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Mechanical Design of Collimators and Manufacturing Strategy Review of the Cryogenic By-pass for the LHC DS Collimators 26.05.2011 Alessandro Bertarelli (EN-MME) on behalf of the EN-MME Collimation Team with inputs from many colleagues in EN, TE and BE departments. TCLD Mechanical Design. - PowerPoint PPT Presentation
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1
Mechanical Design of Collimators and Manufacturing Strategy
Review of the Cryogenic By-pass for the LHC DS Collimators26.05.2011
Alessandro Bertarelli (EN-MME)on behalf of the EN-MME Collimation Team with inputs from many colleagues in EN, TE and BE departments
A. Bertarelli EN/MME 26.05.2011 2
TCLD MECHANICAL DESIGN
A. Bertarelli EN/MME 26.05.2011 3
COLLIMATOR MODULE (TCLD) LAYOUT
Ion Pump(30 L/s)
Ion Pump(30 L/s)
Pirani Gauge
Penning Gauge
Angle valve
Collimator Support Assembly (HTC_)
Warm Module (VMGDA)
Key Features• TCLD fully independent
from QTC• Specific support and
jacks for TCLD.• Horizontal Orientation• Hydraulic and
electrical manual connections
Vacuum Equipment
Mechanical Equipment
Collimator Jack
Collimator Module(TCLD)
A. Bertarelli EN/MME 26.05.2011 4
TCLD
Actuation system
Vacuum tank
Vacuum tankand jaws
TCLD PRODUCT BREAKDOWN
A. Bertarelli EN/MME 26.05.2011 5
Key Features• Total length: 1200 mm
(including 100m tapering)• Active length: 1000 mm (5
blocs x 200 mm)• Asymmetric jaw
supporting system
• Continuous cooling circuit
• Contactless RF shielding
• BPM pickups: 2 per jaw• Temperature Diagnostics
(2 PT100 per jaw)
TCLD JAW DESIGN (1/2)
BPMPick-up buttons
Back Stiffener(Glidcop C15715)
Jaw Support System
Cooling Tube(Copper-Nickel CuNi10)
Jaw Block x 5(Tungsten Alloy)
Support(Glidcop C15715)
A. Bertarelli EN/MME 26.05.2011 6
75mm
69mm
40mm
TCLD JAW DESIGN (2/2)
Key Features• Block width: 20 mm• Block height: 30 mm• Bloc material:
95%W+3.5%Ni+1.5%Cu (Inermet IT180)
• Water Flow rate: ≤ 5 L/min (3 m/s)
• Water Inlet Pressure 9÷16 bar
• Test pressure 50 bar
Jaw assembling principles
Brittle W block contained by Glidcop support
Vacuum Brazing betweenSupport, Pipe and Stiffener
Free pressed contact between W and Glidcop
(15 bar pressure)Contact between W and Glidcop ensure by A4 St.
Steel Screw
A. Bertarelli EN/MME 26.05.2011 7
• Specified Heat Loads− 40 W (Steady-state – 1 hr Beam
Lifetime)− 200 W (10 s transient – 0.2 hr Beam
Lifetime)• Specified max Thermal Deflection
• 50 µm (Steady-state)
• Expected thermal deflection• 12 µm (Steady-state)• 20 µm (10 s transient)
7
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10.0E+00
2.0E-06
4.0E-06
6.0E-06
8.0E-06
1.0E-05
1.2E-05
1.4E-05
1.6E-05
1.8E-05
2.0E-05
Displ. (m)/40 W cont. Displ. (m)/200 W for 10s
Position in the jaw (m)
Dis
plac
emen
t (m
)
Beam
fact
or 4
THERMAL LOAD ON JAW
A. Bertarelli EN/MME 26.05.2011 8
RF Bridge(CuBe)
RF Ferrite Tiles
RF screen/tank contact (CuBe)
RF CONFIGURATION FOR TCLD
BEAM
Design validated by BE-RF simulations
RF Extremity Fingers
(Ag-coated CuBe)
RF Screen(Stainless Steel)
A. Bertarelli EN/MME 26.05.2011 9
9/26
ACTUATION SYSTEM
Support Frame
(Al 6082)
Stroke switch x 5
Sliding Table 1
(Al 6082)
Sliding Table 2
(Al 6082)
Stroke LVDT x 3
Stepping MotorX 2Linear Bearing and Shaft
X 2
Return SpringX 2
Key Features• 1 D.o.F per jaw (1
motor, no angular adjustment)
• Jaw stroke: 25 mm • Jaw auto-retraction up
to ~ 170 mNm (no auto-retraction in case of motor short-circuit)
• Phase 1 Stepping Motors and Electronics
A. Bertarelli EN/MME 26.05.2011 10
SFERAX 4060Dim.= D60; d40; L72 mmStainless steel(tested on Phase 2 Table
for 30000 cycles) 10/26
ACTUATION SYSTEM
• All-metal sealed Linear Ball Bearings
• Graphite Dry Film Lubricated (DAG 156)
• Graphite Sealing Ring
A. Bertarelli EN/MME 26.05.2011 11
MANUFACTURING STRATEGY
A. Bertarelli EN/MME 26.05.2011 12
1. DS Collimators for IR3 (LTC) – 5 units• Engineering & Design• Manufacturing and assembly of 5 units (QTC+TCLD)
2. Phase 1 collimators for IR3 (Phase 1+) – 7 units. • Design update.• Manufacturing of 1 Primary Collimator (TCP)• Procurement of raw material and strategic components.
3. TCTP (Tertiary Collimators with BPMs) – 18 units.• Engineering & Design • Manufacturing of 1 prototype. • Procurement of raw material and strategic components.
4. Phase 2 Advanced Collimators – 3 prototypes.• R&D, Engineering, Design • Manufacturing of 3 prototypes.
EN-MME WORK-PACKAGE
Object of this review
A. Bertarelli EN/MME 26.05.2011 1313/13
JPh Tock TE/MSC-CI
WORK-PACKAGE ORGANISATION
WP Coordinator (A. Bertarelli)
TCTP Engineering and Design
(A. Dallocchio)
Engineering Support
Collimator Design
(L. Gentini)
LTC Engineering and Design
(D.D. Ramos)
Cryostat design(P. Minginette)
Collimator design
(M. Timmins)
Engineering support
LTC and TCTP Manufacturing
(A. Cherif)
QTC manufacturing
(R. Claret)
TCLD and TCTP manufacturing
(A. Cherif)
Procurement &Subcontracting
(P. Moyret)
Logistics
Quality Assurance (EN-MEF support)
Phase 1+ and Phase 2 not shown
A. Bertarelli EN/MME 26.05.2011 14
• Extensively rely on existing/proven designs and technologies • Co-Design / Close cooperation with “Technology-owner” groups
− Bus-bar (TE-MSC), UHV components (TE-VSC), Cryogenics (TE-CRG), Cold Tests (TE-MSC), Survey (BE-ABP), Fluka (EN-STI), Integration (EN-MEF), BPMs (BE-BI) …
• Extensive subcontracting of manufacturing− Machined components, “controllable” welded components
• In-house critical activities− Critical welding, assembly, controls, tests …
− CERN resources complemented by Industrial Support contracts
• Separate manufacturing lines for TCLD and QTC− TCLD in specific facility at B.100
− QTC in B.112 or SMI2 (feasibility analysis ongoing)
WORK APPROACH
A. Bertarelli EN/MME 26.05.2011 15
Fina
l Des
ign
Rel
ease
d
Sept. 2011
TCLD Manufacturing in the shadow of QTC
May 2011D
rafti
ng a
nd d
esig
n re
view
Long-lead items Procurement – Facility Preparation
Manufacturing & Cold Test of QTC 1 (1st Prototype)
June 2011
Manufacturing & Cold Test of QTC 2 and QTC 3
Manufacturing & Cold Test of QTC 4 and QTC 5
MANUFACTURING TIMELINE
May 2012
Col
limat
ion
Rev
iew
(ins
tall.
rele
ase)
Dec.2012
July 2013
Kept as spare Two Assembly Teams (Staff + Ind. Supp.)
A. Bertarelli EN/MME 26.05.2011 16
• Many interactions with several parties during assembly and testing phases.
• Use of subcontracted resources for QTC manufacturing requiring training and close follow-up.
• Risks of manufacturing conflict with other priority projects (Linac4, Shut-down preparation, other collimators) in case of delays.
• LTC production to end by late spring 2013. Conflicts in manpower allocation with Splice Consolidation cannot be ruled out.
CHALLENGES
A. Bertarelli EN/MME 26.05.2011 17
Thank you for your attention!
A. Bertarelli EN/MME 26.05.2011 18
BPM CABLES CONFIGURATION
Cable rooting
4 feadthrough connections on tank cables
Brazed Jaw
Tungsten support
Cooling circuit
Back stiffener
A. Bertarelli EN/MME 26.05.2011 20
Screwed from behind after brasing
5 Tungsten blocks (20 x 30 x 200)
Tungsten block assembly
A. Bertarelli EN/MME 26.05.2011 21
Seen from the inside15o slopes
1.6mm gap
50mm (maximum opening)
A. Bertarelli EN/MME 26.05.2011 22
RF CONFIGURATION FOR TCLD COLLIMATOR – extra illustrations
RF screen/tank contactRF screen contacts
RF extremity fingersHorizontal fixed contactVertical mobile contact
4 Temperature probes (1at each jaw extremity)
TEMP. PROBE CONFIGURATION
A. Bertarelli EN/MME 26.05.2011 24
Step Motor Bearing
Roller screw SpringMechanical Stops
Stroke adjustment
ACTUATION SYSTEM
A. Bertarelli EN/MME 26.05.2011 25
W-GLIDCOP THERMAL CONTACT
hc P( ) 1.55ks a
Rq
2 PE' a
0.94
Glidcop to WPressure 15 barhc = ~5000 kW/m2.K
0 5 105 1 106 1.5 106 2 1060
2 103
4 103
6 103
8 103
hc P( )
P
26
27
A. Bertarelli EN/MME 26.05.2011 28
ID Task Name
2 LTC (DS Collimator Assy) In-house production3 Engineering9 QTC (By-pass Cryomodule)10 Design and drafting29 Drawings released30 Material Procurement35 Manufacturing36 Production Release Review37 Preparation38 Bus-bars39 Bus-bars Avai lable40 End covers (x12)41 Flat End Assy (Welded & T ested)42 Conical shells integrated with End Covers43 Machined components (Bottom tray, ancil laries …)44 Cold Vacuum components (Beam screens, plug-ins, …)45 Vacuum Vessel SubAssemblies (Cradle, Seagull Plate, Flat Covers)46 MLI Manufacturing47 Tools Manufacturing48 Components cleaning49 Leak tests of subcontracted subassies50 QTC 1111 QTC 1 ex-works (ready for SM18)112 SM18 electrical/cold tests113 Preparation for Instal lation (stripping)114 QTC 1 ready for installation transport115 QTC 2176 QTC 2 ex-works (ready for SM18)177 SM18 electrical/cold tests178 Preparation for intal lation (stripping)179 QTC 2 Ready for intallation transport180 QTC 3241 QTC 3 ex-works (ready for SM18)242 SM18 electrical/cold tests243 Preparation for intal lation (stripping)244 QTC 3 Ready for intallation transport245 QTC 4306 QTC 4 ex-works (ready for SM18)307 SM18 electrical/cold tests308 Preparation for intal lation (stripping)309 QTC 4 Ready for intallation transport310 QTC 5371 QTC 5 ex-works (ready for SM18)372 SM18 electrical/cold tests373 Preparation for intal lation (stripping)374 QTC 5 Ready for intallation transport
26/05
16/06
28/09METSO
NortemecanicaNortemecanica
NortemecanicaTE-VSC
NortemecanicaJehier
TE-VSCTE-VSC
25/04TE-MSC
30/05
19/11TE-MSC
10/01
03/12TE-MSC
24/01
04/06TE-MSC
09/07
18/06TE-MSC
23/07
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug SepQtr 2, 2011 Qtr 3, 2011 Qtr 4, 2011 Qtr 1, 2012 Qtr 2, 2012 Qtr 3, 2012 Qtr 4, 2012 Qtr 1, 2013 Qtr 2, 2013 Qtr 3, 2013
SCHEDULE
A. Bertarelli EN/MME 26.05.2011 29
DRAFT BUDGET
Total (TBP)
Prov. (61711)
2011 (TBP) 2012 2013 2014 Total
(TBP)Prov.
(61711)2011 (TBP) 2012 2013 2014
Total 737.6 480.6 122.8 52.1 562.8 0.0 5949.0 1151.4 3095.6 2287.1 566.3 0.0
Sub-Total 971.6 30.6 0.0 12.8 5.1 12.8 0.0 306.0 285.6 204.0 91.8 10.2 0.0
Sub-Total 7725.2 707.0 480.6 110.0 47.0 550.0 0.0 5643.0 865.8 2891.6 2195.3 556.1 0.0
Total 1.4 0.2 0.8 0.4 0.0 0.0 20.4 5.7 7.8 6.9 3.5 0.0
Sub-Total 18.6 0.5 0.0 0.4 0.1 0.0 0.0 7.0 3.5 3.5 2.3 1.2 0.0
Staff 15.0 0.4 0.0 0.3 0.1 0.0 0.0 6.2 3.5 3.2 2.0 1.0 0.0
Fellows 3.6 0.1 0.0 0.1 0.0 0.0 0.0 0.8 0.0 0.3 0.3 0.2 0.0
Sub-Total 25.2 0.9 0.2 0.4 0.3 0.0 0.0 13.4 2.2 4.3 4.6 2.3 0.0
Staff 18.5 0.7 0.2 0.4 0.3 0.0 0.0 8.9 2.0 3.5 3.6 1.8 0.0
Fellows 2.3 0.0 0.0 0.0 0.0 0.0 0.0 2.3 0.2 0.8 1.0 0.5 0.0
43.8
Engineering
Production
Personnel(FTE)
Engineering
Production
8696.8
DS Collimators
Engineering, design
5 LTC ex-works. The budget includes work provided by SU and VSC as embedded "service". Components provided by MSC, BI, VSC for the as-delivered product are not included. It does not include components added at a later stage, e.g. Vacuum valves and gauges, motorization, electronics etc.
Scope
Grand Total(To Be Provisioned)
Phase 1+
Updated design
1 TCP + Plan B (backup production in case industry fails). Material procurement for Plan A and for equipment added after delivery (supports, plugins, cabling, support stands, cradles etc. ) is not included in this budget even if done by MME.
Material (kCHF)
Engineering
Production
A. Bertarelli EN/MME 26.05.2011 30
DRAFT BUDGET
Total (TBP)
Prov. (61711)
2011 (TBP) 2012 2013 2014 Total
(TBP)Prov.
(61711)2011 (TBP) 2012 2013 2014
Total 482.9 0.0 245.7 212.0 25.2 0.0 1527.3 552.1 237.0 458.9 548.1 283.3
Sub-Total 971.6 79.1 0.0 53.6 25.5 0.0 0.0 555.9 127.5 51.0 165.2 229.5 110.2
Sub-Total 7725.2 403.8 0.0 192.2 186.5 25.2 0.0 971.4 424.6 186.0 293.6 318.6 173.1
Total 3.8 0.0 1.9 1.9 0.0 0.0 18.2 4.5 2.4 4.1 5.2 4.5
Sub-Total 18.6 2.4 0.0 1.5 0.9 0.0 0.0 8.7 2.5 1.2 2.3 2.7 2.5
Staff 15.0 1.6 0.0 1.0 0.6 0.0 0.0 6.8 1.5 0.8 1.8 2.2 2.0
Fellows 3.6 0.8 0.0 0.5 0.3 0.0 0.0 1.9 1.0 0.4 0.5 0.5 0.5
Sub-Total 25.2 1.4 0.0 0.4 1.0 0.0 0.0 9.5 2.0 1.2 1.8 2.5 2.0
Staff 18.5 1.4 0.0 0.4 1.0 0.0 0.0 7.5 2.0 1.2 1.8 2.5 2.0
Fellows 2.3 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
43.8
Engineering
Production
Personnel(FTE)
Engineering
Production
Phase 2
R&D, Engineering, design
3 prototypes
8696.8
1 TCTx
Engineering, design
Tertiary Collimators with BPM
Scope
Grand Total(To Be Provisioned)
Material (kCHF)
Engineering
Production
A. Bertarelli EN/MME 26.05.2011 31
TCSG QTC TCLD TCSM BPM Proto Facility0
50000
100000
150000
200000
250000
300000
350000
400000
450000
500000
550000
600000Collimation Upgrade Spending for Manufacturing (2010 -
Jan 2011)
FacilityR&DSTI AssyToolingMockupEquipmentFinished PartsRaw mat