Thierry RENAGLIA / Ramon FOLCH FP420 Manchester Workshop December 2006 FP420 Connection Cryostat Mechanical Design & Construction Key capabilities of CERN TS/MME

2 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 CONTENT Mechanical design & construction Key capabilities of CERN TS/MME 2. CONSTRUCTION1. DESIGN 3. CONCLUSION FP420 versus DFB ATM Pre-design Version #1 Pre-design Version #2 Mechanical analysis Pre-design Version #3 Open issues Advantages with CERN TS/MME Required framework conditions Main processes involved Schedule and possible lead times Cost drivers DFB ATM assembly experience

3 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 FP420 versus DFB ATM Continuity of the X and C lines Higher contraction of the busbar lines Fixed point to be relocated Longer interconnection bellow length Detector constraints (accessibility, precision) Radiation shielding Arc Termination Module Distribution Feed Box FP420 Cryostat

4 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Pre-design Version #1 Dipole cold foot to replace compensation system Couple two DFB ATM Allow contraction of the BB line

5 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Pre-design Version #2 Redesigned supporting beam Double cold feet to free space for line X

6 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Version #2 – Displacement analysis VACUUM CONDITION

7 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Version #2 – Displacement analysis VACUUM CONDITION + INTERCONNECTION at cold (operation conditions)

8 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Version #2 – Reaction analysis Bellow force - 10’000 N Reaction z - 32’500 N Reaction y 55’000 N Reaction z 70’000 N Cold condition (vacuum, bellow force)

9 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Pre-design Version #3 Two lowered supporting beams One single piece

10 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Version #3 – Open issues & next steps Detector supported by the cryostat: need to deal with movements during cooling down and operation Need of additional central fixed point and supporting jack Use the transport buggies and the lifting beams of the DFBAs Pre-design v#3 approval awaited

11 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Construction – Processes involved Machining (both heavy and accurate) Sheet metal forming (vacuum tanks, piping) MIG/TIG welding Thermal treatments / Surface treatments Mechanical fitting (Beam screen integration) Metrology / Alignment Vacuum test / x-Ray inspection Thermal super-insulation Electrical insulation assembly and test

12 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Schedule projection attempt Green light needed on time to allow the design work to start The production cannot start before the design is fully approved

13 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Cost drivers – What helps cutting them Re-use existent designed parts (cold feet, jacks, dished heads, etc) Experienced and multi-skilled workforce Avoid specific tooling Optimize the logistics between operations

14 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 CERN TS/MME experience on DFB ATM Design and mechanical analysis Full production and assembly of 16 ATM Budget and time constraints sealed in a interdepartmental workpackage agreement  Results: Early deliveries and costs below expectations after the 3 first units  Results: Early deliveries and costs below expectations after the 3 first units Arc Termination Module Distribution Feed Box

15 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Shuffling Box assembly

16 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Welding of the dished heads

17 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Cryostating of the Shuffling Module

18 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Thermal Super-insulation

19 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Final assembly

20 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 DFBA (ATM & HCM) Transport

21 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Conclusions Advantages with CERN/TS/MME – Design and construction synergy benefits – Shortened learning curve (skilled resources and appropriate equipment available) – Highly responsive multi-technological environment – Reduction of the logistics time and cost – Design and construction traceability (CDD/ EDMS / MTF) Required framework conditions – Obtain the formal approval of the pre-design – Obtain the final version of the technical specification – Adopt a workpackage oriented approach combining the mechanical design and the construction

22 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 The CERN TS/MME Mechanical and Materials Engineering group received the Golden Hadron Award (LHC best suppliers) Fair and efficient partnership with CERN Member States (here: Bulgaria)

23 / 23 FP420 Connection Cryostat FP420 Manchester Workshop - December 2006 Thanks for their contribution … Utilisation des ATM pour le projet FP420 - EDMS – Thierry Renaglia Use of the ATM for the FP420 Project EDMS – Thierry Colombet General information from the TS/MME ATM assembly team (Said Atieh, Laurent Préver-Loiri, Didier Lombard, and al.) …and thanks for your attention.