context alternative design of ds collimators pre-design 1 pre-design 2 favorite option

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DS Collimators at IR3: mechanical engineering and design

LHC Collimation Upgrade Review08.07.2010

Alessandro Bertarelli, Alessandro Dallocchio, Delio Duarte Ramos, Luca Gentini, Christophe Mucher, Thierry Renaglia, Marc Timmins (EN-MME)

A. Bertarelli EN/MME 08.07.2010 2

• Context

• Alternative design of DS collimators

• Pre-design 1

• Pre-design 2

• Favorite option

• WP scope and deliverables

• Schedule and ressources (tentative)

• Conclusions

OUTLINE


1. Overall 70 WPs for 61+ units to be installed between 2012 and 2014.

2. 14 Dispersion Suppressor Collimators in DS of IR3, IR7 and IR2.

3. 4 DS Collimators in IR3 required for 2012 shutdown.

4. 10 Phase 1 Collimators (TCP, TCSG) to be installed in IR3 in 2012

(combined Betatron/Momentum cleaning).

This presentation focuses on the engineering, design and manufacturing of 4 DS Collimators for IR3 (Ralph’s WP 15 and 18) !

WORK-PACKAGE CONTEXT

Reminder of work-package breakdown proposed by R. Assmann for the upgrade of the Collimation System:

A. Bertarelli 16.06.2010 4

• Kick-off May 2010. All concerned groups represented/invited

(BE/ABP, EN/MME, EN/STI, TE/CRG, TE/MSC, TE/VSC, ….)

• Assess the possibility to have 4 collimators installed at the end of 2012 shutdown at point 3.

• Ensure that all system engineering issues related to the integration of the collimators in the LHC dispersion suppressors (DS) at point 3 are addressed.

• Issue specifications for all implied technical systems (collimation, cryogenics, SC lines, vacuum, motorization/controls, interfaces, RP …).

4/13JPh Tock TE/MSC-CI

TECHNICAL WORKING GROUP


Functional Specification (Excerpts) (See V. Parma’s talk) Main goal: gain a factor ~10 in (peak) power deposition on DS magnets (SC coils) both for protons and ions

1. 1m long movable Tungsten jaw2. 200 W max (during 10 s) per jaw.3. Two jaws per collimator (because of back-scattering and

positive DP/P for ions) Major complication for Collimator design

DS COLLIMATORS: SPECIFICATION


In principle two different technical approaches are possible for the design of DS collimators

1. Warm collimator with cold-warm transitions and cryogenic by-pass.

2. Cold collimator: jaws at cryogenic temperature (at ~ 80 -130K).

DS COLLIMATORS: ALTERNATIVE APPROACHES


TECHNICAL SOLUTIONS: PRE-DESIGN 1

Cryo by-passWarm CollimatorCollimator

external support

Cryo by-passjack

Collimatorjack



X line

Beam pipe 2

Vacuum Gate Valves (2 per

beam line)

Pre-installed collimator support

Collimator with vacuum equipment

Th . RenagliaM. TimminsL. Gentini

Collimator actuation system

Sliding space for W-bellows



Cold-warm transition

Bus-bar fixed point

In-situ formed bus-bar end

Pre-formed bus-bar end

Th . Renaglia



M. TimminsL. Gentini

Off-set actuating bellows



Tungsten Collimator jaws

Quad + Dipole Bus-bars (M1+M3)

Quad bus-bars (M2)



D. Duarte RamosCh. Mucher

External actuation system

Cold mass



D. Duarte RamosCh. Mucher

Jaw cooling hose (from

E-line)

Cu/W Collimator jaws with

embedded cooling pipe

He heater (from 55K to >80K)


Warm pre-design

Pros:1.Design inspired by FP420 project (TR).2.Mainly standard and known solutions.3.Warm collimators decoupled from

cryogenic by-pass (can be independently installed/removed)

Cons:4.Dimensions (up to 4.5 m).5.Intricate cryo-lines rerouting6.More complex manufacturing (two

separate objects): higher costs and times

7.Harder to accommodate in IR7 and IR2 (lack of space): new cold design required in 1,5 yrs?

Possible showstoppers:8. No showstoppers found so far …

TECHNICAL SOLUTIONS: PROS AND CONS

Cold pre-design

Pros:1. Compact and simpler cryostat (~3.2m vs. 4.5m), not

affecting cryo-lines (no re-routing)2. Less components, shorter manufacturing times(?), less

expensive construction (??).3. Synergy possible with GSI/FAIR project???

Cons:4. New concept (Cu jaw at >~80K?), requiring cryo-cooling.5. New design validation requires lot of testing.6. More engineering resources needed.7. Non-accessible collimator jaws (no in-situ repair or easy

replacement).8. Additional constraints to cryogenic operation.9. Cooling circuit derived from E-line with active controls in

cold and vacuum: reliability?

Possible showstoppers:10.Beam vacuum operation at 100K.11.Tungsten brittleness at low temperature.12.Possible additional heat from RF heating.


In view of risk assessment, the favorite option is clearly pre-design 1 (warm collimator)

Main features and issues:

1. Up to 4.5 m long between interconnection planes

2. Vacuum equipment required (per beam line): sector valves, ion pump, vacuum gauges…

3. Bus-bar routing concept agreed with TE-MSC (complete on-site forming).

4. W-type bellows can be used as-is provided sector valves are partially dismountable.

5. Special cryostat and X-Line are non-dismountable.

6. Warm collimator can be installed and removed independently from cryogenic by-pass.

7. Lateral displacement (up to ~4.5 cm) (to be further verified for transport, integration etc.)

TECHNICAL SOLUTIONS: FAVORITE OPTION


1. Work-package for the engineering, design, manufacturing and assembly of 4 integrated

DS Collimators (WP 15 + 18 from Ralph’s breakdown list) – Pre-design 1

2. Starting date: July 2010

3. Required inputs:

1. Successfully completed pre-study (no major showstoppers identified).

2. Go-ahead by this Technical Review.

3. Approved functional specification (BE-ABP, TE-MSC, TE-VSC, TE-CRG, EN-STI …)

4. WP deliverables: 5 (including 1 spare) complete units assembled and pre-tested

(pressure, leak, torque, metrology …).

5. Not included in WP:

1. Supply of bus-bars and splices, motors, sensors, vacuum equipment, cables …

2. Final collimator assembly (motors, cables, sensors, supports – WP26 EN-STI),

electric tests, cold tests (TE-MSC), transport and installation.

EN-MME WP SCOPE AND DELIVERABLES


1. Functional specification is frozen in July and no modifications occur afterwards.

2. All required resources are available.

3. Material procurement starts immediately after review go-ahead.

4. Externally manufactured components (in particular bus-bars and BB ancillaries)

are made available on time (~May 2011).

5. Collimator production and test facilities at b.100 and b.112 are set up on time (Is

b. 252 lab really lost for good?)

6. Reliability of all workshop production machines is assured.

7. Test equipment not owned by EN-MME (e.g. motor torque-meters) are made

available.

8. … No unexpected showstoppers are found on the way …(this is still pre-design!)

Schedule assumptions (pre-requisites)

TCRYO WP1: TENTATIVE SCHEDULE



Preliminary planning (no safety margin)


0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

2010 2011 2012 2013

FTE

Year

Required FTE by type and year

Engineering&Design Production&Quality Control

TCRYO WP1: ESTIMATED RESSOURCES

Estimated Personnel for TCRYO WP1: 36 FTE (14 Eng&Des, 22 Prod), including

staff, FSU and outsourced personnel (mainly for Production, partly for Drafting).


1. The planning does not take into account final assembly and tests (EN-STI,

TE-MSC, TE-VSC) (experience with Phase 1 Collimators is 1 month EN-STI

plus 1 week TE-VSC) ready for installation ~2 months after ex-works.

2. A production readiness review is to take place in June 2011 to give green light

to installation in late 2012 / early 2013.

3. Work sharing with other groups to be fine-tuned (ex. measurements with EN-

STI, bus-bar tooling with TE-MSC ….)

4. Additional Phase 1 collimators (6 units) and components for other Phase 2

WPs to be produced in parallel by EN-MME.

Some considerations



1. Two alternative solutions (cold and warm) were pre-studied by TCRYO WG:

best option is the warm solution.

2. No major technical showstoppers were identified for warm solution.

3. EN-MME WP scope is to manufacture 5 complete units (final assembly and

cold tests excluded).

4. Manufacturing of 4 complete units seem feasible by end of 2012 (with no

contingency), provided specification is frozen and procurement starts now.

5. Production Readiness Review to be held in June 2011.

6. Estimated Personnel for TCRYO WP1: 36 FTE, including staff, contract

personnel and outsourced personnel.

CONCLUSIONS


Thank you for your attention!


Bonus Slides!


CRYO-COLLIMATORS: PRE-DESIGN 1


WP Work Package IR # devices Start End Responsible EN-MME involved3 Design of CERN phase 2 collimators started giu-11 EN/MME Yes9 Shock wave & damage theory support giu-10 giu-15 Kurchatov Yes

10 Beam testing phase 2 collimators 5 mag-10 dic-11 EN/STI Yes13 External beam damage testing started dic-12 Kurchatov Yes14 Cryo-components for magnet movements: design mag-10 dic-12 TE/MSC Yes

15

I ntegrated mechanical engineering: Cryo collimators and warm-cold transitions mag-10 dic-12 EN/MME Yes

16 Vacuum components for cryo regions: design mag-10 dic-12 TE/VSC Yes24 Specify and procure cooling equipment (warm regions) mag-10 dic-14 EN/STI Yes6 Prototyping for CERN phase 2 collimators 3 started giu-11 EN/MME Yes7 Final assembly phase 2 prototypes 3 started giu-11 EN/STI Yes

17 Cryo-components for magnet movement: construction 3 mag-10 dic-12 TE/MSC Yes18 Cryo collimators: construction 3 4 mag-10 dic-12 EN/MME Yes19 Vacuum components for cryo regions: construction 3 mag-10 dic-12 TE/VSC Yes20 Construct additional phase 1 collimators (TCP, TCSG) 6 mag-10 dic-12 EN/MME Yes25 Vacuum components for scraper locations (TCHS) 3 2 mag-10 dic-12 TE/VSC Yes50 Cryo-components for magnet movement: construction 7, 2 gen-13 giu-14 TE/MSC Yes51 Cryo collimators: construction 7, 2 10 gen-13 giu-14 EN/MME Yes52 Vacuum components for cryo regions: construction 7, 2 gen-13 giu-14 TE/VSC Yes53 Phase 2 collimators for warm regions 3, 7 34 giu-11 dic-13 EN/MME Yes54 Construct additional phase 1 tungsten collimators 2, 6 4 giu-11 dic-13 EN/MME Yes56 Remote handling: construction 3, 7 gen-13 set-14 EN/HE Yes2 Simulation and optimization of collimation phase 2 started dic-14 EN/STI ?

23

Specify and procure cables for in-jaw diagnostics, 30 collimators 3, 7 mag-10 dic-14 BE/BI ?

26

Final assembly (motors, support, sensors) and test of collimators 14 gen-12 dic-12 EN/STI ?

27 Prepare & tests existing TCLP collimators 4 gen-12 dic-12 EN/STI ?

33

I nstallation & test cables for cryo collimators. Prepare the 12 cryo collimator locations as much as possible (ALARA).

3, 7, 2 nov-11 feb-13 EN/STI ?

55 Remote handling: design 3, 7 gen-11 dic-12 EN/HE ?

59

Final assembly (motors, support, sensors) and test of collimators 44 mag-12 giu-14 EN/STI ?

62

Implement changed layout in cryo region (24 magnets moved per IR) 7, 2 nov-14 apr-15 TE/MSC ?

PHASE2: EN-MME PROBABLE CONTRIBUTION


WP CONTEXT: EN-MME REQUIRED CONTRIBUTION

EN-MME as WP owner

WP Work Package IR # devices Start End Responsible3 Design of CERN phase 2 collimators started giu-11 EN/MME

15

I ntegrated mechanical engineering: Cryo collimators and warm-cold transitions mag-10 dic-12 EN/MME

6 Prototyping for CERN phase 2 collimators 3 started giu-11 EN/MME18 Cryo collimators: construction 3 4 mag-10 dic-12 EN/MME20 Construct additional phase 1 collimators (TCP, TCSG) 6 mag-10 dic-12 EN/MME51 Cryo collimators: construction 7, 2 10 gen-13 giu-14 EN/MME53 Phase 2 collimators for warm regions 3, 7 34 giu-11 dic-13 EN/MME54 Construct additional phase 1 tungsten collimators 2, 6 4 giu-11 dic-13 EN/MME


TCRYO WP1: MATERIAL PROCUREMENT

Preliminary list (non exhaustive) of components to be urgently procured

Components to be urgently procured : How many Who When WhereSC by-pass

1 1. Dished heads (5+5) 102 2. Pieds froids (10) 103 3. Bottom trays (5x4m) 54 4. CWT with bellows (LHC std) 20 205 5. Beam screen 20x1mxD50 106 6. Busbar 5 x 6 + 5 spools 307 7. Goulottes 5 x 6 308 8. Vannes DN63 20 209 9. Pompes ioniques 5 5

10 10. Cu LSS NEG-coated pipes 5 511 11. BS bellows 5 x 4 2012 12. Warm bellows 5 x 4 2013 13. Vacuum gauges and instrum.14 14. N-line hoses

Warm Collimator15 15. Roller screws 5 x 2 1016 16. Linear ball bearings 5 x 2 (axes + 2 douilles) 1017 17. Collim. bellows 5 x 4 2018 18. Tungsten blocs (200 mm) 5 x 10 5019 19. Ferrites20 20. Motors 5 x 2 10

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