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Context Alternative design of DS collimators Pre-design 1 Pre-design 2 Favorite option

DS Collimators at IR3: mechanical engineering and design LHC Collimation Upgrade Review 08.07.2010 Alessandro Bertarelli , Alessandro Dallocchio, Delio Duarte Ramos, Luca Gentini, Christophe Mucher, Thierry Renaglia, Marc Timmins (EN-MME). Outline. Context

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Context Alternative design of DS collimators Pre-design 1 Pre-design 2 Favorite option

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  1. DS Collimatorsat IR3: mechanical engineering and designLHC Collimation Upgrade Review08.07.2010Alessandro Bertarelli, Alessandro Dallocchio, Delio Duarte Ramos, Luca Gentini, Christophe Mucher, Thierry Renaglia, Marc Timmins (EN-MME)

  2. Outline • Context • Alternative design of DS collimators • Pre-design 1 • Pre-design 2 • Favorite option • WP scope and deliverables • Schedule and ressources (tentative) • Conclusions

  3. Work-Package Context • Reminder of work-package breakdown proposed by R. Assmann for the upgrade of the Collimation System: • Overall 70 WPs for 61+ units to be installed between 2012 and 2014. • 14 Dispersion Suppressor Collimators in DS of IR3, IR7 and IR2. • 4 DS Collimators in IR3 required for 2012 shutdown. • 10Phase 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) !

  4. Technical Working Group • 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 …).

  5. DS collimators: Specification • 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  • 1m long movable Tungsten jaw • 200 W max (during 10 s) per jaw. • Two jaws per collimator (because of back-scattering and positive DP/P for ions)  Major complication for Collimator design

  6. DS collimators: Alternative approaches • In principle two different technical approaches are possible for the design of DS collimators • Warm collimator with cold-warm transitions and cryogenic by-pass. • Cold collimator: jaws at cryogenic temperature (at ~ 80 -130K).

  7. Technical solutions: Pre-Design 1 Collimator external support Warm Collimator Cryo by-pass Cryo by-passjack Collimatorjack

  8. Technical solutions: Pre-Design 1 Vacuum Gate Valves (2 per beam line) X line Collimator actuation system Sliding space for W-bellows Pre-installed collimator support Beam pipe 2 Collimator with vacuum equipment Th . Renaglia M. Timmins L. Gentini

  9. Technical solutions: Pre-Design 1 Bus-bar fixed point Pre-formed bus-bar end In-situ formed bus-bar end Cold-warm transition Th . Renaglia

  10. Technical solutions: Pre-Design 1 Off-set actuating bellows M. Timmins L. Gentini

  11. Technical solutions: Pre-Design 1 Tungsten Collimator jaws Quad + Dipole Bus-bars (M1+M3) Quad bus-bars (M2)

  12. Technical solutions: Pre-Design 2 Cold mass External actuation system D. Duarte Ramos Ch. Mucher

  13. Technical solutions: Pre-Design 2 Cu/W Collimator jaws with embedded cooling pipe He heater (from 55K to >80K) D. Duarte Ramos Ch. Mucher Jaw cooling hose (from E-line)

  14. Technical solutions: Pros and Cons • Warm pre-design • Pros: • Design inspired by FP420 project (TR). • Mainly standard and known solutions. • Warm collimators decoupled from cryogenic by-pass (can be independently installed/removed) • Cons: • Dimensions (up to 4.5 m). • Intricate cryo-lines rerouting • More complex manufacturing (two separate objects): higher costs and times • Harder to accommodate in IR7 and IR2 (lack of space): new cold design required in 1,5 yrs? • Possible showstoppers: • No showstoppers found so far … • Cold pre-design • Pros: • Compact and simpler cryostat (~3.2m vs. 4.5m), not affecting cryo-lines (no re-routing) • Less components, shorter manufacturing times(?), less expensive construction (??). • Synergy possible with GSI/FAIR project??? • Cons: • New concept (Cu jaw at >~80K?), requiring cryo-cooling. • New design validation requires lot of testing. • More engineering resources needed. • Non-accessible collimator jaws (no in-situ repair or easy replacement). • Additional constraints to cryogenic operation. • Cooling circuit derived from E-line with active controls in cold and vacuum: reliability? • Possible showstoppers: • Beam vacuum operation at 100K. • Tungsten brittleness at low temperature. • Possible additional heat from RF heating.

  15. Technical solutions: Favorite option • In view of risk assessment, the favorite option is clearly pre-design 1 (warm collimator) • Main features and issues: • Up to 4.5 m long between interconnection planes • Vacuum equipment required (per beam line): sector valves, ion pump, vacuum gauges… • Bus-bar routing concept agreed with TE-MSC (complete on-site forming). • W-type bellows can be used as-is provided sector valves are partially dismountable. • Special cryostat and X-Line are non-dismountable. • Warm collimator can be installed and removed independently from cryogenic by-pass. • Lateral displacement (up to ~4.5 cm) (to be further verified for transport, integration etc.)

  16. EN-MME WP Scope and deliverables • 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 • Starting date: July 2010 • Required inputs: • Successfully completed pre-study (no major showstoppers identified). • Go-ahead by this Technical Review. • Approved functional specification (BE-ABP, TE-MSC, TE-VSC, TE-CRG, EN-STI …) • WP deliverables: 5 (including 1 spare) complete units assembled and pre-tested (pressure, leak, torque, metrology …). • Not included in WP: • Supply of bus-bars and splices, motors, sensors, vacuum equipment, cables … • Final collimator assembly (motors, cables, sensors, supports – WP26 EN-STI), electric tests, cold tests (TE-MSC), transport and installation.

  17. TCRYO wp1: Tentative SCHEDULE • Schedule assumptions (pre-requisites) • Functional specification is frozen in July and no modifications occur afterwards. • All required resources are available. • Material procurement starts immediately after review go-ahead. • Externally manufactured components (in particular bus-bars and BB ancillaries) are made available on time (~May 2011). • Collimator production and test facilities at b.100 and b.112 are set up on time (Is b. 252 lab really lost for good?) • Reliability of all workshop production machines is assured. • Test equipment not owned by EN-MME (e.g. motor torque-meters) are made available. • … No unexpected showstoppers are found on the way …(this is still pre-design!)

  18. TCRYO wp1: Tentative SCHEDULE • Preliminary planning (no safety margin)

  19. 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).

  20. TCRYO wp1: Tentative SCHEDULE • Some considerations • 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. • A production readiness review is to take place in June 2011 to give green light to installation in late 2012 / early 2013. • Work sharing with other groups to be fine-tuned (ex. measurements with EN-STI, bus-bar tooling with TE-MSC ….) • Additional Phase 1 collimators (6 units) and components for other Phase 2 WPs to be produced in parallel by EN-MME.

  21. Conclusions • Two alternative solutions (cold and warm) were pre-studied by TCRYO WG: best option is the warm solution. • No major technical showstoppers were identified for warm solution. • EN-MME WP scope is to manufacture 5 complete units (final assembly and cold tests excluded). • Manufacturing of 4 complete units seem feasible by end of 2012 (with no contingency), provided specification is frozen and procurement starts now. • Production Readiness Review to be held in June 2011. • Estimated Personnel for TCRYO WP1: 36 FTE, including staff, contract personnel and outsourced personnel.

  22. Thank you for your attention!

  23. Bonus Slides!

  24. Cryo-collimators: Pre-Design 1

  25. Cryo-collimators: Pre-Design 1

  26. PHASe2:EN-MME Probable Contribution

  27. WP Context: EN-MME required contribution • EN-MME as WP owner

  28. TCRYO wp1: Material procurement • Preliminary list (non exhaustive) of components to be urgently procured

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