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IR ABSORBER STATUS Bill Elliott LBNL Presented at the TIS SAFETY REVIEW 13 Dec. 2000 Berkeley,CA

US LHC ACCELERATOR PROJECT. brookhaven - fermilab - berkeley. IR ABSORBER STATUS Bill Elliott LBNL Presented at the TIS SAFETY REVIEW 13 Dec. 2000 Berkeley,CA. IR ABSORBERS - OVERVIEW. ENGINEERING DESIGN TAN - Neutral Absorber TAS - Front Quadrupole Absorber FABRICATION PLAN

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IR ABSORBER STATUS Bill Elliott LBNL Presented at the TIS SAFETY REVIEW 13 Dec. 2000 Berkeley,CA

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  1. US LHC ACCELERATOR PROJECT brookhaven - fermilab - berkeley • IR ABSORBER STATUS • Bill Elliott • LBNL • Presented at the • TIS SAFETY REVIEW • 13 Dec. 2000 • Berkeley,CA Bill Elliott IR ABSORBER STATUS

  2. IR ABSORBERS - OVERVIEW • 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) Bill Elliott IR ABSORBER STATUS

  3. IR ABSORBERS - TAN DESIGN The TAN consists of two major sub-assemblies: - Absorber Box - Steel Shielding. Upper shielding Junction box Through bolt Absorber box Copper bars Side shielding (2) Marble Upper base plate Beam tube vacuum chamber Lower base plate Beam tube support bracket The steel shielding is a pinned structure with four through bolts for transport. Jacks (3) Bill Elliott IR ABSORBER STATUS

  4. 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 plans developed and reviewed at PRR. - FEA thermal model completed to verify analytic calculations Bill Elliott IR ABSORBER STATUS

  5. IR ABSORBERS - TAS LOCATION (ATLAS) Bill Elliott IR ABSORBER STATUS

  6. TAS ASSEMBLY (EXPLODED) UPPER COPPER CLAMSHELL HEATER, THERMOCOUPLES COPPER BEAM TUBE 34 mm ID 40 mm ID LOWER COPPER CLAMSHELL SUPPORT CRADLE (ASSY ONLY) Bill Elliott IR ABSORBER STATUS

  7. TAS DESIGN/ENGINEERING SUMMARY • 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. Bill Elliott IR ABSORBER STATUS

  8. FABRICATION PLAN Bill Elliott IR ABSORBER STATUS

  9. BUILDING 60 Assembly- Stage 4 4 TAN-Base plate 4 TAS- In test • Building 60 • 30 Ton overhead crane • Floor load capability • Office and Clean room • Open floor space IR Absorber PRR 02 Nov 2000, LBNL Bill Elliott TAN/TAS ASSEMBLY 9

  10. TAN/TAS SCHEDULE IR Absorber PRR 02 Nov 2000, LBNL Bill Elliott TAN/TAS ASSEMBLY 10

  11. SAFETY RELATED DESIGN FEATURES Lifting and Handling Surface Temperatures during Vacuum Bakeout Seismic Stability These items detailed in LBNL Engineering notes: TAN Safety Note M7090 TAS Safety Note M7905 Radiation: Bill Turner is in contact with Grahm Stevenson Bill Elliott IR ABSORBER STATUS

  12. SAFETY - LIFTING AND HANDLING Bill Elliott IR ABSORBER STATUS

  13. 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

  14. TAN I.S.- 4.2 Subassembly Lifting Locations Locations:

  15. TAS I.S.- 4. Rigging 4.1 Safety Engineered Hoist Rings - Configuration: - Size: 4200 kg

  16. TAS I.S.- 4.2 Subassembly Lifting Locations Locations:

  17. SAFETY - Surface Temps TAN - Operational Bakeout TAS - Operational Bakeout Bill Elliott IR ABSORBER STATUS

  18. TAN surface temperature at ultimate luminosity is less than the 57 °C ASTM C-1055 requirement Bill Elliott IR ABSORBER STATUS

  19. SAFETY - SEISMIC STABILITY Bill Elliott IR ABSORBER STATUS

  20. TAN Safety & Lifting • • 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 IR Absorber EDR 13 July 2000, CERN J.H. Bercovitz TAN Design 30

  21. TAN Safety - Seismic IR Absorber EDR 13 July 2000, CERN J.H. Bercovitz TAN Design 31

  22. 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. IR Absorber EDR 13 July 2000, CERN J.H. Bercovitz TAN Design 22

  23. TAS - Safety Issues 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 horizontal 0.35g vertical Bill Elliott IR ABSORBER STATUS

  24. TAS - Safety Issues (continued) Seismic continued: - Here the worst case is when the TAS is assembled in the Tas Assembly Fixture with the highest stress condition in the vertical support rods: LoadingStress(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 Bill Elliott IR ABSORBER STATUS

  25. TAS - Safety Issues (continued-2) 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. Bill Elliott IR ABSORBER STATUS

  26. 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 Bill Elliott IR ABSORBER STATUS

  27. IR ABSORBERS - Engineering Design Review • 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 Bill Elliott IR ABSORBER STATUS

  28. The Production Readiness Review (PRR) for the IR ABSORBERS was held on 2 Nov. 2000 • 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 Bill Elliott IR ABSORBER STATUS

  29. IR ABSORBERS - PRODUCTION PLAN • 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) Bill Elliott IR ABSORBER STATUS

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