1. Cryostat procurement, status and plan, QA/QC
D. Ramos, V. Parma, C. Mucher, H. Prin, M. Souchet, J. Hrivnak, M. Moretti, L. Mora, F. Savary, M. Struik
Review of the 11T Dipoles at Collimator Section for the HL-LHC

2. Outline
Recalling the production workflow
Production strategy and schedule
Procurement status
Tooling
QA and QC
Risks and mitigation

3. TE-MSC-LMF & TE-MSC-CMI & TE-VSC
Summary workflow
Cryostat components
SMI2
Assembled cold mass
Cryostat assembly
TBD
Storage
SM18
Cold test
Storage
SM18(tbc)
Stripping
Fiducialization
Section/group in charge:
SMA18
Beam screens and CWT
WP12(TE-VSC)
TE-MSC-LMF
Beam line fiduc.
WP15
Storage
TE-MSC-CMI
LHC tunnel
Installation
TE-MSC-TF
TE-MSC-LMF & TE-MSC-CMI & TE-VSC
Interconnect
EN-ACE

4. Production strategy Vacuum vessels
Procurement as “build-to-print” in industry: detailed specification drawigns provided by CERN; fabrication prepared by the contractor
Quality assurance as if pressure vessels (materials, welding, traceability, etc)
Delivered clean and leak tested, including long term storage protection flanges
Raw material provided by the contractor.
Only qualified firms allowed to tender (Qualif. Criteria and Technical Questionnaire documents attached to specification)

5. Production strategy Bottom trays
Machining subcontracted following CERN drawings
Raw material: from extrusions availabe in stock
Pipe welding done at CERN as part of the assembly work, in particular the weld of the Al to stainless steel transition.

6. Aluminium to stainless steel transitions: in stock
Production strategy
Support posts:
Fixed: In stock (from procurement made for the QTC)
Sliding: Standard dipole sliding posts, in stock
Aluminium to stainless steel transitions: in stock

7. Cryo lines for bypass cryostat
Production strategy
MLI:
Procured as finished blankets with velcro bands for assembly
Design by the supplier as part of the deliverable
Cryo lines for bypass cryostat
Contracted as assembled and tested units
Design to be adapted by the manufacturer according to its own standards and available tooling

8. Facbrication schedule up to LS2
11T Prototype
Cold mass proto available
1st series cold mass available
Bypass prototype
Note: Tendering acconted for but not shown.
Series for LS2: 2 units + 1 spare

9. Status of vacuum vessel for prototype
Order CA (29517/HL/LHC) to Cadinox (ES) for 1 prototype unit, issued Jan 2016
Delivery expected: July 2016
Fabrication drawings by contractor ready and approved by CERN
Material procurement incl. certificates done
Welding QA well advanced (some samples to be impact tested at -50C)
Contract running according to initial plan

10. Vacuum vessel prototype: Production plan

11. Bottom tray for prototype
Drawings ready to start production (see HCQBAHB019 in edms)
Subcontracting of machining to be ordered
Manufacturing and inspection plan ready (Edms LHC-QBAH-FP-0001)

12. SMI2 Assembly hall - present layout
Welding cabinet for bottom tray transitions
11 T Cryostating
Bypass cryostat assembly
Bottom tray assembly

13. SMI2 Assembly hall – Max. capacity
Activities requiring handling of cold masses or cryostated magnets can only be done under the 40 ton overhead crane
Activities possible under the 10 ton overhead crane:
Bypass cryostats
Feedboxes
Bottom tray sub-assemblies
40 ton
10 ton

14. Rollers bolted to CM end cover
Tooling
Short cold mass length: Handling at the extremities (no rails inside vacuum vessel)
Rollers bolted to CM end cover
Mobile girder

15. Tooling Cryostating bench Bottom tray assembly bench
Bottom tray welding cabinet
Thermal shield rolling machine

16. Quality assurance
Full traceability: Materials, qualification of procedures and personnel, measurements, tests
Asset management approach: documentation linked to equipment in database
Equipment naming according to LHC QAP
Manufacturing and inspection plans list main steps and give references to input and output documents
Management of documentation by the 11T project QA team
Implementation and extent of application as done for the magnets and cold masses

17. Quality assurance example: Bottom tray assembly for 11T prototype
Items (part numbers) created in edms

18. Quality assurance example: Bottom tray assembly for 11T prototype

19. Quality assurance example: Bottom tray assembly for 11T prototype
Asset number (physical equipment) = item number + serial number

20. Quality assurance example: Bottom tray assembly for 11T prototype
List of manufacturing steps: “Traveller” for a given equipment

21. Risks and mitigation Risk Mitigation Unproven solutions
Priority to usage of existing designs, components and assembly procedures
Integration of current leads in the limited space between cold mass and vacuum vessel
Start the design of the leads immediately
Interface management (especially between beam vacuum, collimator and cryostat)
Approved interface layout drawings
Instability of interconnect expansion joints between 11 T cold masses
Design according to standards
As redundancy:
Protective shells limiting transverse displacement
Pipe supports without contact during normal operation but limiting lateral displacement in case of buckling
Pressure / vacuum tightness
All components designed and fabricated according to pressure vessel stardards, including vacuum components
Aluminium leak tight welds
Performed at CERN according to qualified procedure in controlled atmosphere

22. Conclusion Production strategy based on “build-to-print” approach
Usage of existing tooling with some adaptations
Standardisation of components and procedures whenever possible
Components for 11T prototype well advanced
Fabrication of the bypass prototype starting soon in order to anticipate work
Quality assurance according to integrated approach and managed by a single team for all 11T project