FP420 Connection Cryostat Mechanical Design Construction

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					               FP420 Manchester Workshop
                          December 2006


  FP420 Connection Cryostat
Mechanical Design & Construction



               Key capabilities of
               CERN TS/MME




                Thierry RENAGLIA / Ramon FOLCH
                      FP420 Connection Cryostat
Mechanical design & construction
Key capabilities of CERN TS/MME         CONTENT

  1. DESIGN                              2. CONSTRUCTION
     FP420 versus DFB ATM                  Main processes involved
     Pre-design Version #1                 Schedule and possible lead times
     Pre-design Version #2                 Cost drivers
     Mechanical analysis                   DFB ATM assembly experience
     Pre-design Version #3
     Open issues




                  3. CONCLUSION
                     Advantages with CERN TS/MME
                     Required framework conditions


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                     FP420 Connection Cryostat
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
      FP420                               Termination
      Cryostat                            Module
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                  FP420 Connection Cryostat
Pre-design Version #1
   Dipole cold foot to replace compensation system
   Couple two DFB ATM
   Allow contraction of the BB line




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Pre-design Version #2

   Redesigned supporting beam
   Double cold feet to free space for line X




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              FP420 Connection Cryostat
Version #2 – Displacement analysis
      VACUUM CONDITION




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                 FP420 Connection Cryostat
Version #2 – Displacement analysis
     VACUUM CONDITION + INTERCONNECTION at cold (operation conditions)




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Version #2 – Reaction analysis

             Cold condition
             (vacuum, bellow force)


  Bellow
   force
- 10’000 N




                                                                        Reaction y
                                                                        55’000 N




                                 Reaction z             Reaction z
                                 70’000 N               - 32’500 N

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                FP420 Connection Cryostat
Pre-design Version #3

   Two lowered supporting beams
   One single piece




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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




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                 FP420 Connection Cryostat
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

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                              FP420 Connection Cryostat
Schedule projection attempt

                               2007                             2008                    2009
                   J   F M A M J J    A S O N D     J   F M A M J J    A S O N D   J     F M
Project Approval

Design

Engineering

Construction

Installation




       Green light needed                    The production
       on time to allow the                cannot start before
       design work to start                 the design is fully
                                                approved


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                     FP420 Connection Cryostat
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



                                     Material

                                     Production

                                     Assembly&cleaning

                                     Tests




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                      FP420 Connection Cryostat
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
                                       Units
                                                                                       E
                                        14

                        Distribution    13
                                        12
                                                                               CD
                                                                                                             Results:
                               Feed     11
                                                                          MB                               Early deliveries
                                Box     10
                                                                      L
                                                                                                           and costs below
                                         9
                                         8                        K                                       expectations after
                                                                GJ
                                         7                                                                  the 3 first units
                                         6
                                         5                  F
                                                           HI
                                         4
    Arc                                  3
                                                       PA                                            ATM delivery
    Termination                          2
                                                                                                     DFBA schedule
                                         1
    Module
                                               J   F   M    A    M    J   J    A   S   O   N   D   2006




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            FP420 Connection Cryostat
Shuffling Box assembly




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            FP420 Connection Cryostat
Welding of the dished heads




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            FP420 Connection Cryostat
Cryostating of the Shuffling Module




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Thermal Super-insulation




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Final assembly




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DFBA (ATM & HCM) Transport




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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
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                                                     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: December
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                    FP420 Connection Cryostat
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.


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