1. Collimator Production and Installation
R. Assmann for the collimation team
29-Mar-2006
Special thanks to O. Aberle, S. Chemli, K. Foraz, J. Inigo-Golfin, M. Jimenez, Y. Kadi, J. Lettry, M. Mayer, R. Perret, J.P. Quesnel, C. Rathjen
RWA, 29/3/2005

2. The Final Collimation System
The LHC collimation system is 100% frozen.
Final system is very powerful but complex:
Ring: 172 database locations (158 in collimation project).
TL: 28 database locations (all in collimation project).
8 types of collimators plus various types of masks and absorbers.
4 phases defined for path to nominal and ultimate intensities.
Different interfaces depending on type of neighboring equipment.
System is necessarily complex to provide the required excellent performance. It is difficult to understand and follow all system aspects (also sometimes for us).
Production of system followed by AB/ATB (collimators, motors, sensors), TS/MME (supports) and AT/VAC (mobile pumping ports)! Many thanks!
System involves 5 major production contracts!
RWA, 29/3/2005

3. Transfer Line Collimation
Installation of several TCDI (transfer line collimators) is required!
Commitment:
4 TCDI for installation in May/June 06. Cover difficult installation points!
Collimator Delivered Ready for installation TCDI 1&2 28/3 & 10/4 8/5 TCDI 3&4 ~ 20/4 11/5 & 15/5
Installation slots: TCDIH87904, TCDIH88121, TCDIV88123, tbd
The rest of the TCDI in January 2007!
This approach:
Allows to test transfer line collimation.
Difficult installation points addressed early on!
Minimal temporary installations: the transfer line is under vacuum!
Does not impact ring installation of collimators (no production delay for the ring)!
TCDIH87904: installation in the presence of both the QRL line directly above and the LHC cryomagnet in front. It is foreseen to bring the collimator underneath the cryomagnet and lift it up in position with the help of a lifting crane permanently installed at that position. TCDIH87441: installation interferes with the presence of a bus bar connecting the MBI87424 to the MQID A special support foot was designed to fit under the bus bar.
RWA, 29/3/2005

4. Planning First 4 TCDI
Y. Kadi
RWA, 29/3/2005

5. Installation Procedure Ring
RWA, 29/3/2005

6. Collimation Tunnel Components
Collimator support
Beam 2
Collimator
tank
Quick-connect flanges
Vacuum pump
Interconnect
support
Survey reference points
Motorization/sensors
Production done in AB, TS, AT!
R. Perret et al
RWA, 29/3/2005

7. Installation Planning LSS
Different parts of the collimators are produced independently.
Installation planning is different for different components.
A list has been worked out, based on:
New collimator production info was sent by company on March 8th and confirmed this Monday.
RWA, 29/3/2005

8. Other production contracts are on schedule: Supports Motors
Position sensors
Mobile pumping ports
No details here…
 Not very detailed planning…
RWA, 29/3/2005

9. Production Schedule Collimators
Delay: 3 months behind contract!
RWA, 29/3/2005

10. Latest Achievements in Production
First collimator has been shipped to CERN!
Finally!!!
… and it arrived yesterday at CERN!
(shock during transport detected and being analyzed)
RWA, 29/3/2005

11. Latest Achievements in Production
RWA, 29/3/2005
Parts for many collimators at CERCA!

12. Production Problem Most urgent problem: Brazing of ring collimators!
Repair of brazing oven required!
CERCA looks for alternative!
TS/MME has offered help: decision this week!
RWA, 29/3/2005

13. Status Collimator Production
We are getting cautiously optimistic about the latest production schedule:
An official CERN letter was sent and caused some reactions! Things are shaken up!
Commitment from CERCA on an updated production schedule. Confirmed this Monday!
CERCA announced increase of manpower by 70%! This is GOOD!
Lots of collimator parts are now visible at the company!
CERCA director is reviewing the production contract and analyzing problems!
We heard yesterday that CERCA director believes contractual rate of 10 collimators per month is overly optimistic!??
Follow-up meeting at CERN end of April, beginning of May with CERCA top management and CERN management. The story is not finished!
Take latest CERCA schedule as baseline! Add 2 months for work at CERN:
Final assembly of collimator.
Installation of motors, sensors, …
Transport and installation.
RWA, 29/3/2005

14. Support Installation
 Committed to install ALL supports in LSS planning!
RWA, 29/3/2005

15. Support Installation
Time for connection of supports to cables & water. Alignment campaign by sector with dummy collimator! Included in installation coordination! HW commissioning!
RWA, 29/3/2005

16. Collimator Installation
Definition of dates (after discussion with Katy, Miguel, …):
“Collimator READY date”: CERCA delivery date plus 2 months for final assembly and installation.
“Start of mechanical installation vacuum”: Install collimators before vacuum is installed! Simplifies vacuum work.
If not possible: Fallback solution is installation of collimators before “start of bake-out”!
Thanks to the planning groups for making all the required info available to us and for taking our needs into account!
RWA, 29/3/2005

17. Collimator Installation
RWA, 29/3/2005

18. Detailed Tables for Planning
Originates from collimation phase but changed!
 PDF file for all LSS’s!
RWA, 29/3/2005

19. Summary Installation Plan
Date
Installation phase
Collimation phase N
LSS 1 75
2007/8 2
1 & 3 9
2008 3 14
2010 4 32
n/a 5 28
Almost full phase 1 system for LHC start-up! No performance limits!
Here 46 replacement chambers required for phase 2 and special phase 1 collimators. 40 exist! We should get 6 more!
In addition a minimum 9 replacement chambers for delayed collimators.
In total an additional 20 replacement chambers are proposed based on present planning!
Can be stainless steel ( impedance team). Flexible in usage (most collimators have the same length and flange diameter)!
RWA, 29/3/2005

20. Fallback Solutions (Proposal)
Goal is to keep the target date, in particular to have the collimators installed before the vacuum installation starts.
If additional delay of up to 2 months:  Install collimators up to the start of the actual bake-out.
If additional delay of more than 2 months:  Leave IR7 partly empty, following advise by the vacuum group (try to complete sectors with new sector valves). To keep some performance we would prefer to delay a secondary collimators (TCS), if needed.  If beneficial skip bake-out in IR7. No problem identified in last meeting of the MIBWG (Machine-Induced Background WG)  acceptable!
RWA, 29/3/2005

21. Residual Problems
Many discussions around the ~200 locations over the last years.
Most (all?) have been resolved and LHC database has all collimators, absorbers, … included now! Final ECR sent!
Ongoing discussions:
Vacuum layout close to tertiary collimators in IR1 (pointed out by S. Chemli). Not enough space for standard mobile pumping ports!?
Interference with installation of air duct in IR7. Before we install collimators support we want the air ducts to be there (in schedule?).
RWA, 29/3/2005

22. Conclusion
Many thanks to the planning team and technical groups for info, feedback, advice and for taking our special needs into account!
We are almost fully compatible with the last draft LHC schedule (for the first time since we started the collimation project). Almost full phase 1 system!?
Further feedback is welcome! Is the presented approach acceptable?
Risks still exist (collimator production) and we need to react if required.
Questions for discussion:
Is the information provided in the collimator installation tables adequate? What can be improved?
What would be the right procedure to adapt the installation planning to the collimator production progress?
What is the shortest acceptable notice for changes?
Decision on replacement chambers?
RWA, 29/3/2005

23. Links
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