LIU-SPS, 15 April 2015
Paul Cruikshank
1
In the beginning….
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First slide that Brennan gave me – everything decided !
LIU-SPS, 15 April 2015
Paul Cruikshank
2
Recall:
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Starting point:
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Extensive work already made by SPS-U and SPS-LIU teams
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J.Bauche, B.Goddard, V.Mertens, M.Taborelli, P. Costa-Pinto, P. Chiggiato ……
Recent discussions with above, plus C.Bertone, P.Bestmann, J.Ferreira, J.PerezEspinos,
Experience of 16 MB and 5 Quad aC coated chambers in SPS – handling,
performance, ageing, etc.
General assumptions for activity:
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LS2 activity and 5 working days/week.
8 months aC duration ( 1m ramp-up + 6m cruise + 1m ramp down)
Chamber is coated in the magnet
Machine components returns to initial slot
Consider arc and DS machine components only (for now):
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aC coat all 744 dipoles = 6 dipoles/working day
aC coat all 192 quads = 1.5 quads/day (new scope)
aC coat all 192 SSS = 1.5 SSS/day (new scope)
LIU-SPS, 15 April 2015
Paul Cruikshank
3
Scope today
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aC coating – Dipole (74% SPS )
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Baseline update
Variants
aC coating – Quads & SSS (15 % SPS )
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additional aC scope - without/with impedance reduction
Cells
84+12
Arc+DS
% SPS
88.9
Chamber
type
X-section
(mm)
Form
Units
/cell
Chamber
(mm)
Chamber
/cell
MBA
152 x 36.5
Rect
4
6660
26640
41.6
37.0
MBB
129 x 48.5
Rect
4
6640
26560
41.5
36.9
QF mag
152 x 38.3
Elipse
1
3346
3346
5.2
4.6
QD mag
Dia 83
Round
1
3346
3346
5.2
4.6
152 x 36.5 Ellipse
1
2052
2052
3.2
2.8
1
2052
2052
3.2
2.8
63995
100.0
88.9
QF SSS
QD SSS
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•
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Dia 83
Round
% cell % SPS
Doesn’t (yet) address aC for LSS components
Doesn’t (yet) address other consolidation needs
Doesn’t (yet) address impact on other LS2 activities
LIU-SPS, 15 April 2015
Paul Cruikshank
4
Radiation considerations
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Extensive SPS radiation campaign Feb 2013 for LS1:
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MB range
0.1 - 100 uSv/hr @ 40 cm
Quad & SSS range
1 - 1000 uSv/hr @ 40 cm
Need to make detailed assessment for each MB, Quad, SSS to coat
Dose ‘cost’ for each item to aC coat – list to compile
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Public road limitations < 5 uSv/hr – otherwise ‘transport containment’ required
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Avoid road transport
aC activity 1 hr,
1 MB
aC activity 1 hr,
744 MB
1 uSv/hr @ 40 cm
1 uSv
744 uSv
10 mSv/hr @ 40 cm
10 uSv
Sextant 1
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(worst)
aC activity 1 hr,
192 Quad
1920 uSv
Sextant 5
(best)
LIU-SPS, 15 April 2015
Paul Cruikshank
5
Costs – the existing numbers
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Baseline: (J.Bauche 2009/2010)
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Consider 744 MB in ECX/EXA5
6 dipoles/day in 124 days
3957 kCHF
APT: LIU e-cloud study
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Considers 744 MB and studies
4.590 kCHF (2015 - 2020)
LIU-SPS, 15 April 2015
Paul Cruikshank
6
aC typical sequence:
Disconnect (vac + mech)
Transport
Clean + aC coat
Transport
Survey (x,y,z,tilt)
Reconnect (vac + mech
Survey (smoothing)
aC factory options
Transit
Surface transport
Surface activity
Underground activity
aC ex-situ factory
BHA5
Other ?
BA2 lift
BA3 lift
BA6 lift
Adjacent quads can’t be
simultaneously removed
192 SSS
192 Quad
744 MB
aC ex-situ factory
B867 via BA3 & road
P1.8 via BA6 & road
B?? via road
Other ?
BA4 crane
BA5 crane
Baseline
Tunnel transport
Transit
aC in-situ factory
LIU-SPS, 15 April 2015
aC ex-situ factory
ECX/ECA5
TCC6
Other ?
Paul Cruikshank
7
Underground to surface:
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MB, Quad, SSS to surface:
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BA1 – nothing.
BA2 – lift, requires mobile crane + crane driver for loading
BA3 – lift, usual exit point, coactivity with cavity works
BA4 – crane, requires opening ECX4 wall & extr.septum removal
BA5 – crane, coactivity new dump, requires opening of ECX5 wall
BA6 – lift, coactivity with P1 (LHC & ATLAS) ground logistics
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Handling team at (each) surface location
Lorry driver(s) if aC factory is elsewhere
Handling team at (each) aC factory
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BA3 exit gives access to Prevessin infrastructure
BA6 exit gives access to P1.8 infrastructure
BA2 exit would block 1 of the 2 CERN mobile cranes (plus road trans)
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Several exit points create flexibility (C.Bertone)
Night shift will add 50% to manpower costs
For cost estimate, consider 1 exit point MB, 1 exit point Quad & SSS
Many constraints !
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65k
???k
100k
130k
65k
130k
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LIU-SPS, 15 April 2015
Paul Cruikshank
8
Ex-situ v in-situ aC coating
Ex-situ benefits:
Working environment
Radiation constraints
Access
Combined consolidations
In-situ benefits:
Transport & logistics needs
Building space needs
Disconnection needs
Realignment needs
To avoid too many combinations in cost estimate consider:
All Dipoles ex-situ or in-situ aC
All Quadrupoles + SSS ex-situ aC only
All Quadrupoles + SSS ex-situ aC only, with impedance reduction
LIU-SPS, 15 April 2015
Paul Cruikshank
9
Cost estimates and considerations:
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TE/VSC
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EN/SU – P.Bestmann
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MB ex-situ, MB re-alignment
MB in-situ, Quad & SSS re-alignment
EN/HE – C.Bertone
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aC coating, MB ex-situ
aC coating, MB in-situ
Wet cleaning, MB ex-situ
Plasma cleaning, MB ex-situ
Plasma cleaning, MB in-situ
Impedance reduction variants for Quad & SSS
Underground to surface
MB transport & logistics
Quad & SSS transport & logistics
TE/MSC & DG/SCR
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From 2010 cost estimates
LIU-SPS, 15 April 2015
Paul Cruikshank
10
Cost for aC options:
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Preliminary totals to be checked by experts
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Excludes on-going TE/VSC works to validate:
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Long hollow cathode solutions eg 13 m
Plasma cleaning as pre-treatment to aC coating
Plasma cleaning with p.port shields not removed
LIU-SPS, 15 April 2015
Paul Cruikshank
11
aC cost estimate details and variants
LIU-SPS, 15 April 2015
Paul Cruikshank
12
aC coating – MB ex-situ (baseline)
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3 day aC cycle, 6 MB/day = 18 MB in work
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Coating in MB pairs = 9 coating stations (+1 reserve)
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1 pumping group with gas inj, RGA, pc
2 cathode trains (6.6m) with 150 mm linear drive
Total 10 stations
70 kCHF
2 x 30 kCHF
1300 kCHF
aC coating manpower (8 months)
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pumping, coating, cathode cooling
4 FSU (coating - 2 x 2 teams)
1 FSU (sample measurements)
312 kCHF
78 kCHF
Surface of 360 m2 (15 x 24 m)
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10 Coating stations = 2 x MB length + footpath
2 transit stations
Min spacing between MB = 1 metre
LIU-SPS, 15 April 2015
Paul Cruikshank
13
aC coating, MB in-situ
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5 day aC cycle
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Insert cathode, pump, coat 1, coat 2, cathode cooling, demount
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Goal 6 MB/day or 30 MB/5 days
MB string (4 x MB) together, so 7.5 strings/5 days
Adjacent quads cannot be removed so working space is 2m
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Coating MB strings = 8 coating stations
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2 pumping group with gas inj, RGA, pc
2 cathode trains (13.2m) with 150 mm linear drive
Total 8 stations
aC coating manpower (8 months)
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2 x 70 kCHF
2 x 50 kCHF
1920 kCHF
4 FSU (coating - 2 x 2 teams)
1 staff eng + 1 staff tech
1 FSU (sample measurements)
312 kCHF
78 kCHF
Considerations
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No MB transport or alignment required.
Requires removal of SSS and Quads
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Remove all SSS
Remove alternate quads – coat MB – reinstall quad – realign quad – remove adjacent quad.
Implies plasma cleaning
LIU-SPS, 15 April 2015
Paul Cruikshank
14
Wet cleaning – MB ex-situ (baseline)
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0.5 d wet cleaning cycle, 6 MB/day = 3 MB in work
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create a table (acetone, detergent, rinse, dry)
3 cleaning stations (+ reserve)
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~3 m3 demin rinsing water/MB
Recirculating pumps, tanks, heaters, blowers
Rinsing water tanks (30)
Hand/foot contamination detector
Dose rate monitors + balisette??
Total 4 stations
100 kCHF
10 kCHF
20 kCHF
40 kCHF
170 kCHF
Cleaning manpower (8 months)
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2 FSU (60 CHF/hr)
156 kCHF
Surface of 120 m2 (6 x 20m)
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4 Cleaning stations = MB length + protection zone
4 transit stations
Min spacing between MB = 1 metre
Independent wet zone
Considerations
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Remove/clean/reinstall RF shielding with wet cleaning
Local system to cleaning, rinse, dry
LIU-SPS, 15 April 2015
156 kCHF
30 kCHF
Paul Cruikshank
15
Plasma cleaning – MB ex-situ
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Under vacuum cleaning
O2 injection and cold plasma discharge to remove hyrocarbons
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+ System built to remove aC coating
+ No pumping shield removal
+ No waste water
+ No contamination transfer
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0.5 d plasma cleaning cycle, 6 MB/day = 3 MB in work
Sequence – insert anode train, pump, plasma clean, extract train.
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Plasma cleaning in MB pairs = 2 stations ( 1 reserve)
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- As aC pre-treatment, to validate.
- With p.port shielding to validate
- No dust removal
1 pumping group with gas inj, RGA, pc
2 anode trains (6.6m)
Total 2 stations
70 kCHF
2 x 15 kCHF
200 kCHF
Plasma cleaning manpower (8 months)
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2 FSU (60 CHF/hr)
156 kCHF
Surface of 60 m2 (15 x 4m)
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Plasma cleaning station = 2 x MB length + footpath
Min spacing between MB = 1 metre
LIU-SPS, 15 April 2015
Paul Cruikshank
16
Plasma cleaning – MB in-situ
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Under vacuum cleaning – O2 injection and plasma discharge
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Consider 1 day plasma cleaning cycle for 4 MB string
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Goal 6 MB/day or 30 MB/week, so 7.5 cleaning cycles/week
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Plasma cleaning MB strings = need 2 stations
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2 x 70 kCHF
2 x 30 kCHF
400 kCHF
Plasma cleaning manpower (8 months)
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2 pumping groups with gas inj, RGA, pc
2 anode trains (13.2m)
Total 2 stations
4 FSU (cleaning & tunnel logistics - 2 x 2 teams)
312 kCHF
Considerations:
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Requires removal of SSS and Quads (special sequence)
Requires tunnel logistics
Requires set-up (2 x SPS dipole) to validate in 2015
LIU-SPS, 15 April 2015
Paul Cruikshank
17
MB underground transport + aC logistics (baseline)
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Underground transport to ECX5
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292 kCHF
2 FSU for cleaning & aC coating factory
50 m2 for transit handling (6 magnets)
130 kCHF
Additional handling infrastructure:
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585 kCHF
Underground logistics in ECX5 & ECA5 for 8 months
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4 hrs x 3 FSU per MB = ~ 800 CHF* x 744
Remove-transport to ECX5-return transport-reinstall
If over night activity add 50% coefficient
1 Dumont
1 Volk tractor
1 trailer
Other handling tooling
Total
250 kCHF
80 kCHF
30 kCHF
20 kCHF
380 kCHF
Other underground aC options?
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TCC6 tunnel (demount 100m of TI2, TT60 for 170 m2 area)
LIU-SPS, 15 April 2015
Paul Cruikshank
18
Quad & SSS transport to surface
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Underground transport to lift (BA2, BA3, BA6)
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Sequence: Remove-transport to surface–return from surface–reinstall
Manpower 585 kCHF for 744 dipoles, so…..
For 372 Quad & SSS (really 384)
292 kCHF
50% coefficient for night shift
146 kCHF
Surface logistics:
Handling team per location
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Additional tunnel infra for SSS:
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130 kCHF
1 Pratt side-loader renovation
1 small trailer
70 kCHF
20 kCHF
Additional tunnel infra for quad if MB are removed
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1 Dumont (quad config)
1 Volk tractor
1 trailer
250 kCHF
80 kCHF
30 kCHF
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If MB coated in-situ, no additional infrastructure
0 kCHF
LIU-SPS, 15 April 2015
Paul Cruikshank
19
MB aC ex-situ – MB alignment
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Inputs & constraints:
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Consider MB must return to initial position
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Is this essential? – field quality, geometry, pumping port, other….
Tilt alignment before vacuum connections (on-line)
Alignment in transport passage (need HE & SU decoupling!)
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SU request 0.5 d for 4 MB string (8 MB/day capacity)
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Manpower needs:
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2 FSU for 8 months – MB & smoothing
156 kCHF
Equipment needs:
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Laser tracker, small tooling
30 kCHF
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LIU-SPS, 15 April 2015
Paul Cruikshank
20
MB aC in-situ – Quad alignment
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Inputs & constraints:
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Returning quad aligned wrt to quad neighbours
Tilt alignment before vacuum connections
No SSS reinstallation until QF & QD realigned
Alignment in trans passage (need HE & SU decoupling)
6 MB/day = 1.5 Quads/day & 1.5 SSS/day
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SU request 0.5 d for 2 quads & 0.5 d for 2 SSS
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Manpower needs:
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2 FSU for 8 months – Quad, SSS & smoothing
156 kCHF
Equipment needs:
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Laser tracker, small tooling
LIU-SPS, 15 April 2015
30 kCHF
Paul Cruikshank
21
Impedance reduction during aC
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max
inter
min
Drift
513
432
0
BPH
494
206
0
max
inter
min
Drift
386
130
0
BPV
325
none
0
QF
Totals (kCHF)
773
1780
206
844
0
0
QD
Total (kCHF)
405
1116
none
130
0
0
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New chamber with off-line aC coating
Modified chamber (upstream flange config) then on-line aC coating
Modified shielding with & isolation then on-line coating
Inputs from J.Perez-Espinos:
192 Quads, 192 SSS of arc & DS,
Where applicable includes cutting/demounting/remounting/welding,
All transport costs in aC estimate,
Additional building surface needs for max and intermediate solutions to do,
Max = 2896 kCHF, min = 0 kCHF
LIU-SPS, 15 April 2015
Paul Cruikshank
22
Summary
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Updated costs:
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aC variants - to be checked by experts
Impedance variants (0 - 2893 kCHF) – to be checked by experts
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Next steps
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Radiation ‘cost’ per magnet
TE/VSC Developments (long hollow cathode, plasma for aC, etc)
Add LSS components to aC cost estimate
Check compatibility of aC variants with other LS activities
Find opportunity to make aC pilot run on significant zone of SPS (with
fixed budget), to validate procedures & process, measure
performance, gather knowledge for SPS deployment and other CERN
needs.
Thanks for your attention !
LIU-SPS, 15 April 2015
Paul Cruikshank
23