The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

Transport and Handling (T&H) considerations for HL-LHC

I. Ruehl – CERN / EN-HE

Standards and Best Practices WorkshopCERN 13th June 2014

HL-LHC Standards and Best Practices Workshop 2

Outline

• General issues• Surface T&H• Surface → LHC underground transfer• LHC underground T&H• Your input• Conclusion

3

General IssuesNeed to consider all phases• Delivery of components

• Assembly

• Test

• Storage

• Transfer to shaft

• Lowering (crane or lift ?)

• Loading underground

• Transport along tunnel (co activities)

• Unloading / Transfer onto supports

• Removal for repair

Integration

• Space for transport, unloading and transfer / installation• Allow for guidance error margin• Allow co-activity (passage next to transport

zone)

• Space for loading lowered items

• Consider logistics (parking and passing places)

• Integrate T&H requirements into equipment and infrastructure design as early as possible – saves time and money; avoids conflicts & increases SAFETY!!!

HL-LHC Standards and Best Practices Workshop

4HL-LHC Standards and Best Practices Workshop

General Issues – Space → INTEGRATION!

5HL-LHC Standards and Best Practices Workshop

Road transports• ≤ 44 tons • Dimensions: 25 m length x 4m wide

(incl. truck and trailer)• (second category – permanent authorization for

CERN during LHC construction)

• >44t ≤ 55 tons• Dimensions upon limitation of roads

and local infrastructure• (third category – special request/authorization)

• > 55 tons• Dimensions as for ≤ 55 tons• need specialized company• (third category – special request/authorization)

CERN road transport equipment

Charges divisibles : PTRA 44 TONNES MAXIMUM

Camion Remorque Poids total roulant PTRA CHARGE(à vide) UTILE (kg)

409 536 12950 40000 27050417 537 20800 44000 23200410 538 20250 44000 23750412 535 33300 44000 10700412 541 30500 44000 13500412 542 29750 44000 14250415 535 28300 44000 15700415 541 25500 44000 18500415 542 24750 44000 19250

Charges indivisibles

Camion Remorque Poids total roulant PTRA CHARGE(à vide) UTILE (kG)

409 536 12950 40000 27050417 537 20800 96000 55000410 538 20250 96000 55000412 535 33300 95000 (61700)412 541 30500 95000 41000412 542 29750 95000 30500415 535 28300 75000 46700415 541 25500 75000 41000415 542 24750 75000 30500

6HL-LHC Standards and Best Practices Workshop

Mobile crane 220t

Mobile crane 55t

Pick & carry 16t

Forklift - Diesel

Road / Surface T&H equipment

Straddle carrier 37t

Cranes:• 2 mobile cranes for loads up to 220t (30t at

100m deep)• 1 pick and carry crane 16t• Telescopic forklift 12t• Straddle carrier 37t• 345 EOT cranes up to 280t Forklifts:• 25 diesel forklift up to 6t• 1 diesel diesel 12t• 13 electrical forklifts up to 4t

Trailers, MEWP etc.Forklift - Electrical

MEWP

HL-LHC Standards and Best Practices Workshop 7

PMI2

PX25

PM25

PM45

PX45

PM65

PX65

PX85

PM85

PMI5

Surface – LHC underground transfer: Cranes

PX15

PX54

8HL-LHC Standards and Best Practices Workshop

Standard shaft zone

Figure shows list of cranes by point with capacity and ‘horizontal’ load dimension.Maximum dimensions can be increased on case by case study.

Surface – LHC underground transfer: Cranes

SHAFTS SWL Length WidthPM PM15 20t 5.5m 1.5m

PM25 10t 4.5m 1.5mPM45 10t 4.5m 1.5mPM65 10t 4.5m 1.5mPM85 10t 4.5m 1.5mPMI2 40t 20m 1.5m

PX PX25 65t 9.5m 1mPX45 80t 9.5m 1mPX65 80t 9.5m 1mPX85 80t 8m 1mPX15 16t 7m 1.5mPX54 20t 7m 1.5m

9HL-LHC Standards and Best Practices Workshop

Example of technical spec:PR719 80T SX6-PX65-UX65

Surface – LHC underground transfer: Cranes

10HL-LHC Standards and Best Practices Workshop

Surface – LHC underground transfer: PM shafts

HL-LHC Standards and Best Practices Workshop 11

Surface – LHC underground transfer: LiftsPoint Pitch Cabin Doors Range Max. load Nb of persons Speed Manufacturer

Depth Width Height Width Access transportedUnit mm mm mm mm - m Kg - m/s

1 PM15 2700 1850 2700 1850 2 (1) 82.481 3000 33 1.6 SchindlerPM18 1550 1450 2000 1200 2 81.7 1000 12 0.6 AlimakPX15 2650 1750 2700 1850 3 (1) 91.81 3000 33 1.6 AS Ascenseurs

2 PM25 2700 1850 2700 1850 2 (1) 45.35 3000 33 1.6 SchindlerPX24 (L1) 1400 1100 2500 800 3 (1) 51.34 630 8 1 SchindlerPX24 (L2) 1400 1100 2500 800 5 (1) 24 1000 13 1 Schindler

3 PZ33 2100 1100 2200 900 2 (1) 99.25 1000 13 1.6 SchindlerPM32 2000 1300 2000 1275 2 67.4 1125 15 0.55 Alimak

4 PM45 2700 1850 2700 1850 2 (1) 138.31 3000 33 1.6 SchindlerPZ 45 2100 1100 2500 900 2 (1) 143.64 1000 13 2.5 Schindler

5 PM54 2700 1850 2700 1850 4 (1) 97.05 3000 33 1.6 AS AscenseursPM56 1950 1050 2500 900 2 (2) 90.015 1000 13 2.5 Schindler

6 PM65 2700 1850 2700 1850 2 (1) 94.845 3000 33 1.6 SchindlerPZ65 2100 1100 2500 900 2 (1) 100.57 1000 13 2.5 Schindler

7 PM76 1950 1050 2500 900 2 (2) 96.432 1000 13 2.5 Schindler8 PM85 2700 1850 2700 1850 2 (1) 99.596 3000 33 1.6 Schindler

PZ85 2100 1100 2500 900 2 (1) 104.24 1000 13 2.5 Schindler

European norms EN81 (Oct 77 Bruxelles)& normsSIA 370/10 (79 - Zurich edition)

(1) Acess from same side(2) Acess from oppposite side

12HL-LHC Standards and Best Practices Workshop

LHC underground T&H

Volume reserved for transport

13HL-LHC Standards and Best Practices Workshop

Fenwick-Linde 6t

Volk 30tMafi 20t

Trans-Lift 2.5tPefra

LHC underground T&H: Standard solutions

Mobilev 2t

14HL-LHC Standards and Best Practices Workshop

LHC underground T&H: Specific solutionsLHC cryo-magnet T&H equipment• Advantages• Allows installation with very limited

clearance (250 to 300 mm) underneath the cryo-module

• Transfer tables allow small longitudinal corrections during resp. after lateral movement

• Disadvantages• Very sophisticated, complex and

consequently maintenance intensive• Tunnel almost entirely blocked

during transport operation

LHC ‘warm’ magnet T&H equipment• Advantages• All-in-one solution for longitudinal transport and

lateral transfer• No longitudinal offset when wheels turn 180°• Operates on slopes up to 7%• Operator friendly

• Disadvantages• Require considerable clearance (>500 mm)

underneath the machine components• Requires exact positioning since jacks can only

compensate for a very slight misalignment• Tunnel almost entirely blocked during transport

operation

LHC underground T&H: Cryo-magnets Courtesy K. Artoss

• 3 trailer types : CTU, MCTU, STU• MCTU (LSS and dipoles)

LHCHMUMV0042 and 43

• Removable support points (3)

Lateral distance: 432, 530, 630 mm

16

LHC underground T&H: Specific solutions Courtesy JL. Grenard

Shielding at each extremity

Power connected to the monorail

Motorized lifting spreader

Side collision detection

Recovery manual hydraulic control

Boom collision detection

Trailer-Crane unit for remote handling of Collimators 1t• Collimators designed with automatic service

connections• Integrated mechanical guiding system

17HL-LHC Standards and Best Practices Workshop

Your inputT&H study specification sheet

Equipment description / characteristics / drawings / specifications indicating:

• Length / Width / Height• Weight• Support / Fix point(s)• Lifting point(s)• Center of gravity• Maximum acceleration limits• Vibration limits• Temperature limits• Natural frequencies• Quantities to be transported & installed• Additional equipment weight & dimension if required for transport e.g. spreader beam• Interconnection details• Cross section drawing of equipment in tunnel• …

HL-LHC Standards and Best Practices Workshop 18

Conclusion• Available T&H means at CERN covers some (most?) of HL-LHC

requirements BUT• new cryo-magnet layout/dimensions may require a complete new

set of equipment for T&H operations• inner triplet (a.o.) replacements needs in-depth studies

• We need your input to define our WPs• integrate T&H requirements into equipment and infrastructure design as early as

possible

• Smart design solutions / layouts to be applied whenever possible and in particular when remote handling becomes necessary (radiation level; ALARA principle)

→ see presentation by K. Kershaw• Please provide a certified spreader / lifting beam with your supply

HL-LHC Standards and Best Practices Workshop 19

ContactsFor more details, questions etc. please contact either

or

The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

HL-LHC Standards and Best Practices Workshop 20

¿QUESTIONS?