OLAV3 Engineering Integration and installation of experimental beam pipes: the case of LHC 7/8/20111P.Lepeule for VSC group OLAV3 7/8/2011P.Lepeule for VSC group2 Outline ATLAS CMS & TOTEM ALICE LHCb Engineering & integration (1 & 2) Transformation process Installation Main issues Installation Conditions ATLAS,CMS,ALICE,LHCb pictures CERN approach Unexpected situations What we learnt 7/8/20113P.Lepeule for VSC group ATLAS 7/8/20114P.Lepeule for VSC group CMS 7/8/20115P.Lepeule for VSC group ALICE 7/8/20116P.Lepeule for VSC group LHCb 7/8/20117P.Lepeule for VSC group Engineering & integration 1 Inputs Final design results from more than 15 years discussion between experiment collaboration, experiment integration team, Vacuum group and machine experts. Contradictory request between machine (Impedance, safety buckling factor) and experiment collaboration (mass to be minimized) has made decision sometimes tricky and longer than planned. Formal design review, production review, installation review were important milestones to freeze parameters in order to be ready on time. 7/8/20118P.Lepeule for VSC group Engineering & integration 2 Design, manufacture & quality Individual specifications for raw material was an important issue for final quality of UHV experimental pipes (magnetic permeability, porosity, weldability) Process of transformation was much longer than for LEP: Beryllium and fully machined optimized conical pipes + VSC lab qualification + CU coating + NEG deposition, increased drastically the delivery time for each segment. Dedicated tooling was developed for each segment and each phase of manufacture or conditioning i.e Cu coating, NEG Deposition and RF bridges integration for sharp transition (CMS hf ct2 case) It was identified at an early stage that extensive Lab tests would be needed to prevent any non- conformities during very tight installation windows. 7/8/20119P.Lepeule for VSC group Transformation process metrolgie 7/8/2011P.Lepeule for VSC group10 machining E.B welding Global metrology Cu coating Transformation process 7/8/2011P.Lepeule for VSC group11 RF bridge integration Sub-assembly + leak test Bake-out + Cu coating testPreparation for NEG coating Installation Main issues 35 segments to install and 27 different environment which impose 27 different accurate studies, tests and types of tooling Limited access time & distance between cavern sites No access after installation Mandatory in-situ leak test after each segment connection Keep integrity of pipes after installation Detector closing Access of collaboration teams nearby fragile beam pipes Full in-situ bake-out at end of first installation Keep good control of alignment during detector closing Follow up day by day cavern experiment activities to define any risk for integrity of beam pipes till complete detector closure Mandatory flexibility of staff 7/8/201112P.Lepeule for VSC group Installation Installation conditions A total of 35 beam pipe segments were installed (without taking into account injection lines) in the 4 different experimental caverns with many changes during installation planning. Installation was strongly coupled with sub-detector delivery time, test and installation Uncertainty or changes in LHC machine date completion led the experiments to sometimes believe they had more time than originally planned. Beam pipes installation was often on critical path of 2008 LHC start up due requirement for full bake-out for NEG activation after beam line closing. 7/8/201113P.Lepeule for VSC group ATLAS pipes installation 7/8/2011P.Lepeule for VSC group14 Insertion of C.pipe with pixel in detector VJ installation Detector closing CMS pipes installation 7/8/2011P.Lepeule for VSC group15 Forward pipe sub-assemblyCentral pipe insertion Lowering of HF/CT2 assembly End Cap pipe lowering Cms pipes installation sequence 7/8/2011P.Lepeule for VSC group16 ALICE pipes installation 7/8/2011P.Lepeule for VSC group17 RB 26/3 insertion RB insertion Heating shells on C.pipe RB insertion LHCb pipes installation 7/8/2011P.Lepeule for VSC group18 Ux 85-1 completion S.Steel Ux 85.4 lowering Ux 85-1 & 2 installed with protection Ux 85-1 & 2 CERN approach Solutions to issues Identification of critical assembly sequence or insertion to be tested in laboratory on dedicated test stands or mock-up with experiment integration teams. Minimum half length of ATLAS and CMS was installed and baked in simulated mechanical environment with dedicated test bench structure. Extensive tests during manufacture phase and then in Laboratory were done to avoid any repair or removal from a pit during detector assembly: x ray control & leak test of each weld Bake out followed by a global leak test Cu Coating adhesion (if required) NEG performance analysis Check leak tightness of optimized flanges with real seals (thermal cycling) 7/8/201119P.Lepeule for VSC group CMS CP tested insertion 7/8/2011P.Lepeule for VSC group20 bake-out & mechanical test 7/8/2011P.Lepeule for VSC group21 length bake-out with 42 m test benchCms /Alice bake-out shells insertion Atlas guiding ring and support testCms HF/CT2 insertion test Unexpected situations on spot 7/8/2011P.Lepeule for VSC group22 Unexpected situations on spot 7/8/2011P.Lepeule for VSC group23 Unexpected situations 7/8/2011P.Lepeule for VSC group24 What we learnt Take care about pipes integrity after installation takes a lot more time than planned and needs additional resources with induced additional stress. Capability for staff to work at high, overtime, in a safe way is an important issue to cope with sometimes difficult working conditions. Decisions on the spot are often necessary in collaboration with the experiments, and flexibility and stamina of staff are a main quality. Organization as a common project led to significant cost savings, flexibility with staffing, good feedback and quality from one installation to another. 7/8/201125P.Lepeule for VSC group END 7/8/2011P.Lepeule for VSC group26 THANK YOU