US LHC Accelerator Project Completion Jim Kerby

1. US LHC ACCELERATOR PROJECT brookhaven - fermilab - berkeley US LHC Accelerator Project CompletionJim Kerby 19 March 2007

2. US-LHC Accelerator Project • Complete…beyond design ’stuff’ on the dock included… • 27 Inner Triplet Quad Assemblies • 8 DFBX • 20 Steering Dipoles • 8 TAN / TAS • Several thousand cable qualification tests “It ain’t over ‘til it’s over…” J. Kerby - US LHC Accelerator Project

3. Sector 7-8 Cooldownhttp://lhc.web.cern.ch/lhc/ J. Kerby - US LHC Accelerator Project

4. Sector 7-8 Cooldown Prep • January 07 • 7-8 Cooldown started • November 06 • Final warm electrical and mechanical tests of 7-8 • 9AM 25 Nov 06 • phone call from Peter Limon on problem in inner triplet region • Boroscope view of interior of corrugation in 7-8 • Piece extracted from 7-8 in December J. Kerby - US LHC Accelerator Project

5. Inner Triplet Heat Exchanger • IP1/5 secondaries at nominal luminosity deposit ~200W in 30m of Inner Triplet in LHC • -energy deposition models of optics, aperture, liners 1995-1999 • Static heat load per assembly on order of 2W • -much higher than typ of cold iron magnet • Inner triplet has three magnet designs of sizable diameter in cryostats, integration an issue • moved external of cold mass J. Kerby - US LHC Accelerator Project

6. Inner Triplet Heat Exchanger J. Kerby - US LHC Accelerator Project

7. Corrugation & End Fittings • Tests Dec 06 @FNAL and CERN show failure mode systematic • -Heat affected zone of ~25cm next at each end of assembly (10 locations per triplet, 5pcs) • Failure mode is due to out of roundness of corrugation and yield of copper at the tight radius • -0.25mm on ~90mm diameter • -HAZ lowers yield by 3+ • Tests Dec 06/Jan07 @FNAL & CERN confirm outside HAZ corrugation OK to 37-39bar J. Kerby - US LHC Accelerator Project

8. Fix • Start of 07 plan has two paths • a) Procure new, thicker corrugation, w/ ends • -appears to only 1 potential vendor, Nexans (Germany, purchased Kabelmetal) • -timescale is ~4 months, too late for 4-5 • b) Procure threaded inserts • -more difficult for tunnel logistics • -OK for tests, cycle tests also showed no degradation • In late January Nexans says they have a window starting 29 Jan / 5 Feb (as opposed to 4 months) if they can get copper • -iterations w/ Nexans/CERN on thickness • -found vendor in Rhode Island, visited, air shipped1-2 Feb • -corrugation run; tested (84 bar external); first delivery to CERN 5 Mar; installed in 5L 15 Mar (morning); remainder arrives this week & next J. Kerby - US LHC Accelerator Project

9. Upcoming Schedule / Comments • This has not been the only problem in sector 7-8 • CERN has great capacity at this point to react • CERN staff have been terrific • FNAL staff, vendors have done a great job • Sector 4-5 triplet pressure test 24 March • 4-5 Global pressure test 7 Apr • 4-5 Cooldown starts ~end April (vacuum check, scrubbing, cooldown…) • Sector 8-1 to follow • The triplets will be included J. Kerby - US LHC Accelerator Project

10. Timeline • January 98 tests are run to prove the design under external pressure, OK including end fitting to 33bar (no failure). • -industrial corrugation, end pieces from FNAL shops, assembly FNAL • A full scale HXTU is constructed (98-99) and assembled in SM18 in 2000 to prove the design—passes safety & performance checks • -same corrugation, end pieces vendor1, assembly at vendor1 • Prototype magnet is constructed and tested (00-01) • -same corrugation, end pieces (final design) vendor2, assembly FNAL • -safety & magnet performance tests OK (MTF relief at 7bar) • Production magnets are constructed and tested (order late 01/early 02) • -same corrugation, end pieces vendor3, assembly vendor3 • -safety & magnet performance tests OK (MTF relief at 7bar) • Warm fit up full inner triplet at CERN Spring 05 • -pressure test deferred due to schedule • -tunnel schedule also changed w/ QRL J. Kerby - US LHC Accelerator Project