logo area Cold Mass Design, Assembly Plans & QC by US HL-LHC-AUP Antonios Vouris MQXF International Review – CERN, June 7 th – 10 th, 2016

logo area Outline  LMQXF cold mass design parameters.  LMQXF He vessel design approach.  Tooling, alignment and assembly process.  Weld procedures & inspection.  Cold Mass assembly site option.  Challenges and risks.  Conclusion Antonios Vouris– MQXF International Review, June 7 th -10 th 20162

logo area LMQXF Cold Mass Design Parameters Antonios Vouris– MQXF International Review, June 7 th -10 th 20163

logo area LMQXF He Vessel Design Approach  Fermi Safety Manual (FESHM) – Chapter 5000, Pressure Vessels.  ASME Boiler & Pressure Vessel Code Sect.VIII div. 1 (Design & Fabrication)  ASME B&PV Code Sect. IX (weld Proc./welder qual): tension, bend, X-ray  Design Note Review  Hazard Analysis  Material Traceability  Testing: NDE (X-ray, Liq. Pen.), Press Test, HMSLD. Antonios Vouris– MQXF International Review, June 7 th -10 th MaterialS allow (ASME) S allow (FESHM: 80% reduction) E=.80 (SPOT RT) NOTES SA SS Shell 20,000 psi16,000 psit= in. (7.42 mm) Sallow = 20 ksi (ASME) Sallow = 16 ksi (FESHM) P= 305 psig (21 bar) R=12.09 in. (307 mm) 304/304L (dual cert mat’l)

logo area LMQXF Cold Mass Tooling, Alignment & Assembly Antonios Vouris– MQXF International Review, June 7 th -10 th  Receive, inspect, align.

logo area LMQXF Cold Mass Tooling, Alignment & Assembly Antonios Vouris– MQXF International Review, June 7 th -10 th  Install tack blocks, weld back up strip in place and fit half shell and tack.

logo area LMQXF Cold Mass Tooling, Alignment & Assembly Antonios Vouris– MQXF International Review, June 7 th -10 th  Arrange clamps to lift and rotate and move to saddles.  Install beam tube, bus bar and instrumentation prior to verifying alignment.

logo area LMQXF Cold Mass Weld Procedures and inspection  GMAW Weld procedure – working with CERN to develop. Presently running samples at FNAL.  Full penetration welds required for Cryogenic pressure vessels.  With both half shells in place – alignment is verified with Stretch Wire measurement for pitch & yaw. Ferret (mole) for roll.  NDE: X-ray long weld seams and Liquid penetrant on nozzle welds.  Pressure test  HMS leak test Antonios Vouris– MQXF International Review, June 7 th -10 th 20168

logo area LMQXF Cold Mass Optional Assembly Site  BNL Antonios Vouris– MQXF International Review, June 7 th -10 th 20169

logo area LMQXF Cold Mass Optional Assembly Site  BNL Antonios Vouris– MQXF International Review, June 7 th -10 th

logo area Open Items Challenges & Risks  Functional requirements under review: Nozzle locations and sizes, support system, etc.  PED requirement – in discussion.  Low cobalt stainless steel material availability in U.S. possible challenge.  GMAW procedure utilized to minimize weld stress ( MPa) and magnet misalignment issues. Antonios Vouris– MQXF International Review, June 7 th -10 th

logo area Conclusion  Design has begun - open communications & continuous efforts are being made with CERN exchanging information and aiming for common design features as interface documents are developed for end dome nozzles, cryostat mounting supports, bus bar routing, instrumentation and electrical scheme.  Welding procedure specification are being developed and fine-tuned.  MQXFS1 Short model shell welding to be done in fall/winter of 2016 will help identify possible welding issues.  Site options are being evaluated for prototype cold mass assembly. Antonios Vouris– MQXF International Review, June 7 th -10 th