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Installation Progress and Challenges of LHC Cold Boxes – Technical Workshop Insights

This document provides an overview of the installation status and technical challenges encountered during the implementation of 13 LHC cold boxes. Led by Caterina Bertone from TS-IC, the workshop discusses the transportation and installation process of cryogenic distribution feed boxes and refrigerators. Key difficulties included structural modifications, intricate maneuvering requirements, and precise coordination among various technical sectors. Successful installation and detailed safety studies were paramount, with a total project cost of approximately 350k CHF, highlighting the complexities of the process.

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Installation Progress and Challenges of LHC Cold Boxes – Technical Workshop Insights

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  1. LHC cold boxes Installation and status Technical Support 2005 workshop Caterina Bertone TS-IC

  2. Cold boxes to be transported • 5 QUI – Cryogenic distribution feed boxes • 8 QURC – Cryogenic refrigerators Caterina Bertone TS-IC

  3. QUI – what is that? Caterina Bertone TS-IC

  4. QURC – what is that? Caterina Bertone TS-IC

  5. Try to concentrate on the most difficult… • A level of difficulty has been determined (1/3) to focus on most difficult cases • Level 3: QURC US85, US25, PM18 • The actual status: 12/13 cold boxes are installed, PM18 QURC in June 2005 Caterina Bertone TS-IC

  6. QURC UX85 – a challenge to prepare another • Installation in US85 passing by UX85 throughout tampon wall: Demolition of the wall • Deviation of general services and gas system • Installation of 20m long Z rail on the vault (to avoid interference with crane) • Preparation of US85 floor to roll electrical switchboards and installation of manifold • Use of hydraulic extra short jacks • Very spectacular flight and installation Caterina Bertone TS-IC

  7. Some pictures to explain Caterina Bertone TS-IC

  8. QURC US25 – what is that? Caterina Bertone TS-IC

  9. QURC US25 – no space, no means -> 3D simulation • Definition of maximum overall dimensions of AL components • Installation of 15t hoist and rail on the US25 vault • Definition of transport means Caterina Bertone TS-IC

  10. Manifolds • Length of manifolds > length of underground shaft – > in 4 parts • Temporary garage behind final position to allow welding : installation on shelf and remove stairs Caterina Bertone TS-IC

  11. QURC horizontal part • QURC higher than metallic structure (dismounted) • Maneuver with no room - > special roller seat + reduced high spreader • QURC width 1900mm, shaft dimension 1950mm -> nylon pads to allow lowering • Position of centre of gravity not correct to lift in US25 and rotate to final position -> addiction of counterweight in feet to compensate Caterina Bertone TS-IC

  12. QURC horizontal show • 1-2cm room in all phases of operation Caterina Bertone TS-IC

  13. QURC Vertical part • QURC longer than shaft -> need to be tilted with hoist chain system, special spreader • QURC width 1900mm, shaft width 1950mm • In underground extra-short rollers (110mm) to pass under the metallic structure • Rotating ring to be welded in the lower part to permit passage from horizontal to vertical in the US25: behind a rotating/rolling cradle, in front hydraulic shortenable spreader on the hook seat to lift • Counterweight on the back to correct center of gravity position • Insertion of K supports under QURC feet when suspended Caterina Bertone TS-IC

  14. Vertical part show Caterina Bertone TS-IC

  15. QURC vertical – show (2) Caterina Bertone TS-IC

  16. Conclusion • 12/13 cold boxes are in places. Installation has been successful • Detailed handling studies (3D, tools definition and construction) have been required • Coordination with different technical sectors (CE for rail and walls, EL for cabling modifications, CV for pipes de-routing, ….) was good • Safety aspects have been studied in detail with all safety procedures respected • Overall cost of installation has been ~350kCHF, i.e. 1% of the 12 cold boxes value • Last challenge QURC in PM18 soon!!! Caterina Bertone TS-IC

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