Status of the tooling

Part 1:From Winding to impregnation

Raúl Morón BallesterTE-MSC-LMF

raul.moron-ballester@cern.ch

From winding to impregnation – Raúl Morón Ballester 2

FNAL

CERN MDT

CERN LMF

Babcock NoellAlstom

11T Prototype (5.5m) Manufacturing system

11T Model Manufacturing system

11T Model Manufacturing system

From winding to impregnation – Raúl Morón Ballester 3

Outlook• Winding• Curing• Reaction/Splicing• Impregnation• Tooling delivery VS. Planning• Conclusions

From winding to impregnation – Raúl Morón Ballester 4

WindingWINDING MACHINE:• Modifications:

• Update of the control program• Shortening of the bench• Elevation of the gantry• New tension-meter• Outer spool holder to support two-layer-winding without internal splice

• Status: Tension control needs improvement – Not critical

From winding to impregnation – Raúl Morón Ballester 5

WindingWinding mandrel and accessories

Status: Ready

Handling equipment for spool manipulation

Status: Ready

From winding to impregnation – Raúl Morón Ballester 6

CuringCURING PRESS:• Modifications:

• Hydraulic system has been modified to allow more pressing configurations• Update of the control system• Resistance heaters instead of warm oil• Extension of the bench to hold the outer spool

• Status: Ready

From winding to impregnation – Raúl Morón Ballester 7

Interlayer tool

Status: Ready

CuringCuring Mould

Status: Half shelves shall be modified – Not critical

Curing Jacket

Status: Ready

From winding to impregnation – Raúl Morón Ballester 8

Lifting girder for curing mould

Status: Ready

Curing - Handling

Coil storing tool

Status: Ready

Coil Handling tool

Status: Delivered. Waiting for load tests (W51)

From winding to impregnation – Raúl Morón Ballester 9

ReactionReaction furnace

Improvements:- More robust ventilation system

- Two oxygen sensors (Reaction Fixture + Retort)

Status: Ready

From winding to impregnation – Raúl Morón Ballester 10

ReactionReaction mould

Status: Some blocks to be re-done. Delivery end of December

- Argon flow is done from mid-plane to poles instead of axially.

- The blocks rest directly on the base plate instead of the seal plates

From winding to impregnation – Raúl Morón Ballester 11

Reaction - SplicingLifting tool for mould

Status: Ready

Splicing tool

Status: Manufacturing launched (in-house)

From winding to impregnation – Raúl Morón Ballester 12

R-S-I HandlingRotating table for Winding – Splicing - Impregnation

Status: Offers received, contract to be placed on W51. Delivery: Mid-March

From winding to impregnation – Raúl Morón Ballester 13

ImpregnationVACUUM PRESSURE IMPREGNATION SYSTEM• Characteristics:

• Pressure difference injection or dosing pump injection• Mixing and outflow reservoirs outside the vacuum chamber• Possibility to apply pressure up to 5 bar in each of the reservoirs independently• Tilting of the chamber up to 18 degrees• Auto-cleaning

Status: Technical documents approved. Components ready by first week of January. First injection tests end of January. Machine commissioned: end of March.

Credits: Elytt Energy

From winding to impregnation – Raúl Morón Ballester 14

ImpregnationImpregnation mould

Status: DO launched Expected end of March

Resin injection can be done from base to top or axially (Axial method has been the usual up to now, but radial method is being tested due to its scalability)

From winding to impregnation – Raúl Morón Ballester 15

Tooling delivery VS. Planning

Missing tool Expected Needed

Winding tension control improvement End of February Mid March

Half-shelves for curing mould Mid-February Mid-March

Coil Handling tool Delivered - To be tested Mid-April

Reaction Mould - Extra blocks End of December First half of January

Splicing tool End of January Mid-February

Rotating table Mid-March End of March

Impregnation fixture End of March End of April

Vacuum Pressure Impregnation System End of March End of April

From winding to impregnation – Raúl Morón Ballester 16

Conclusions• The process has been proven successful up

to curing.

• The reaction and impregnation changes always allow a fall-back solution. Tests are in progress to validate the concepts.

• The delivery of the missing tooling/machines does not interfere with the planning.

From winding to impregnation – Raúl Morón Ballester 17

Acknowledgments• F. Savary, H. Prin, S. Luzieux, S. Izquierdo Bermudez,

F. Lackner, R. Principe, L. Grand-Clement, E. Grospellier, C.H. Löffler, J.C. Perez, F.O. Pincot, R. Gauthier,D. Smekens, J. Mazet, M. Karppinen, T. Sahner, J. Parrilla Leal, A. Temporal, L. Favre, C. Mucher (CERN)

• A.R. Nobrega (FNAL)• P. Revilak, S. G. Will (Babcock Noell)• V. Letellier, T. Genestier (Alstom)