1. Scrubbing Review, 8/9/2015 Paul Cruikshank1

2. Contents SPS Layout aC factory options Assumptions & Scenarios Transport issues Radiation issues Coating issues aC & Impedance reduction Cost estimates Summary (costing details in annex – info only) Scrubbing Review, 8/9/2015 Paul Cruikshank2

3. aC deployment studies - past work & on-going SPS-U era presentations Nov 2008 @ SUSG - Oct 2009 @ AEC - April 2010 @ TFSU, J.Bauche April 2010, LMC & MAC, V.Mertens Nov 2010, J.Bauche (start of LIU-SPS era) April 2015, LIU-SPS, P.Cruikshank – update & variants Scrubbing Review, 8/9/2015 Paul Cruikshank3 Extract from draft report ‘Nine years of carbon coating for SPS upgrade: achievements and heritage’ Experience with coating and performance of 16 MB and 5 Quads in SPS

4. SPS Layout Scrubbing Review, 8/9/2015 Paul Cruikshank4

5. SPS Layout Scrubbing Review, 8/9/2015 Paul Cruikshank5 MBB MBA QFSSSMBASSSQDMBB MBA SSSQF Cells% SPSChamber type X-section (mm) FormUnits /cell Chamber (mm) Chamber /cell % cell% SPS 84+12 Arc+DS 88.9 MBA152 x 36.5Rect466602664041.637.0 MBB129 x 48.5Rect466402656041.536.9 QF mag152 x 38.3Elipse13346 5.24.6 QD magDia 83Round13346 5.24.6 QF SSS152 x 36.5Ellipse12052 3.22.8 QD SSSDia 83Round12052 3.22.8 63995100.088.9 1 cell = 63995 mm

6. SPS layout Scrubbing Review, 8/9/2015 Paul Cruikshank6 BA1 BA2 BA3 BA4 BA5 BA6 Meyrin, P1 LHC (magnet lift) Prevessin (magnet lift) RF TT40 ext TT20 ext Future dump Injection & Dump TT60 ext ECX5 BHA5 (magnet lift) DS LSS ARC 1 cell BA Total for SPS arc & DS = 744 Dipoles, 198 Quads, 192 SSS 14 cells

7. aC factory options Scrubbing Review, 8/9/2015 Paul Cruikshank7 BA2 lift BA3 lift BA6 lift BA4 bridge crane BA5 bridge crane Transit aC ex-situ factory (underground, eg EXC5) aC in-situ factory aC ex-situ factory (local) aC ex-situ factory (remote) 192 SSS 198 Quad 744 MB Tunnel transport Surface transport Underground activity Surface activity aC typical sequence: Disconnect (vac + mech) Transport aC coat Transport Survey (x,y,z,tilt) Reconnect (vac + mech Survey (smoothing) Eg BHA5Eg 867 or SMA18

8. Ex-situ v in-situ aC coating Scrubbing Review, 8/9/2015 Paul Cruikshank8 Ex-situ benefits: Working environment Radiation constraints Access Combined consolidations Parallelism of LS activities Corrective actions In-situ benefits: Transport & logistics Transport risks Building space Disconnection Realignment Recommisioning

9. Some assumptions…. To determine costings, a time window had to be assumed. For a-C case, 1 year project (LS2 baseline at that time). Nominal rate of 6 magnets/day Analysis limited to standard zones (arc & DS) Industrial support required to support specialist staff teams (VSC, SU, MSC, HE, ….) Scrubbing Review, 8/9/2015 Paul Cruikshank9

10. Scenarios considered Scrubbing Review, 8/9/2015 Paul Cruikshank10 MBB MBA QFSSSMBASSSQDMBB MBA SSSQF

11. Transport issues (1) Inputs C. Bertone EN-HE Tunnel transport: MB using ‘Dumont’ + ‘Volk’ tractor + tailor(s) Quad using Dumont (in quad configuration) 2 Dumonts in operation 3 rd Dumont requires renovation Cruise of 6 magnets/day requires 3 Dumonts, with associated tractors and trailors (~ 380 kCHF investment). SSS using Pratt side lifter + tractor 1.5 SSS/day requires additional Pratt & tractor (90 kCHF). Night shifts add 50% to manpower cost Scrubbing Review, 8/9/2015 Paul Cruikshank11

12. Transport issues (2) Lifting to surface BA1 - no facilities BA2 - lift, no surface infrastructure BA3 - lift, coactivity with cavity works in LS2 BA4 - bridge crane, requires opening ECX4 wall and ext septum removal BA5 –bridge crane, requires opening ECX5 wall, coactivity with beam dump in LS2 BA6 - lift, coactivity with P1 ground logistics BA7 - lift, requires demounting of TT60 chicane (plus transfer lines - photo?) Surface logistics Requires lorry & driver(s) if a-C factory not at shaft head Requires mobile crane for loading if transport via BA2 (1 of 2 CERN mobile cranes) Requires handling team at lifting point, and also destination if aC factory not at shaft head Surface transport Via BA3 implies passage in front of CCC (night only?) Via BA2 implies public road transport – see radiation considerations. Via BA6 implies public road transport – solution to temporarily link P1 (CH) & P1.8 (Fr)? Via BA7 gives access to zone 1.8 infrastructure. Several exit/logistic zones creates flexibility (C. Bertone) Scrubbing Review, 8/9/2015 Paul Cruikshank12 BA7 BA6 LHC SPS BA6 BA7 SMA18 ??

13. Radiation issues (1) Inputs H.Vincke & N.Conan Extensive radiations surveys made in SPS by RP team Dose rates known for machine components @ 40cm & 100 cm SPS survey Feb 2013 gives some indication for future LS LSS significantly higher than arcs Scrubbing Review, 8/9/2015 Paul Cruikshank13

14. Radiation issues (2) aC works will require work dose planning, DIMR Sequencing of arcs to gain from cooling – eg start BA1 six months later than BA5. Scrubbing Review, 8/9/2015 Paul Cruikshank14 6 months

15. Radiation issues (3) Estimate time at 40 cm – eg in-situ tasks on magnets Estimate time at 100 cm – eg transport area 6 magnet/day implies up to 1000 hrs in tunnel for in-situ aC. For dipoles @ 40 cm : 5% > 50 uSv/hr, 14% > 15 uSv/hr, 43% > 2 mSv/hr (Feb 2013) Optimisation for work method to minimize exposure Need dose estimates for each arc/sextant Hotter zones will need special approach – shielding, ex-situ…. Contact dose > 2 mSv/hr requires ‘containment’ for public road transport Work closely with RP experts when coating needs are confirmed Scrubbing Review, 8/9/2015 Paul Cruikshank15 LSS

16. Survey issues Inputs P. Bestmann SPS has no reference network. Wall brackets no longer in use. SPS machine is its own reference - Quads Annual alignment campaigns performed. Extensive alignment experience for SPS machine components Survey activities during LS1 < 2 mSv integral for team For aC: Simultaneous removal of adjacent quads for a-C would lead to heavy realignment procedures (recommissioning/performance risks??) Removing adjacent QF or adjacent QD is acceptable Realignment activities use transport passage (decoupling with magnet tunnel transport required). Longer procedures if magnets change their slot after a-C. Twist realignment required prior to vacuum flange closures. Scrubbing Review, 8/9/2015 Paul Cruikshank16

17. Coactivity issues EYETS and LS2 activities in SPS are already numerous. BA3 – Cavity works in LS2 BA5 – New dump, including civil works, in LS2. aC activities need to be confirmed asap as magnet transport & in- situ aC works will impact on the already approved & planned activities. Scrubbing Review, 8/9/2015 Paul Cruikshank17

18. a-C coating issues Significant experience with SPS ex-situ coating Proven performance of coated chambers. Coating cycle 3 days minimum Insert cathode, pump, coat, cathode cooling, demount Challenges: Industrialisation of set-ups Duplication of coating benches Long hollow cathode development - 13m to coat 2 adjacent dipoles in-situ. Open points: Plasma cleaning for in-situ solution – on-going trials (wet cleaning used on ex-situ solutions) Scrubbing Review, 8/9/2015 Paul Cruikshank18 In-situ MBBMBA QFSSSMBASSSQDMBB MBA SSSQFMBB In-situ Ex-situ In-situ

19. a-C coating & impedance reduction ? Impedance reduction under study (LIU-SPS) Priority 1 at SSS QF, Priority 2 at SSS QD Possible synergies with aC Proposal to start impedance pilot in EYETS - 1 or 2 arcs of SSS QF. Scrubbing Review, 8/9/2015 Paul Cruikshank19 In-situ MBBMBA QFSSSMBASSSQDMBB MBA SSSQFMBB In-situ Ex-situ In-situ MBB MBA QFSSSMBASSSQDMBB MBA SSSQF a-C + Imp’d a-C + Imp’d a-C + Imp’d a-C + Imp’d EYETS pilot LS2 full LS2 pilot LS3 full Implementation Proposal

20. a-C coating scenarios Scrubbing Review, 8/9/2015 Paul Cruikshank20 In-situ MBBMBA QFSSSMBASSSQDMBB MBA SSSQFMBB In-situ Ex-situ In-situ → Make costing for: transport, survey, deconnection, coatings, reconnection,…..

21. Detailed cost estimates: TE/VSC aC coating, MB ex-situ aC coating, MB in-situ, aC coating MBB & QF in-situ, full & sextant Wet cleaning, MB ex-situ Plasma cleaning, MB ex-situ Plasma cleaning, MB in-situ, Plasma cleaning MBB & QF in-situ, Impedance reduction variants for QF, QD, SSS QF, SSS QD EN/SU – P.Bestmann MB ex-situ, MB re-alignment MB in-situ, Quad & SSS re-alignment EN/HE – C.Bertone Underground to surface MB transport & logistics Quad & SSS transport & logistics TE/MSC & DG/SCR From 2010 cost estimates Detailed costings in annex of presentation Scrubbing Review, 8/9/2015 Paul Cruikshank21

22. aC cost estimate details and variants Scrubbing Review, 8/9/2015 Paul Cruikshank22 Many inputs from VSC, TE-MSC, EN-SU, EN-HE, LIU-SPS team

23. Cost for aC options: Preliminary totals to be checked by experts Scrubbing Review, 8/9/2015 Paul Cruikshank23

24. Impedance reduction costs Scrubbing Review, 8/9/2015 Paul Cruikshank24 Costs courtesy of J. Perez-Espinos, TE-VSC. Transport + disconnection costs (~ 325 kCHF for SSS QF ) are included in a-C costing. ‘Working line’ cost in range 844k to 1213k QF QD

25. Planning EYETS starts in December 2016 Pilot run for aC ? Pilot run for impedance reduction? 1 arc ? Procurement of equipment must start early 2016 (~ 9 months duration) Confirmation to go ahead needed in coming weeks. Detailed designs completed and validated by end of 2015 16 SSS QF & QF to treat in 12 week intervention (1 arc) 4 per week = 8 weeks 2 weeks to complete first assembly 2 weeks to reclose/repump/debug. Assume SSS QF to surface and QF in-situ Arcs 3-4 or 4-5 as working line If via BA3, then SSS QF transport to 867. Will require ~ 50 m2 for activity, plus ~ 50 m2 for handling (Not excluded that SSS QF treated underground, eg ECX5, if aC not (yet) required) Experience will dictate how to execute for future arcs a-C coating (& impedance reduction) implementation not yet approved. Scrubbing Review, 8/9/2015 Paul Cruikshank25

26. Summary Deployment study builds upon work done under SPS-U, MD, coating developments, LIU-SPS team aC coating is a validated technical solution - no show stoppers to industrialization aC coating variants studied: Transport & logistics can be optimized by mixed ex-situ & in-situ approach Significant reduction in surface building needs if MB magnets are coated in-situ Radiation ‘cost’ needs to be fully accessed when aC variants are reduced Coating solution without removal of adjacent quads is possible Development of 13.2m long hollow cathodes and plasma cleaning on-going. LS2 activities at BA3 & BA5 reduce access and transport options Combining with impedance reduction has been considered aC coating variants have been costed: Only standard lattice of arc and DS so far considered Costing for several variants (full or partial coating), and full SPS or sextant Synergies with impedance reduction are possible Costing of pilots for EYETS and LS2 considered Costings need to be assessed and approved by experts Next step: Decision on what needs to be aC coated aC pilot run on significant zone of SPS would provide opportunity to validate procedures & process, measure performance, gather knowledge for full-scale SPS deployment and other potential CERN needs. Groups involved need a clear sign to go ahead with final developments, procurements and staffing provisions in view of EYETS and LS2 preparations. Scrubbing Review, 8/9/2015 Paul Cruikshank26 Thanks for your attention !

27. aC coating – MB ex-situ (baseline) 3 day aC cycle, 6 MB/day = 18 MB in work pumping, coating, cathode cooling Coating in MB pairs = 9 coating stations (+1 reserve) 1 pumping group with gas inj, RGA, pc70 kCHF 2 cathode trains (6.6m) with 150 mm linear drive2 x 30 kCHF Total 10 stations1300 kCHF aC coating manpower (8 months) 4 FSU (coating - 2 x 2 teams)312 kCHF 1 FSU (sample measurements)78 kCHF Surface of 360 m2 (15 x 24 m) 10 Coating stations = 2 x MB length + footpath 2 transit stations Min spacing between MB = 1 metre Scrubbing Review, 8/9/2015 Paul Cruikshank27

28. aC coating, MB in-situ 5 day aC cycle Insert cathode, pump, coat 1, coat 2, cathode cooling, demount Goal 6 MB/day or 30 MB/5 days MB string (4 x MB) together, so 7.5 strings/5 days Adjacent quads cannot be removed so working space is 2m Coating MB strings = 8 coating stations 2 pumping group with gas inj, RGA, pc2 x 70 kCHF 2 cathode trains (13.2m) with 150 mm linear drive2 x 50 kCHF Total 8 stations1920 kCHF aC coating manpower (8 months) 4 FSU (coating - 2 x 2 teams)312 kCHF 1 staff eng + 1 staff tech 1 FSU (sample measurements)78 kCHF Considerations No MB transport or alignment required. Requires removal of SSS and Quads Remove all SSS Remove alternate quads – coat MB – reinstall quad – realign quad – remove adjacent quad. Implies plasma cleaning Scrubbing Review, 8/9/2015 Paul Cruikshank28

29. aC coating, MBB in-situ, SPS 4 day aC cycle Insert cathode, pump, coat 1, coat 2, cathode cooling, demount Goal 3 MBB/day or 12 MB/4 days MB string (2 x MBB) together, so 6 strings/4 days Working space to insert cathode train is SSS + QD = 5.4 m Coating MB strings = 6 coating stations 2 pumping group with gas inj, RGA, pc2 x 70 kCHF 1 cathode trains (13.2m) with 150 mm linear drive1 x 50 kCHF Total 6 stations1140 kCHF aC coating manpower (8 months) 4 FSU (coating - 2 x 2 teams)312 kCHF 1 staff eng + 1 staff tech 1 FSU (sample measurements)78 kCHF Considerations No MB transport or alignment required. Requires removal of SSS and QD only Implies plasma cleaning Scrubbing Review, 8/9/2015 Paul Cruikshank29 MBB MBA QFMBAMBB MBA

30. aC coating, MBB in-situ, sextant 4 day aC cycle Insert cathode, pump, coat 1, coat 2, cathode cooling, demount Goal 0.5 MBB/day or 2 MB/4 days MB string (2 x MBB) together, so 1 strings/4 days Working space to insert cathode train is SSS + QD = 5.4 m Coating MB strings = 1 coating stations 2 pumping group with gas inj, RGA, pc2 x 70 kCHF 1 cathode trains (13.2m) with 150 mm linear drive1 x 50 kCHF Total 1 stations190 kCHF aC coating manpower (8 months) 2 FSU (coating - 1 x 2 teams)156 kCHF 1 staff eng + 1 staff tech 1 FSU (sample measurements)78 kCHF Considerations No MB transport or alignment required. Requires removal of SSS and QD only Implies plasma cleaning Scrubbing Review, 8/9/2015 Paul Cruikshank30 MBB MBA QFMBAMBB MBA

31. Wet cleaning – MB ex-situ (baseline) 0.5 d wet cleaning cycle, 6 MB/day = 3 MB in work create a table (acetone, detergent, rinse, dry) 3 cleaning stations (+ reserve) ~3 m3 demin rinsing water/MB Recirculating pumps, tanks, heaters, blowers100 kCHF Rinsing water tanks (30)10 kCHF Hand/foot contamination detector20 kCHF Dose rate monitors + balisette??40 kCHF Total 4 stations170 kCHF Cleaning manpower (8 months) 2 FSU (60 CHF/hr)156 kCHF Surface of 120 m2 (6 x 20m) 4 Cleaning stations = MB length + protection zone 4 transit stations Min spacing between MB = 1 metre Independent wet zone Considerations Remove/clean/reinstall RF shielding with wet cleaning156 kCHF Local system to cleaning, rinse, dry30 kCHF Scrubbing Review, 8/9/2015 Paul Cruikshank31

32. Plasma cleaning – MB ex-situ Under vacuum cleaning O 2 injection and cold plasma discharge to remove hyrocarbons + System built to remove aC coating - As aC pre-treatment, to validate. + No pumping shield removal- With p.port shielding to validate + No waste water- No dust removal + No contamination transfer 0.5 d plasma cleaning cycle, 6 MB/day = 3 MB in work Sequence – insert anode train, pump, plasma clean, extract train. Plasma cleaning in MB pairs = 2 stations ( 1 reserve) 1 pumping group with gas inj, RGA, pc70 kCHF 2 anode trains (6.6m) 2 x 15 kCHF Total 2 stations200 kCHF Plasma cleaning manpower (8 months) 2 FSU (60 CHF/hr)156 kCHF Surface of 60 m2 (15 x 4m) Plasma cleaning station = 2 x MB length + footpath Min spacing between MB = 1 metre Scrubbing Review, 8/9/2015 Paul Cruikshank32

33. Plasma cleaning – MB in-situ Under vacuum cleaning – O 2 injection and plasma discharge Consider 1 day plasma cleaning cycle for 4 MB string Goal 6 MB/day or 30 MB/week, so 7.5 cleaning cycles/week Plasma cleaning MB strings = need 2 stations 2 pumping groups with gas inj, RGA, pc2 x 70 kCHF 2 anode trains (13.2m)2 x 30 kCHF Total 2 stations400 kCHF Plasma cleaning manpower (8 months) 4 FSU (cleaning & tunnel logistics - 2 x 2 teams)312 kCHF Considerations: Requires removal of SSS and Quads (special sequence) Requires tunnel logistics Requires set-up (2 x SPS dipole) to validate in 2015 Scrubbing Review, 8/9/2015 Paul Cruikshank33

34. Plasma cleaning – MB in-situ, SPS Under vacuum cleaning – O 2 injection and plasma discharge Consider 1 day plasma cleaning cycle for 2 MBB string Goal 3 MBB/day or 15 MBB/week, so 7.5 cleaning cycles/week Plasma cleaning MB strings = need 2 stations 2 pumping groups with gas inj, RGA, pc2 x 70 kCHF 1 anode train (13.2m)1 x 30 kCHF Total 2 stations340 kCHF Plasma cleaning manpower (8 months) 4 FSU (cleaning & tunnel logistics - 2 x 2 teams)312 kCHF Considerations: Requires removal of SSS and QD Requires tunnel logistics Scrubbing Review, 8/9/2015 Paul Cruikshank34

35. Plasma cleaning – MB in-situ, sextant Under vacuum cleaning – O 2 injection and plasma discharge Consider 1 day plasma cleaning cycle for 2 MBB string Goal 0.5 MBB/day so 1 cleaning cycle every 4 days Plasma cleaning MB strings = need 1 stations 2 pumping groups with gas inj, RGA, pc2 x 70 kCHF 1 anode train (13.2m)1 x 30 kCHF Total 1 stations170 kCHF Plasma cleaning manpower (8 months) 2 FSU (cleaning & tunnel logistics – 1 team shared with coating)0 kCHF Considerations: Requires removal of SSS and QD Requires tunnel logistics Scrubbing Review, 8/9/2015 Paul Cruikshank35

36. Underground to surface: MB, Quad, SSS to surface: BA1 – nothing. BA2 – lift, requires mobile crane + crane driver for loading65k BA3 – lift, usual exit point, coactivity with cavity works BA4 – crane, requires opening ECX4 wall & extr.septum removal???k BA5 – crane, coactivity new dump, requires opening of ECX5 wall100k BA6 – lift, coactivity with P1 (LHC & ATLAS) ground logistics Handling team at (each) surface location130k Lorry driver(s) if aC factory is elsewhere65k Handling team at (each) aC factory130k BA3 exit gives access to Prevessin infrastructure BA6 exit gives access to P1.8 infrastructure BA2 exit would block 1 of the 2 CERN mobile cranes (plus road trans) Several exit points create flexibility (C.Bertone) Night shift will add 50% to manpower costs For cost estimate, consider 1 exit point MB, 1 exit point Quad & SSS Many constraints ! Scrubbing Review, 8/9/2015 Paul Cruikshank36

37. MB underground transport + aC logistics (baseline) Underground transport to ECX5 4 hrs x 3 FSU per MB = ~ 800 CHF* x 744585 kCHF Remove-transport to ECX5-return transport-reinstall If over night activity add 50% coefficient292 kCHF Underground logistics in ECX5 & ECA5 for 8 months 2 FSU for cleaning & aC coating factory130 kCHF 50 m2 for transit handling (6 magnets) Additional handling infrastructure: 1 Dumont250 kCHF 1 Volk tractor80 kCHF 1 trailer30 kCHF Other handling tooling20 kCHF Total 380 kCHF Other underground aC options? TCC6 tunnel (demount 100m of TI2, TT60 for 170 m2 area) Scrubbing Review, 8/9/2015 Paul Cruikshank37

38. Quad & SSS transport to surface Underground transport to lift (BA2, BA3, BA6) Sequence: Remove-transport to surface–return from surface–reinstall Manpower 585 kCHF for 744 dipoles, so….. For 372 Quad & SSS (really 384)292 kCHF 50% coefficient for night shift146 kCHF Surface logistics: Handling team per location130 kCHF Additional tunnel infra for SSS: 1 Pratt side-loader renovation70 kCHF 1 small trailer20 kCHF Additional tunnel infra for quad if MB are removed 1 Dumont (quad config)250 kCHF 1 Volk tractor80 kCHF 1 trailer30 kCHF If MB coated in-situ, no additional infrastructure0 kCHF Scrubbing Review, 8/9/2015 Paul Cruikshank38

39. MB aC ex-situ – MB alignment Inputs & constraints: Consider MB must return to initial position Is this essential? – field quality, geometry, pumping port, other…. Tilt alignment before vacuum connections (on-line) Alignment in transport passage (need HE & SU decoupling!) SU request 0.5 d for 4 MB string (8 MB/day capacity) Manpower needs: 2 FSU for 8 months – MB & smoothing 156 kCHF Equipment needs: Laser tracker, small tooling30 kCHF Scrubbing Review, 8/9/2015 Paul Cruikshank39

40. MB aC in-situ – Quad alignment Inputs & constraints: Returning quad aligned wrt to quad neighbours Tilt alignment before vacuum connections No SSS reinstallation until QF & QD realigned Alignment in trans passage (need HE & SU decoupling) 6 MB/day = 1.5 Quads/day & 1.5 SSS/day SU request 0.5 d for 2 quads & 0.5 d for 2 SSS Manpower needs: 2 FSU for 8 months – Quad, SSS & smoothing 156 kCHF Equipment needs: Laser tracker, small tooling30 kCHF Scrubbing Review, 8/9/2015 Paul Cruikshank40