1. 1 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)

2. A. Bertarelli EN/MME 08.07.20102 ContextContext Alternative design of DS collimatorsAlternative design of DS collimators Pre-design 1Pre-design 1 Pre-design 2Pre-design 2 Favorite optionFavorite option WP scope and deliverablesWP scope and deliverables Schedule and ressources (tentative)Schedule and ressources (tentative) ConclusionsConclusions

3. A. Bertarelli EN/MME 08.07.20103 1.Overall 70 WPs for 61+ units to be installed between 2012 and 2014. 2.14 Dispersion Suppressor Collimators in DS of IR3, IR7 and IR2. 3.4 DS Collimators in IR3 required for 2012 shutdown. 4.10 Phase 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) ! Reminder of work-package breakdown proposed by R. Assmann for the upgrade of the Collimation System:

4. A. Bertarelli 16.06.20104 Kick-off May 2010. All concerned groups represented/invited (BE/ABP, EN/MME, EN/STI, TE/CRG, TE/MSC, TE/VSC, ….)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.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 …).Issue specifications for all implied technical systems (collimation, cryogenics, SC lines, vacuum, motorization/controls, interfaces, RP …). 4/13 JPh Tock TE/MSC-CI

5. A. Bertarelli EN/MME 08.07.20105 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  1.1m long movable Tungsten jaw 2.200 W max (during 10 s) per jaw. 3.Two jaws per collimator (because of back-scattering and positive  P/P for ions)  Major complication for Collimator design

6. A. Bertarelli EN/MME 08.07.20106 In principle two different technical approaches are possible for the design of DS collimators 1.Warm collimator with cold-warm transitions and cryogenic by-pass. 2.Cold collimator: jaws at cryogenic temperature (at ~ 80 - 130K).

7. A. Bertarelli 16.06.20107 Cryo by-pass Warm Collimator Collimator external support Cryo by-pass jack Collimator jack

8. A. Bertarelli 16.06.20108 X line Beam pipe 2 Vacuum Gate Valves (2 per beam line) Pre-installed collimator support Collimator with vacuum equipment Th. Renaglia M. Timmins L. Gentini Th. Renaglia M. Timmins L. Gentini Collimator actuation system Sliding space for W- bellows

9. A. Bertarelli 16.06.20109 Cold-warm transition Bus-bar fixed point In-situ formed bus-bar end Pre-formed bus- bar end Th. Renaglia

10. A. Bertarelli 16.06.201010 M. Timmins L. Gentini M. Timmins L. Gentini Off-set actuating bellows

11. A. Bertarelli 16.06.201011 Tungsten Collimator jaws Quad + Dipole Bus-bars (M1+M3) Quad bus- bars (M2)

12. A. Bertarelli 16.06.201012 D. Duarte Ramos Ch. Mucher D. Duarte Ramos Ch. Mucher External actuation system Cold mass

13. A. Bertarelli 16.06.201013 D. Duarte Ramos Ch. Mucher D. Duarte Ramos Ch. Mucher Jaw cooling hose (from E-line) Cu/W Collimator jaws with embedded cooling pipe He heater (from 55K to >80K)

14. A. Bertarelli EN/MME 08.07.201014 Warm pre-design Pros: 1.Design inspired by FP420 project (TR). 2.Mainly standard and known solutions. 3.Warm collimators decoupled from cryogenic by-pass (can be independently installed/removed) Cons: 1.Dimensions (up to 4.5 m). 2.Intricate cryo-lines rerouting 3.More complex manufacturing (two separate objects): higher costs and times 4.Harder to accommodate in IR7 and IR2 (lack of space): new cold design required in 1,5 yrs? Possible showstoppers: 1.No showstoppers found so far … Cold pre-design Pros: 1.Compact and simpler cryostat (~3.2m vs. 4.5m), not affecting cryo-lines (no re-routing) 2.Less components, shorter manufacturing times(?), less expensive construction (??). 3.Synergy possible with GSI/FAIR project??? Cons: 1.New concept (Cu jaw at >~80K?), requiring cryo-cooling. 2.New design validation requires lot of testing. 3.More engineering resources needed. 4.Non-accessible collimator jaws (no in-situ repair or easy replacement). 5.Additional constraints to cryogenic operation. 6.Cooling circuit derived from E-line with active controls in cold and vacuum: reliability? Possible showstoppers: 1.Beam vacuum operation at 100K. 2.Tungsten brittleness at low temperature. 3.Possible additional heat from RF heating.

15. A. Bertarelli EN/MME 08.07.201015 In view of risk assessment, the favorite option is clearly pre- design 1 (warm collimator) Main features and issues: 1.Up to 4.5 m long between interconnection planes 2.Vacuum equipment required (per beam line): sector valves, ion pump, vacuum gauges… 3.Bus-bar routing concept agreed with TE-MSC (complete on-site forming). 4.W-type bellows can be used as-is provided sector valves are partially dismountable. 5.Special cryostat and X-Line are non-dismountable. 6.Warm collimator can be installed and removed independently from cryogenic by-pass. 7.Lateral displacement (up to ~4.5 cm) (to be further verified for transport, integration etc.)

16. A. Bertarelli EN/MME 08.07.201016 1.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 2.Starting date: July 2010 3.Required inputs: 1.Successfully completed pre-study (no major showstoppers identified). 2.Go-ahead by this Technical Review. 3.Approved functional specification (BE-ABP, TE-MSC, TE-VSC, TE-CRG, EN-STI …) 4.WP deliverables: 5 (including 1 spare) complete units assembled and pre-tested (pressure, leak, torque, metrology …). 5.Not included in WP: 1.Supply of bus-bars and splices, motors, sensors, vacuum equipment, cables … 2.Final collimator assembly (motors, cables, sensors, supports – WP26 EN-STI), electric tests, cold tests (TE-MSC), transport and installation.

17. A. Bertarelli EN/MME 08.07.201017 1.Functional specification is frozen in July and no modifications occur afterwards. 2.All required resources are available. 3.Material procurement starts immediately after review go-ahead. 4.Externally manufactured components (in particular bus-bars and BB ancillaries) are made available on time (~May 2011). 5.Collimator production and test facilities at b.100 and b.112 are set up on time (Is b. 252 lab really lost for good?) 6.Reliability of all workshop production machines is assured. 7.Test equipment not owned by EN-MME (e.g. motor torque-meters) are made available. 8. … No unexpected showstoppers are found on the way …(this is still pre-design!) Schedule assumptions (pre-requisites)

18. A. Bertarelli EN/MME 08.07.201018 Preliminary planning (no safety margin)

19. A. Bertarelli EN/MME 08.07.201019 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. A. Bertarelli EN/MME 08.07.201020 1.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. 2.A production readiness review is to take place in June 2011 to give green light to installation in late 2012 / early 2013. 3.Work sharing with other groups to be fine-tuned (ex. measurements with EN- STI, bus-bar tooling with TE-MSC ….) 4.Additional Phase 1 collimators (6 units) and components for other Phase 2 WPs to be produced in parallel by EN-MME. Some considerations

21. A. Bertarelli EN/MME 08.07.201021 1.Two alternative solutions (cold and warm) were pre-studied by TCRYO WG: best option is the warm solution. 2.No major technical showstoppers were identified for warm solution. 3.EN-MME WP scope is to manufacture 5 complete units (final assembly and cold tests excluded). 4.Manufacturing of 4 complete units seem feasible by end of 2012 (with no contingency), provided specification is frozen and procurement starts now. 5.Production Readiness Review to be held in June 2011. 6.Estimated Personnel for TCRYO WP1: 36 FTE, including staff, contract personnel and outsourced personnel.

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30. A. Bertarelli EN/MME 08.07.201030 EN-MME as WP owner

31. A. Bertarelli EN/MME 08.07.201031 Preliminary list (non exhaustive) of components to be urgently procured