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FP420 Connection Cryostat Mechanical Design & Construction

FP420 Connection Cryostat Mechanical Design & Construction. Key capabilities of CERN TS/MME. CONTENT. Mechanical design & construction Key capabilities of CERN TS/MME. 1. DESIGN. 2. CONSTRUCTION. FP420 versus DFB ATM Pre-design Version # 1 Pre-design Version # 2 Mechanical analysis

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FP420 Connection Cryostat Mechanical Design & Construction

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  1. FP420 Connection Cryostat Mechanical Design & Construction Key capabilities of CERN TS/MME

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

  3. 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 Distribution Feed Box Arc Termination Module FP420 Cryostat FP420 Manchester Workshop - December 2006

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

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

  6. Version #2 – Displacement analysis VACUUM CONDITION FP420 Manchester Workshop - December 2006

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

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

  9. Pre-design Version #3 • Two lowered supporting beams • One single piece FP420 Manchester Workshop - December 2006

  10. 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 FP420 Manchester Workshop - December 2006

  11. 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 FP420 Manchester Workshop - December 2006

  12. Scheduleprojectionattempt Green light needed on time to allow the design work to start The production cannot start before the design is fully approved FP420 Manchester Workshop - December 2006

  13. 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 FP420 Manchester Workshop - December 2006

  14. 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 Distribution Feed Box Arc Termination Module FP420 Manchester Workshop - December 2006

  15. Shuffling Box assembly FP420 Manchester Workshop - December 2006

  16. Welding of the dished heads FP420 Manchester Workshop - December 2006

  17. Cryostating of the Shuffling Module FP420 Manchester Workshop - December 2006

  18. Thermal Super-insulation FP420 Manchester Workshop - December 2006

  19. Final assembly FP420 Manchester Workshop - December 2006

  20. DFBA (ATM & HCM) Transport FP420 Manchester Workshop - December 2006

  21. 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 FP420 Manchester Workshop - December 2006

  22. 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) FP420 Manchester Workshop - December 2006

  23. Thanks for their contribution … • Utilisation des ATM pour le projet FP420 - EDMS 771549 – Thierry Renaglia • Use of the ATM for the FP420 Project EDMS 743628 – 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. FP420 Manchester Workshop - December 2006

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