2. 2 Technical seminar - 5 th June 2014 Vincent Roger - TE-MSC-TF

3. Outlook Introduction Part I – General description Part II – The new insert of the Long station 2.1 Design stage 2.2 Safety file 2.3 Follow up of the production Part III – The future inserts 3.1 Projects progress 3.2 The insert of the Cluster D Conclusions 3 Upgrade of the vertical test station in SM18

4. Introduction 4 In order to increase our capacity of testing magnets, current leads and diode stacks, several projects have been set up to realise new insert or to update them. With these new inserts we will gain also in : Flexibility Cooling Time Handling & operation In a general way, the purpose of an insert is to : Support mechanically the magnet or other devices Connect electrically this device to the power supply via the current leads Cool down the device from 293 K to 4.2 K or 1.9 K Upgrade of the vertical test station in SM18

5. 5 Inserts already in use in SM18 The insert used to test the diode stacksThe insert used to test current leads The design of these inserts were simple since they work at 4.2 K : No exchangers and instrumentations No λ plate No tie holdings and helium guards Upgrade of the vertical test station in SM18

6. 6 Inserts in progress  The second insert of the long station  The insert of the Siegtal station  The insert of the Auxiliary station  The insert of HFM  The insert of the Cluster D Upgrade of the vertical test station in SM18

7. Part I – General description 7 Magnet λ plate Top plate LHe / LHe exchanger 4.2 K helium bath 1.9 K helium bath GHe / LHe exchanger Upgrade of the vertical test station in SM18

8. 8 Cryogenic devices To reach 1.9 K, two thermal exchangers are needed : The GHe / LHe exchanger used to reach 1.9 K (using gaz helium at very low pressure vapour saturised and JT valve) The LHe / LHe exchanger used to cool the main helium bath to 1.9 K by conduction GHe pumping Command of the Joule Thomson valve GHe / LHe exchanger LHe / LHe exchanger Instrumentations Upgrade of the vertical test station in SM18

9. 9 Use of a PLC & Operation A PLC (Programmable Logic Controller) has been set up in order to manage automatically cryogenic devices for standard operations as cool down or warm up but especially to guarantee facilities and staff safety. Upgrade of the vertical test station in SM18

10. Part II – The new insert of the Long station 10 2.1 Design stage In order to reduce the delay between two magnet tests on the long station, it has been decided to design a new insert. This insert is NOT a copy of the existing insert, cryogenic performance have been improved, and instrumentations have been automatized. Group project of 9 peoples: Follow up : TE-MSC-TF Design : EN-MME-EDM Manufacturing : EN-MME-FS Cryogenic devices : TE-CRG-ME Safety : DGS-SEE-SI Upgrade of the vertical test station in SM18

11. 11 Design of the existing insert Upgrade of the vertical test station in SM18

12. 12 Main improvements A new GHe / LHe exchanger to increase the helium flow A new LHe / LHe exchanger to increase its surface A new GHe outflow on the safety line Automatize the safety valve on the λ plate Use new instrumentation boxes Use an helium guard on the tie holdings to prevent leak Use of a new standard valves for the LHe inflow Upgrade of the vertical test station in SM18

13. 13 Design of the new insert Upgrade of the vertical test station in SM18

14. 14 One of the main difficult part was to design a bigger LHe / LHe exchanger by keeping a good handling. To decrease the cooling magnet time from 4.2 K to 1.9 K, the exchange’s surface has been increased from 0.3 m 2 to 1.0 m 2 Upgrade of the vertical test station in SM18

15. 15 More than 200 elements have been modelled and 120 drawings have been realised !!! There are hundreds of welds which will be done and controlled by the main workshop !!! From 600 to 700 hours of work !!! Upgrade of the vertical test station in SM18

16. 16 2.2 Safety file The maximum allowable pressure (PS) of the insert has been defined. From this the opening pressure of safety valves and the pressure tests are defined. Upgrade of the vertical test station in SM18 Working pressure : around 0.2 barg 0.9 barg : opening of the valve to the balloon PS = 1.5 barg 1.1 * PS = 1.7 barg (primary safety system) 1.2 * PS = 1.8 barg (secondary safety system) Test pressure : 2.5 barg

17. 17 According to the Pressure Equipment Directive 97/23/EC (PED), this insert belongs to a risk category III. Upgrade of the vertical test station in SM18

18. 18 Therefore a safety file need to be set up in which all the following information have to be documented. Upgrade of the vertical test station in SM18

19. 19 Moreover the percentage of radiographic tests on butt ‐ welds shall be in agreement with the following table. All non standard welds need to be calculated, and the workshop needs also to be certified for all weld types. Electron beam welds Brazing Copper / Stainless steal Upgrade of the vertical test station in SM18

20. 20 For this safety file, an EDMS structure has been set up. Upgrade of the vertical test station in SM18

21. 21 2.3 Follow up of the commands & the manufacturing To certify the insert, it is needed to check rigorously the material certificate of each part even if these parts are ordered on the CERN store. At the main workshop, each material pieces are identified and attached to one element of one drawing to keep the material traceability. Upgrade of the vertical test station in SM18

22. 22 The manufacturing has begun, and the weld process is going to start : Upgrade of the vertical test station in SM18

23. 23 2.4 Synthesis It’s the first time that a such project is realised with regards to the new standards. The approach is now well defined, and based on this experience we can go ahead with the following new inserts. Design stage Safety file Technical description of the project Calculations Weld analysis Definition of the pressure tests Design Validation With EN-MME With DGS-SEE Commands Manufacturing process & Definition of the weld controls Manufacturing Material traceability Weld control report Upgrade of the vertical test station in SM18

24. Part III – The future inserts 24 3.1 Projects progress The insert of the Siegtal station The insert of the Auxiliary station The insert of HFM The insert of the Cluster D Design stageSafety file Design Validation Manufacturing process Design stageSafety file Design Validation Manufacturing process Design stageSafety file Design stage 11/2014 To be defined 12/2015 Upgrade of the vertical test station in SM18

25. 25 3.2 The Cluster D New cryostat New insert New cryogenics devices New power supply & equipment New rack for the acquisition and new PLC New control room Upgrade of the vertical test station in SM18

26. 26 A preliminary study has been done in order to choose a design strategy based on the Long test station or on the HFM test station.

27. 27 Based on this criteria, we estimated that HFM type design would fit better both in time and price estimate to our needs for serving HL-LHC magnet tests. Design based on the design of the HFM test station Design based on design of the LONG test station Price of the cryostat × Price of the insert × Time for fabrication of cryostat × Time for fabrication of insert × Price of fabrication of cryogenic lines × Handling of the insert in operation × Adaptability × Upgrade of the vertical test station in SM18

28. 28 Today a first design of the insert is done, to go further with the design stage we would need some inputs (design of the current leads, final geometry of the cryostat, magnet interface, …) Upgrade of the vertical test station in SM18

29. 29 Upgrade of the vertical test station in SM18

30. 30 Design Office and Main workshop : EN-MME Vincent Maire, Emilien Rigutto, Luca Dassa Magnet Test Facilities: TE-MSC-TF Marta Bajko, Christian Giloux, Patrick Viret Cryogenic Team : TE-CRG Vladislav Benda Safety group: DGS-SEE Cecile Pinto Cryostats & Machine Integration : TE-MSC-CMI Arnaud Vande Craen Upgrade of the vertical test station in SM18