TCLD Mechanical Design

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


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)


TCLD

Actuation system

Vacuum tank

Vacuum tankand jaws

TCLD PRODUCT BREAKDOWN


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)


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


• 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


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)


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


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


MANUFACTURING STRATEGY


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


• 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


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.)


• 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


Thank you for your attention!


BPM CABLES CONFIGURATION

Cable rooting

4 feadthrough connections on tank cables

Brazed Jaw

Tungsten support

Cooling circuit

Back stiffener


Screwed from behind after brasing

5 Tungsten blocks (20 x 30 x 200)

Tungsten block assembly


Seen from the inside15o slopes

1.6mm gap

50mm (maximum opening)


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


Step Motor Bearing

Roller screw SpringMechanical Stops

Stroke adjustment

ACTUATION SYSTEM


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


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


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


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


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

TCLD Mechanical Design

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