Scrubbing Review, 8/9/2015 Paul Cruikshank1. Contents SPS Layout aC factory options Assumptions &...

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LIU-SPS

Scrubbing Review:

a-C Coating Deployment Strategy

P. Cruikshankon behalf TE-VSC & LIU-SPS team

Scrubbing Review, 8/9/2015 Paul Cruikshank

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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)


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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


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

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SPS Layout


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SPS Layout


MBBMBBMBAMBAQFSSSMBA SSS QD MBB MBB MBA MBA SSS QF

Cells % SPS Chamber type

X-section (mm)

Form Units /cell

Chamber (mm)

Chamber /cell

% cell % SPS

84+12 Arc+DS 88.9

MBA 152 x 36.5 Rect 4 6660 26640 41.6 37.0

MBB 129 x 48.5 Rect 4 6640 26560 41.5 36.9

QF mag 152 x 38.3 Elipse 1 3346 3346 5.2 4.6

QD mag Dia 83 Round 1 3346 3346 5.2 4.6

QF SSS 152 x 36.5 Ellipse 1 2052 2052 3.2 2.8

QD SSS Dia 83 Round 1 2052 2052 3.2 2.8

63995 100.0 88.9

1 cell = 63995 mm

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SPS layout


BA1

BA2

BA3

BA4

BA5

BA6

Meyrin, P1 LHC(magnet lift)

Prevessin(magnet lift)

RF

TT40 extTT20 ext

Future dumpInjection& Dump

TT60 ext

ECX5BHA5

(magnet lift)

DS DS LSSLSS ARC

1 cell 1 cell 1 cell 1 cellBA BA

Total for SPS arc & DS = 744 Dipoles, 198 Quads, 192 SSS

14 cells

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aC factory options


BA2 liftBA3 liftBA6 lift

BA4 bridge craneBA5 bridge crane

Transit

Transit

aC ex-situ factory(underground, eg EXC5)

aC in-situ factory

aC ex-situ factory(local)

aC ex-situ factory(remote)

192 SSS198 Quad744 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 BHA5 Eg 867 or SMA18

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Ex-situ v in-situ aC coating


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

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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, ….)


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Scenarios considered


Scenario Case MBA MBB QD SSSQD QF SSSQFMB in EXC5 Full Ex-situ Ex-situ Ex-situ Ex-situ Ex-situ Ex-situMB in BHA5 Full Ex-situ Ex-situ Ex-situ Ex-situ Ex-situ Ex-situMB in remote Full Ex-situ Ex-situ Ex-situ Ex-situ Ex-situ Ex-situMB in stu Full In-situ In-situ Ex-situ Ex-situ Ex-situ Ex-situMB in stu Partial x In-situ Ex-situ Ex-situ In-situ Ex-situMB in stu Partial - 1 arc x In-situ Ex-situ Ex-situ In-situ Ex-situImp reduction Partial x x x x In-situ Ex-situImp reduction Partial - 1 arc x x x x In-situ Ex-situ


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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• 3rd 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


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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)


BA7

BA6

LHC

SPS

BA6

BA7

SMA18

??

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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


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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.


6 months

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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


LSS

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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.


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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.


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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)


In-situ

MBBMBAMBAQFSSSMBA SSS QD MBB MBB MBA MBA SSS QFMBB

In-situ In-situ In-situEx-situEx-situEx-situ Ex-situIn-situ

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a-C coating & impedance reduction ?• Impedance reduction under study (LIU-SPS)

• Priority 1 at SSSQF, Priority 2 at SSSQD

• Possible synergies with aC

• Proposal to start impedance pilot in EYETS - 1 or 2 arcs of SSSQF.


In-situ




a-C a-Ca-C a-C+

Imp’d

a-C+

Imp’d

a-C+

Imp’d

a-Ca-C+

Imp’d

EYETS pilotLS2 full

LS2 pilotLS3 full

ImplementationProposal

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a-C coating scenarios


In-situ



→ Make costing for: transport, survey, deconnection, coatings, reconnection,…..

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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, SSSQF, SSSQD

• 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


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aC cost estimate details and variants


Many inputs from VSC, TE-MSC, EN-SU, EN-HE, LIU-SPS team

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Cost for aC options:

Preliminary totals to be checked by experts


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Impedance reduction costs

•

•


Drift BPH QF Totals (kCHF)max 513 494 773 1780inter 432 206 206 844min 0 0 0 0

Drift BPV QD Total (kCHF)max 386 325 405 1116inter 130 none none 130min 0 0 0 0

New chamber (pre-manufacturing option)Modified chamber (upstream flange config)Modified shielding & isolation

Costs courtesy of J. Perez-Espinos, TE-VSC.

Transport + disconnection costs (~ 325 kCHF for SSSQF) are included in a-C costing.

‘Working line’ cost inrange 844k to 1213kQF

QD

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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 SSSQF & 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 SSSQF to surface and QF in-situ• Arcs 3-4 or 4-5 as working line• If via BA3, then SSSQF transport to 867.

• Will require ~ 50 m2 for activity, plus ~ 50 m2 for handling

• (Not excluded that SSSQF 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.


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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.


Thanks for your attention !

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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, pc 70 kCHF• 2 cathode trains (6.6m) with 150 mm linear drive2 x 30 kCHF• Total 10 stations 1300 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


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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, pc 2 x 70 kCHF• 2 cathode trains (13.2m) with 150 mm linear drive 2 x 50 kCHF• Total 8 stations 1920 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


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aC coating, MBB in-situ, SPS


• 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



• Considerations• No MB transport or alignment required.• Requires removal of SSS and QD only• Implies plasma cleaning


MBBMBBMBAMBAQFMBA MBB MBB MBA MBA

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aC coating, MBB in-situ, sextant


• 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



• Considerations• No MB transport or alignment required.• Requires removal of SSS and QD only• Implies plasma cleaning


MBBMBBMBAMBAQFMBA MBB MBB MBA MBA

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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, blowers 100 kCHF• Rinsing water tanks (30) 10 kCHF• Hand/foot contamination detector 20 kCHF• Dose rate monitors + balisette?? 40 kCHF• Total 4 stations 170 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 cleaning 156 kCHF• Local system to cleaning, rinse, dry 30 kCHF


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Plasma cleaning – MB ex-situ

• Under vacuum cleaning• O2 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, pc 70 kCHF• 2 anode trains (6.6m) 2 x 15 kCHF• Total 2 stations 200 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


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Plasma cleaning – MB in-situ

• Under vacuum cleaning – O2 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, pc 2 x 70 kCHF• 2 anode trains (13.2m) 2 x 30 kCHF• Total 2 stations 400 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


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Plasma cleaning – MB in-situ, SPS


• 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, pc 2 x 70 kCHF• 1 anode train (13.2m) 1 x 30 kCHF• Total 2 stations 340 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


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Plasma cleaning – MB in-situ, sextant


• 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, pc 2 x 70 kCHF• 1 anode train (13.2m) 1 x 30 kCHF• Total 1 stations 170 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


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Underground to surface:

• MB, Quad, SSS to surface:• BA1 – nothing.• BA2 – lift, requires mobile crane + crane driver for loading 65k • 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 wall 100k• BA6 – lift, coactivity with P1 (LHC & ATLAS) ground logistics

• Handling team at (each) surface location 130k• Lorry driver(s) if aC factory is elsewhere 65k• Handling team at (each) aC factory 130k

• 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 !•


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MB underground transport + aC logistics (baseline)

• Underground transport to ECX5• 4 hrs x 3 FSU per MB = ~ 800 CHF* x 744 585 kCHF• Remove-transport to ECX5-return transport-reinstall• If over night activity add 50% coefficient 292 kCHF

• Underground logistics in ECX5 & ECA5 for 8 months• 2 FSU for cleaning & aC coating factory 130 kCHF• 50 m2 for transit handling (6 magnets)

• Additional handling infrastructure:• 1 Dumont 250 kCHF• 1 Volk tractor 80 kCHF• 1 trailer 30 kCHF• Other handling tooling 20 kCHF• Total 380 kCHF

• Other underground aC options? • TCC6 tunnel (demount 100m of TI2, TT60 for 170 m2 area)


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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 shift 146 kCHF

Surface logistics:

Handling team per location 130 kCHF

• Additional tunnel infra for SSS:• 1 Pratt side-loader renovation 70 kCHF• 1 small trailer 20 kCHF

• Additional tunnel infra for quad if MB are removed• 1 Dumont (quad config) 250 kCHF• 1 Volk tractor 80 kCHF• 1 trailer 30 kCHF

• If MB coated in-situ, no additional infrastructure 0 kCHF


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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 tooling 30 kCHF

•


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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 tooling 30 kCHF


Scrubbing Review, 8/9/2015 Paul Cruikshank1. Contents SPS Layout aC factory options Assumptions &...

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Transcript of Scrubbing Review, 8/9/2015 Paul Cruikshank1. Contents SPS Layout aC factory options Assumptions &...