TIS Review 13 Dec. 2000 Bill Elliott IR ABSORBER STATUS1 Bill Elliott LBNL Presented at the TIS...

TIS Review13 Dec. 2000

Bill ElliottIR ABSORBER STATUS 1

IR ABSORBER STATUS

Bill Elliott

LBNL

Presented at the

TIS SAFETY REVIEW

13 Dec. 2000

Berkeley,CA

brookhaven - fermilab - berkeleyUS LHC ACCELERATOR PROJECT



ENGINEERING DESIGN

TAN - Neutral Absorber

TAS - Front Quadrupole Absorber

FABRICATION PLAN

Sequence of Production

SAFETY ISSUES

Lifting and Handling

Surface Temperatures during Vacuum Bakeout

Seismic Stability

Radiation

IMPLEMENTATION OF SAFETY MoU

Engineering Design Review (EDR)

Production Readiness Review (PRR)

IR ABSORBERS - OVERVIEW



IR ABSORBERS - TAN DESIGN

Lower base plate

Upper base plate

Absorber box

Junction box

Side shielding (2)

Upper shielding

Marble

Beam tubevacuum chamber

Jacks (3)

Copper bars

Beam tube support bracket The steel shielding is

a pinned structure withfour through bolts fortransport.

Through bolt

The TAN consists of two major sub-assemblies: - Absorber Box - Steel Shielding.



TAN DESIGN/ENGINEERING SUMMARY

- TAN requirements, parameters and interfaces have been defined

- Interface and Functional Specifications have been approved by CERN

- TAN engineering calculations for tolerances, stress/deflection, bakeout

and cooling have been completed.

- Drawing details completed and released

- Quality control, Acceptance, Fabrication, Procurement plansdeveloped and reviewed at PRR.

- FEA thermal model completed to verify analytic calculations



IR ABSORBERS - TAS LOCATION (ATLAS)



TAS ASSEMBLY (EXPLODED)

HEATER,THERMOCOUPLES

LOWER COPPER CLAMSHELL

UPPER COPPER CLAMSHELL

COPPER BEAM TUBE34 mm ID40 mm ID

SUPPORT CRADLE (ASSY ONLY)



• TAS requirements, parameters and interfaces have been defined.

• TAS engineering completed– calculations for tolerances, stress/deflection, bakeout and cooling– 3D Pro-Engineer model– Safety issues documented.

• Detailed design drawings nearly completed.

• FEA thermal model needed to check analytic calculations.

TAS DESIGN/ENGINEERING SUMMARY



FABRICATION PLAN

IR Absorber PRR02 Nov 2000, LBNL

Bill ElliottTAN/TAS ASSEMBLY 9

BUILDING 60 Assembly- Stage 4

4 TAN-Base plate4 TAS- In test

Building 60•30 Ton overhead crane•Floor load capability•Office and Clean room•Open floor space

IR Absorber PRR02 Nov 2000, LBNL

Bill ElliottTAN/TAS ASSEMBLY 10

TAN/TAS SCHEDULE



Lifting and HandlingSurface Temperatures during Vacuum BakeoutSeismic Stability

These items detailed in LBNL Engineering notes:TAN Safety Note M7090TAS Safety Note M7905

Radiation: Bill Turner is in contact with Grahm Stevenson

SAFETY RELATED DESIGN FEATURES



SAFETY - LIFTING AND HANDLING

TAN I.S.- 4.1 Safety Engineered Hoist Rings

Configuration:

3 sizes to be used:

- Four 11,000 kg rated Hoist Rings for lifting the

entire TAN assembly with a spreader beam.

- 7,000 kg rated Hoist Rings for lifting the 8 TAN

subassemblies.

- Two 400 kg rated Hoist Rings for lifting the

transport housing

TAN I.S.- 4.2 Subassembly Lifting Locations

Locations:

No. Subassembly Weight

(kg)

SubassemblyLength

(mm)

Permanent HoistRing Location *

(mm)

Additional Hoist

Ring Locations *

(mm)

1 Lower Base Plate 4900 3000 1500 600

2 Upper Base Plate 4900 3000 1500 600

3 Absorber Box 5000 3800 1900 240

4 Aisle Side Shielding 4100 3000 1500 600

5 Cryo Side Shielding 4100 3000 1500 600

6 Upper Shielding 5000 3000 1500 600

7 Aisle Side Marble 700 450 225

8 Cryo Side Marble 700 450 225

* Measured from either end of a subassembly.

TAS I.S.- 4. Rigging

4.1 Safety Engineered Hoist Rings

- Configuration:

- Size: 4200 kg

TAS I.S.- 4.2 Subassembly Lifting Locations

Locations:

Part or Assembly Weight

(kg)

Part/Assembly

Length

(mm)

AssemblyHoist RingLocation

X (mm)

AssemblyHoist RingLocation*

Y (mm)

PermanentHoist RingLocation

X (mm)

PermanentHoist RingLocation*

Y (mm)

Lower CopperClamshell - topside

1600 1800 190

-190

375

1425

Lower CopperClamshell -underside

1600 1800 0.0

0.0

280

1520

Upper CopperClamshell - topside

1600 1800 0.0

0.0

280

1520

TAS Assembly 3200 1800 0.0 900

* Measured from either end of a part or assembly.



SAFETY - Surface Temps

TAN -

Operational

Bakeout

TAS -

Operational

Bakeout



TAN surface temperature at ultimate luminosity is less than the 57 °C ASTM C-1055 requirement



SAFETY - SEISMIC STABILITY

TAN Safety & Lifting

IR Absorber EDR13 July 2000, CERN

J.H. BercovitzTAN Design 30

• TAN meets CERN seismic requirements as designed, and LBNL seismic requirements with the addition of temporary extra bracing.

• Shielding surface temperature during bakeout will be approximately 75° C.

Temporary personnel barriers will be required to protect against burns.

The exposed end of the absorber will be covered by a blanket.

•Lifting

•The 30-tonne TAN assembly is to be lifted by four 11000 kg hoist rings from the lower base plate using a spreader bar.

•The longitudinal clear space under the TAN is 2.4 m, sufficient for the

2.3 m long transfer carriage.

•Individual TAN components all have masses less than 5000 kg.

See LBNL Eng. Note M7909 for details

TAN Safety - Seismic



TAN Safety - Seismic (cont.)



To overturn in an earthquake, the lateral acceleration must exceed gravity*[(base/2)/height]

If the vertical acceleration of the earthquake is .11 g, then the restoring force due to gravity comes from the remaining .89 g.

Currently, max. allowable lateral acceleration = .89*200.5/534.2 = .334 g See sketch, above.



Lifting: - The 3200 kg TAS is designed to be lifted with a single 4200 kg rated Hoist Ring. Hoist Ring is to be proof tested to 6300 kg (150% of rated load) and thereafter non- destructive testing is to be performed.Seismic: - LBNL seismic criteria are, greater than CERN criteria so satisfy CERN requirements, and are:

0.70 g horizontal0.35g vertical

TAS - Safety Issues



Seismic continued: - Here the worst case is when the TAS is assembled in theTas Assembly Fixture with the highest stress condition in thevertical support rods:

Loading Stress(MPa) Half the absorber weight 126 Bending load 430 Maximum operational load 556

Additional vertical load due to 0.35g 44 Max. load under seismic conditions 600 Stressproof: Ultimate strength 889 Mpa

Safety Factor 1.5 based on ultimate strength

TAS - Safety Issues (continued)



BAKEOUT: - During vacuum bakeout the TAS will be held at 200 C for a minimum of 24 hours. At LBNL: The TAS will not be surrounded by shielding, therefore it will be insulated with blankets and personnel barriers will be placed around the bakeout area. At CERN: Barriers need to be erected around the TAS to prevent access to the TAS during bakeout. The surrounding ATLAS shielding will only rise to 35 C and the surrounding CMS shielding will rise to 75 C during a typical 24 hour heatup and 24 hour bakeout cycle.

TAS - Safety Issues (continued-2)



Implementation of Safety MoU

MoU Milestones Completed:

Completed Engineering Reviews:Engineering Design Review: 13 July 2000 Production Readiness Review: 2 Nov. 2000

Planned LBNL Internal Safety Reviews

Building 60 Crane: TAN is over Crane rated capacity

Vacuum Bakeout : Personnel safety



• Engineering Design Review: July 13, 2000 at CERN

• Design and Engineering of the TAN and TAS presented– Design is Complete, proceed to final details necessary for fabrication

– TAN

• 16 detailed LBNL/CERN action items– Redesign the Pair of Pants transition zone to eliminate the vacuum pumping

slots, allow NEG coating

– TAS

• 21 detailed LBNL/CERN action items– LBNL required to build test stand for the jacks/fiducial checkout

– Test stand to simulate slopes in the LHC tunnel

IR ABSORBERS - Engineering Design Review



DETAILS PRESENTED

• PROCUREMENT PLAN

– Internal and external fabrications, vacuum beam tube methodology

• FABRICATION PLAN

– LBNL site location, Lead technician, Testing resources, Alignment resources

• RESOURCE LOADED SCHEDULE

• ACCEPTANCE PLAN

• QA PLAN

• PROPOSED ENGINEERING DOCUMENT FILE

The Production Readiness Review (PRR) for the IR ABSORBERS was held on 2 Nov. 2000



PRR RECOMMENDATIONS:

• Fabricate a first article TAN vacuum chamber ASAP

• Schedule a Pre-Assembly Review in March‘01 before start of assembly– Final checkout of QA and Acceptance plan

• Logistics– Develop a logistics plan for tracking parts

– Consider additional staff for logistics tracking, QC/QA work

• Schedule– Examine a 1+3 production method instead of 4 units in parallel

– Incorporate resource constraints into schedule (30 ton crane, test equipment, floor space, technicians)

IR ABSORBERS - PRODUCTION PLAN

TIS Review 13 Dec. 2000 Bill Elliott IR ABSORBER STATUS1 Bill Elliott LBNL Presented at the TIS...

Documents

Transcript of TIS Review 13 Dec. 2000 Bill Elliott IR ABSORBER STATUS1 Bill Elliott LBNL Presented at the TIS...