audio-visual inspections) maintenance limits problems during runsIn 50 years of operation failures on PS main units, excluding water leaks, can be counted on the fingers of a

single person


Proposed actions on PS main units

Considering that : the PS shall operate for 10 more years we have 1 spare magnet + one set of components per magnet type three consecutive failure on each magnet type can be covered failures have been rare episodes so far the most critical magnets have already been treated in phase I replacing a magnet requires few days any “typical” fault is repairable EXCEPT the PFW the machine without PFW does not work (are we sure?) time to manufacture new PFW is longWe propose to : launch the manufacture of 50 sets of PFW (~ 3 MCHF, 2 years) carefully monitor magnet performance with LHC cycles continue annual inspections (on Main Coils, F8W, PFW, Yoke, Leaks) be ready to reconsider the strategy at any time


Documentation / 1

- Inventory

- Accelerators PX, SPS and LHC

- Spares

- Components

- Documentation

- Recovering of the paper archives

- Identification and scanning

- Activities procedures

- Web Tools

- Wiki http://normawiki.web.cern.ch/normawiki/

- Database


Documentation / 2

Pilote work for naming and labeling old & new magnets

we are coordinating a PS Complex Equipment Catalogue

very large consensus and interest for a CERN wide strategy

Total of 1993 magnet found

1880 correctly identified and 113 under investigation

Total of 1463 magnets installed and 530 spares

212 different equipment design codes

1542 magnets created in the MTF (80% of the total)

1751 magnets physically labelled (91% of the total)


Machine Total Magnets Created in MTF Labelled

PS Main Ring 245 244 240

LINAC 2 52 46 51

LINAC 3 30 0 29

BOOSTER 264 252 264

BOOSTER TL 96 96 77

East Hall 62 59 58

Ion Beam Lines 47 46 47

AD 196 183 186

CTF 3 371 333 351

LEIR 44 2 42

TT2 56 55 55

1463 1316 1400

Documentation / 3


The PS complex


• Type I, II, IV, V, VII - spares are available (not tested).• Type III – LINAC 2 spares being used in 3 MeV test stand (tested 2007 AJN).• Type IX – LINAC 3 spare being used in 3 MeV test stand – other spare failed Under 5 Hz testing for 3 MeV test stand (Detailed in EDMS Document: 466793 ). Problem occurs when LINAC 4 goes into operation, NO SPARES!

Current policy is that 3 MeV test stand quads can be taken if needed for LINAC 2,When LINAC 4 becomes operational LINAC 2 quads become spares.

TYPE LINAC 2 LINAC 3 ION BEAM LINES 3 MeV TEST STAND SPARES COMMENTI 6*** - - - 3*** Spares b.290II 9*** - - - 3*** Spares b.290III 17*** - - 6*** 1+2*** 1 original (poor condition) spare with Marco Buzio, 2 proto-types AJNIV 19*** - - 2*** 2*** Spares b.290V 77*** - - - 3*** Spares b.290VI - - - - 2*** Spares b.290VII (PXMQNAIFAP) 20 - 7 2*** 2*** Spares b.363, b866 (AB/PO) (LCR - 6 spares to be confirmed, not found) VIII - - - - 3 Spares b.150IX (PXMQNAQFAP) - 3 - 1*** 0 Spare failed while under test with AB/POX - - - - 4*** Spares b.290

Produce spare magnets• Type III – Desirable• Type IX – Recommended

LINAC type I to X Quadrupoles


Antony Newborough TE/MSC - MNC

Multipoles 11 ONO/XNO/QSK (Type I) 4 ONO/XNO/QNO (Type II) 1 OSK/XSK/QNO (Type III B)4 ONO/OSK/XNO/XSK (Type A) 4 OSK/XSK/DVT/DHZ (Type B)

Booster Multi-pole correctors

No or few spares, however :cannibalization possible

retuning possible

PS Booster


Bending magnet TBH (PXMBHFBWWP)

Only one unit in the Booster Transfer line(BT.BHZ.10)

• 0 Spares – essential for LHC operation. Bends to either PS or ISOLDE. Spare coils used in 1997, forced into yoke with 7 tone concrete block!• Laminated machined yoke due to tapered aperture (CERN 1975)• Water leak discovered Friday 13th February 2008 (Bust Water Hose)

• Absolute minimum fabricate spare coils• Fabrication of new spare magnet recommended• In parallel search for alternative solutions


Frequent failures of cooling channels/brazed joints

10 magnets installed, one old spare available !

Proposed actions on PS main unitsBending magnets 205 in the PS


IONS : LINAC 3LINAC 3 ATC/ABOC Days, January 08 - T. Zickler

Medium Risk Solenoid (2)

Bruker quads (4)

Spectrometer (2)

Doublet B (2)

Triplet (3)

Bending 106º (2)

Proposed Mitigation

Produce spare coils

Produce spare coils

Produce spare coils

Produce spare coils

Produce spare coils

Produce spare coils

Costs [kCHF]

35 25 40 25 40 50

Manpower[FTE*y]

0.2 0.2 0.2 0.2 0.2 0.3

Delay[months]

12 12 12 12 12 18


IONS : TL and LEIRLEAR + TL ~ 10 magnet types with no spares

These tables are not fully correct : situation of spares still to be assessed

For main quadrupoles cannibalization may work


Conclusions PS consolidation :

with the exception of PFW, everything is repairable in a short time we may not need phase II if the machine has to be operated for just 10 more years

Other machines on the injection way to the LHC consolidate the status of spares (storage and certification) spare situation for Booster TL, Linac 3, Ion Beam TL, LEIR needs to be improved

We propose to purchase 50 sets of PFW ( ~ 3 MCHF, 2 y) produce 2 spare type IX quadrupoles for LINAC 3 (~ 30 kCHF, 12 m) manufacture a TBH magnet + spare coils OR find alternative optics ( ~ 200 kCHF, 2 y) manufacture spare coils for six LINAC 3 magnet types ( ~ 300 kCHF, 18 m) manufacture a spare coil set for the LEIR main bending magnets (~150 kCHF,18 m) LEIR TL : perform a more detailed review of status of spares before taking decisions manufacture 2 sets of spare coils for the 205 pulsed dipole (~ 35 kCHF,12 m) except if the ones on the extraction line will be no longer used (thanks to MTE)

davide tommasini status and prospects of the ps magnet consolidation program atop days march 4 th...

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