JHF Horn construction status and K2K horn experience YAMANOI Yutaka - - PowerPoint PPT Presentation

JHF Horn construction status and K2K horn experience

• K2K Horn system
• The operation result of K2K Horns

–

Trivial troubles (2002-2003)

• Status of JHF Horns
• Basic parameters

–

Mechanism and Merit of FSW

–

Concrete stuffing strip line

–

The pulse currents test by the power supply of K2K Horn

• Schedule
• Summary

YAMANOI Yutaka (KEK)

K2K Horn system

• Built-in production target (φ30mm)
• (Blue) Removable train:
• A distance between horns is about 8.06 m.
• (Green) Adjustment table:
• decline to Super-Kamiokande with 1.05°
• Accuracy is equal to about 0.04 mrad.
• Operation current 250k Amp at both horns
• High pulsed current 2.5ms width, 2.18s cycle
• Total Joule’s heat= 7740 kcal/h

Beam

Pulse Current Target & First HORN

Second HORN 1.05°

00.E+00 02.E+06 04.E+06 06.E+06 08.E+06 10.E+06 12.E+06 14.E+06 '99/01 '99/03 '99/05 '99/07 '99/09 '99/11 '00/01 '00/03 '00/05 '00/07 '00/09 '00/11 '01/01 '01/03 '01/05 '01/07 '01/09 '01/11 '02/01 '02/03 '02/05 '02/07 '02/09 '02/11 '03/01 '03/03 '03/05 '03/07 '03/09 '03/11 '04/01 '04/03

1st Horn 2nd Horn

Run1999 Run2000

第１－５号機φ２５ 第１－４号機 φ３０ 第２－２号機 第２－１号機 第１－７号機 第２ー３号機 第１－３号機 φ２５ 第１－２号機 φ２０ 第１－６号機 par a b cap

Run2001-02

第１－８号機 第１－８号機 第２－４号機

Run2002-03

Now

The operation result of K2K Horns

January 10, 2003 After underwater for 4 years The water level gauge made from Teflon broke.

Eliminator unit Reservoir, Pump unit

K2K Horns Logbook (1) Water level gauge

Radioactive dirty water

April 4, 2003 Water leaked from the mechanical seal of a swirl pump. The pump was changed into the canned-rotor pump.

(2) Canned-Rotor Pump

The swirl pump of a multi-stage type A canned-rotor pump is no liquid leak and low noise without a mechanical seal and a cooling fan.

(3) Harness of a sticking-by-pressure terminal

1st Horn Transformer 2nd Horn Transformer

Jun 06, 2003 After 25.8 million operations The harness of a cable shook and broke.

shake

• Horn system optical design (Ichikawa)
• Target station design for Target and Horns (Yamada)
• Basic parameters (NBI03 version)
• High priority subjects
• Consideration to recycle of K2K equipments
• Welding technology for making a inner conductor
• Design to installation to Target station with He-tight
• Durability test by the power supply of K2K horn
• Construction Schedule

Status of JHF Horns

φ470 φ1400 φ800 1500 2000 2500 φ360 φ900 φ56

Basic parameters

Horn #1 Horn #2 Horn #3 Proton beam energy Beam Intensity Ring cycle Pulse length Horn current peak Inductance 0.55 µH 0.46µH 0.48µH Resistance 118µΩ 100µΩ 90µΩ Transformer ratio Peak risetime 0.31ms Joule heating 1.1kW Radiation Heating 10kW Capacitance 1.0mF Charging voltage 5400V 300 kA 5 50 GeV 3x1014ppp 3.6s 5 µs

1st Horn

D 56mm Thickness 3mm 300kA R 75mm t 3.6mm t 3.6mm 30 mm 1500 mm D 360mm 250mm TARGET

A6061、or (A2219, A7003, A5083)

2nd Horn

D60mm 300kA D470mm 30mm 2000 mm Thickness 3mm D900mm

3rd Horn

2500mm Thickness 3mm 300kA 30mm D100mm D800mm D1400mm

Comparison with the welding method

Proof stress (A6061) Heat distortion Workability Cost Merit/ Demerit Laser Beam Welding

○ ○ ○ ○ ～ ～ ～ ～85% ◎ ◎ ◎ ◎ ○ ○ ○ ○ △ △ △ △

A welding pretreatment is

• required. The large equipment is
• required. Triming is needed after

welding. Electron Beam Welding

○ ○ ○ ○ ～ ～ ～ ～85% ◎ ◎ ◎ ◎ ○ ○ ○ ○ △ △ △ △

The vacuum chamber containing a horn is needed. Triming is needed after welding. Friction Stir Welding

○ ○ ○ ○ ～ ～ ～ ～80% ◎ ◎ ◎ ◎ ◎ ◎ ◎ ◎ ○ ○ ○ ○

New technology. No-Trimming after welding. Easy to adjust the

• length. ～0.3mm

MI G (metel inert gas) Welding

△ △ △ △ ～ ～ ～ ～60% △ △ △ △ ○ ○ ○ ○ ◎ ◎ ◎ ◎

Welding distortion is large. There is variation in the quality by skill. TI G (tungsten inert gas) Welding

△ △ △ △ ～ ～ ～ ～60% △ △ △ △ ○ ○ ○ ○ ◎ ◎ ◎ ◎

Welding distortion is large. There is variation in the quality by skill.

Mechanism and Merit of FSW (Friction Stir Welding)

• Invented at TWI(1991)
• Applied to space rocket, train body
• Very low distortion
• Good dimensional stability

and repeatability

• Fully mechanical process
• No fume, porosity or spatter
• Excellent mechanical/metallurgical

properties

• Very cost effective

FSW

HITACHI, Ltd.

tim e P max(σ max) P min(σ min)

• 2.25kN
• 22.5kN

R = P min / P max = 0.1 LOAD P

It carried out 1.09x10^ 7 times by the maximum load 22.5kN. The damage by repetition fatigue was not found.

• 1000
• 800
• 600
• 400
• 200

200 400 1.0E+00 1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08

Number of repetition times N

• Max. Distortion ε

（×10-6）

Result

θ-axis

z-axis 90 deg 270 deg

Target Station (Y.YAMADA)

To reduce NOx and Tritium in the target station > The He gas is filled in TS.

He

Tr. Tr. Tr.

Concrete stuffing strip line

Surface treatment (t 25μm hard anodic oxide coating + sealing) Withstand voltage 2.8kV-2x1010ohm Heat resistance 300 degrees C-4hr Corrosion resistance Salt spray test OK (ASTM-B-117)

The pulse currents test by the power supply of K2K Horn

Power supply of K2K Horn Transformer

２次コイル・４回路分 １次コイル ４回路分 並列接続

Secondary circuit 2 turns x 4 circuits Primary circuit 20 turns

• JHF Inner conductor

+ K2K Outer conductor

• Transformer ratio: 10 -> 5

250kA -> 300kA(Max.500kA) The pulse test will be begun in spring of 2004.

Horns Construction Schedule

Fiscal year 4 7 10 1 4 7 10 1 4 7 10 1 4 7 10 1 4 7 10 1 4 7 10 1 K2K Horns Running Running Remake of K2K power supply #1,#2 power supply Design of JHF Horns and TS Design Production of Horn #1 full-size Install of peripheral equipment peripheral Durability test of JHF Horn #1 test Combines with a target Production of Horn #2 full-size Durability test of JHF Horn #2 test Production of Horn #3 full-size Durability test of JHF Horn #3 test Production of new power supply #3 power supply Production of 3 Horns full-size Construction of TS Construction of TS Preparation of peripheral equipment Install in TS Commissioning 2007(H19) 2008(H20) 2003(H15) 2004(H16) 2005(H17) 2006(H18)

Summary

• Now our K2K horns are very stable.
• We should pay attention more and more to

peripherals.

• Now we design JHF Horns and Target station.
• I want to excitation tests about full size horn and all

peripherals in the real situation as soon as possible.