1. HRM Technical Board April 28 th, 2015 Fausto Lorenzo Maciariello, on behalf of many colleagues: F-X Nuiry, V. Kain, J. Uythoven, O. Aberle, R. Folch, R. Losito, G.E. Steele, M. Butcher, A. Lechner, R. Ferriere.

2. Outline Motivations The Experimental Set Up On-Line Instrumentation Monitoring List Of Materials Preparation & Installation Phase Operational Phase “Short-Term” Cool-Down & Storage Post-Irradiation Phase & Failure Scenarios RP Related Hazard Inventory & Radiation Level Disposal Risk Analysis Conclusions 2

3. Motivations 1.Assess the Integrity of Graphite for TCDIs and TDIs during Run 3. The goal is to reproduce the worst accidental scenario that the TCDI and the TDI can see during their life time. 2.Test New Promising Materials for BIDs 3.Benchmark Simulations Temperature and Displacement Measurements foreseen. BeamIntensitySig X[mm] * Sig Y[mm] Peak per Primary [GeV/cm 3 ] Max Temperature [ ° C] M-C Safety Factor* Run 3 BCMS5.76 E130.320*0.5110.43614500.8 HiRadMat3.46 E130.313*0.3130.66313420.7 3

4. The Experimental Set Up Active Part Materials: Upper Jaws Stroke: +/- 30mm. The upper jaws will begin at z=400mm. Lower Jaws Stroke: +/- 30mm. The upper jaws will begin at z=0 mm. Tank Stroke (5 th axis): +/- 60mm. Instrumentation Stroke (6 th axis): +/- 60mm. 4 400mm On-Line Instrumentations 5 th Axis Collimator Feet Plug-In System Jaws Beryllium Beam Window Tank

5. On-Line Instrumentation Monitoring 5 150mm 80mm X Z Y * Detailed Simulations on expected thermo-mechanical loads are contained in the Safety file.

6. List of Materials Boron Nitride (1.9g/cm 3 ) Graphite (1.83g/cm 3 ) 3D C/C (Wrapping Process Technnique,1.7g/cm 3 ) 3D C/C (Plane Process Technique,1.7g/cm 3 ) Aluminum AW-6082 T6 Collimator support feet77600 Aluminum AW-6082 T6 5 th axis132160 Aluminum AW-6082 T6 Plug-in32215 Stainless SteelVacuum tank363112 Stainless SteelCollimator jaw housing and stiffener 7133 MaterialComponents Estimated Weight [Kg] Approximate distance to the beam axis [mm] BrassLVDTs axis0.1290 BerylliumVacuum Windows0.012On Beam Rad-Hard GlassOptical windows1.580 Stainless Steel 316LBellows0.578 6

7. Layout 7 TT61 Side TNC Side Table Position 2

8. List of Materials - Instrumentation Instrumentation Tank & HRM Table Position Optomet LDV passive head Inside the tank 140mm from the beam Pyrometer Passive Head Inside the tank 140mm from the beam Radiation Hard CameraOutside the tank Instrumentation TT61 Position Optomet LDV Acquisition System In The TT61 bunker. Connected to the Optomet LDV passive head through TT61- TNC feedthroughs. Pyrometer Acquisition System In The TT61 bunker. Connected to the Polytec passive head through TT61-TNC feedthroughs. Camera Acquisition SystemIn The TT61 bunker. Connected to RadHard camera Beam (TNC Side) Instrumentation Location Table B Location (TNC Side) Main part of the instrumentation and equipment connected through the standard HRM table. Additional cabling not present on HRM table will be connected through TT61-TNC feedthroughs *Detailed List of Instrumentation in the Safety File 8 TT61 Side TNC Side Instrumentation Location Beam Table B

9. Preparation & Installation Phase 1) Experiment Integration and Assembly Manufacturing of the tank and Collimator jaw housing by EN/MME. Collimator feet, plug-in, 5 th axis, instrumentation and equipment: EN/STI. All parts assembled, instrumented and tested in EN/STI bldg. 867 and at bldg. 272. BPKG support, tank and in-tank instrumentation alignment in Metrology Lab. 2) Integration in SPS-BA7 – estimated time ~ 3 weeks Integration of the experimental tank interface plate on to the HRMT lifting table. Alignment cross-check of the LDV and pyrometer head(s). Integration of the electrical connectivity. First testing of the acquisition system and of the remote control system of the online systems. Connection and installation of the rad-hard cameras to the test-bench. 3) Installation in TNC estimated time ~ 1 week Transported to the TNC HiRadMat area via a trolley transport system, vertical lift and then remotely controlled crane. Connection of the instrumentation feed-throughs via the TNC/TT61 holes. Alignment cross-check of the experimental set-up. 9

10. Operational Phase 10 Alignment Procedure to be followed before impacting Jaws: 1.Establish trajectory – collimator open 2.Set up interlock thresholds 3.Copy settings to high intensity cycle 4.Set up collimator 0.5 sigma steps with nominal bunch: scan gap. [Small gap]

11. Operational Phase 5.Move collimators out: calculate jaw setting with defined beam center. 6.Verification with fast 12 bunch shot: check trajectory. 7.Move in jaw: impact 1.5 sigma 8.Verification shot with 12 bunch shot. Check beam loss signal, check position on BPKG (Vertical Alignment accuracy: +/-0.5 σ) 9.Alignment Instrumentation with the beam, scanning the jaw with few 12 bunch individual shots (Horizontally) using the 5 th axis (best Horizontal alignment accuracy= beam Jitter). 10.288 Bunch Shot 5 th Axis Instrumentation The same procedure has to be done for the lower jaws, while for the upper ones there is no need of instrumentation-beam alignment (n. 8). Type of beam: Trajectory indiv.

12. Operational Phase The goal is to reproduce the worst accidental scenario that the TCDI and the TDI can see during their life time. Mohr-Coulomb Safety factor as INDICATOR of material survival. The material survives if M-C > 1. Each jaw will see: 2 pulses @ 1.5 sigma impact parameter. Allowing enough cool-down between the two (>10minutes) Intensity per pulse: 1.2 E11 protons/bunch Number of bunches: 288 Sigma X*Sigma Y= 0.313*0.313 Dependency of M-C safety factor and maximum energy density on impact parameter (in σ) for a round beam with a σ=0.295mm. For a round beam with a different beam spot size will be expected the same behavior. As already mentioned, the induced stresses are affected by the distance to the next free surface. Hence the proposal of having two opposite jaws in order to perform a high-precision alignment ◦ Scanning the beam with a small gap ◦ Detecting induced showers with BLMs Expected beam deviation accuracy Vertically: +/-0.5 σ 12

13. “Short-Term” Cool-Down & Storage 1.After the experiment, the tank-pump line is closed with a valve and the vacuum is broken (0.8-1bar). 2.The experimental set-up will need to remain at the experimental area for ~1 month for radiation cool-down. Then, fast disconnection of services not included in standard HRMT table (<1 mSv/h tank wall). 3.Remote transport with the crane to the cool-down storage area downstream in TNC tunnel. 4.6 months of cooling at the storage area downstream in TNC tunnel,radiation dose rate drops to levels below 200μSv/h at contact with the tank wall. 13

14. “Short-Term” Cool-Down & Storage: Envelope The test-bench exceeds the limits of the default space available to experimental hardware. Discussion and approval by the HRM Technical Board is needed. BTV, on going design About 42mm inside the “forbidden area”. Cooling pipes NOT used !! 14 600mm 230mm

15. Failure Scenarios 1.Global deformation that makes the flatness larger than 100 μm. 2.Cracks on fragile materials (Graphite and BN) can be really dangerous and not acceptable. On 3D C/C “small” cracks (not affecting the surface flatness requirements and not affecting the block integrity) can be accepted due to its ductility. Expected results are based on material static limits (displacement rate 0.02mm/s) while we are under dynamic load conditions (2000 mm/s) 15 *Mohr-Coulomb safety factor should be larger than 1 as an indicator for the material survival (Criterion to be applied to fragile materials as graphite)

16. Post-Irradiation Phase 1.Ultrasounds (CERN, MME Lab) Detectable defects: 1mm on 25mm thickness, 2mm on 50mm thickness 2.Microscopy Inspection (CERN, MME Lab) 3.Metrology Control (Bldg. Metrology, 72) > (M. Widorski, DGS-RP-AS) Microscopy Inspection on Graphite. Defects detectable 10 to 50 microns. Depends on the chosen magnification. Sound Wave direction No Defects bigger than 1.5mm (resolution) detected in the material. Difference in the intensity of the ultrasound crossing the block. Inhomogeneous material, due to: Micro porosity, Micro defects smaller than the resolution, Grain size *Detailed Metrology report EDMS 1497604, Detailed Ultrasound report EDMS 1504923. Detectable deformations less than 1mm. Depends on the chosen sampling. 16 4. Micro-Tomography (RX SOLUTIONS, Annecy) 5. X-Ray

17. RP Related Hazard Inventory & Radiation Levels Simulations were performed with the following assumptions: The full total of 8 high intensity shots all impacted one jaw in exactly the same position, thus maximizing the activation for both the jaw and the downstream tank. 17 Cooling timeResidual dose jaw Residual dose tank Residual dose 0.4m from tank 1 hour7900mSv/hr2300mSv/hr21mSv/hr 1 day7mSv/hr13mSv/hr0.6mSv/hr 1 week2mSv/hr4mSv/hr80μSv/hr 1 month0.6mSv/hr0.9mSv/hr23μSv/hr 6 months85μSv/hr0.1mSv/hr5μSv/hr 1 year26μSv/hr40μSv/hr1μSv/hr Radiation dose at contact of the tank wall. Conservative Approach

18. Disconnection By Hand, Cabling not on HRM Table 18 2 x LDV fibres 1 x Pyrometer fibre 1 x Radhard camera cable 1 x Miniature camera feedthrough (2 screws) Each Disconnection: 30 s Total Exposure Time: 3 min Radiation Dose: 1month (at contact with tank wall), <1 mSv/hr Total Radiation Dose: 50 μSv

19. Disposal & Jaw Extractions 19 Disassemble at BA7 surface of the tank, BPKG and HRM table. HRM table, BPKG and collimator feet are sent to radioactive disposal, building 953. 2. 1. Full assembly after 6 months of storage at TNC

20. Disposal & Jaw Extractions Opening the tank and extracting jaws in 867. Radioactive Workshop. 20 Time Needed: 2min (multiple people holding the clamps) Radiation Dose: < 200 μSv/hr Total Radiation Dose: 6.6 μSv Time Needed per jaw: 4 min Radiation Dose: < 200 μSv/hr Total Radiation Dose: < 53.3 μSv (4 Jaws) 4.1 3. 4.2

21. Disposal & Jaw Extractions Jaw extraction in 867. Radioactive Workshop. 5. 21 Time: 20 s/screw (6screw to tight) + 2 min target extraction Radiation dose: < 200 μSv/hr Total time per Jaw ≈ 4min Total Radiation Dose: < 53.4 μSv (4 Jaws)

22. Disposal & Jaw Extractions 22 Total Exposure Time ≈ 35 min Expected Activation (Contact on tank surface): < 200 μSv/hr Cumulated Radiation Dose ≈ 120 μSv Number of People needed for the Operation: 6

23. Risk Analysis EventDescriptionHazardMeasures/Precautions Installation and Assembly Manual Handling Work to be done during the assembly Injury due to lifting heavy objects Several handles for single component, to facilitate the lifting by multiple people (e.g. tank door). Modular design easy to mount and dismount Use of crane/lift Dismounting Radiation exposure during the disconnection of cable After the experiment some cables need to be disconnected manually from the HRM table Exposure to ionizing radiationChecking the radiation level. Minimizing time for the operation in TNC with test before the actual experiment (practice the procedure). Activation of the tank and jaws Extracting the irradiate materialsExposure to ionizing radiationDesign made to facilitate the jaw extraction and reducing the dismounting time Tools for dismounting procedure further from the activated components Post Irradiation Phase Metrology tests Radiation exposure during PIE of irradiated targets Exposure to ionizing radiationPIE carried out only after RP greenlight in a delimited “radioactive” are or radioactive workshop Ultrasound tests Microscopy Inspections Microtomography tests Exposure to ionizing radiation Exposure to ionizing radiation and Shipping the targets externally 23 *A detailed list of risks is given in the safety file.

24. Conclusion We will REPRODUCE the worst case scenario for the thermo- mechanical stresses and assess the TCDI & TDI survival. The design and the instrumentation integration is progressing. Simulations on expected thermo-mechanical loads and radiation levels were done (detailed information in the Safety File) Post Irradiation Analysis will be able to detect material failure. Safety aspects represent a major priority during all the phases of the experiment. 6 months cool down period in TNC will be sufficient for residual dose rate to fall down <200 μ Sv/h at contact with the tank wall. 24

25. Thank For Your Attention !!!

26. Risk Analysis EventDescriptionHazardMeasures/Precautions Installation and Assembly Manual HandlingWork to be done during the assemblyInjury due to lifting heavy objectsSeveral handles for single component, to facilitate the lifting by multiple people (e.g. tank door). Modular design easy to mount and dismount Use of crane/lift Electrical connectionsWorking with electrical connectionsElectrical shockInsulated wiring/low voltage Pre-existing activation of the experimental area Exposure during the installation phaseIonizing radiationMinimizing time for the operation in TNC with test VacuumVacuum inside the tankRopture of the WindowCalculations to choose the needed thickness Excessive bowCalculations to choose the needed thickness Instrumentation misalignmentThe final alignment will be done with vacuum (for the pre-alignment procedure and the alignment with the real beam) Testbench liftPositioning on Position 2 in TNCFall of heavy loadsVerification Crain maximum lifting weigth> total testbench weight Transport Test bench transportationThe test-bench needs to be transported from BA7 to TNC Fall of heavy loadsSlower transport and verification of maximum weights TransportVibration occurring during the transportLoosing of jaw/instrumentation alignmentAfter the pre-alignment on the BA7 surface anotheer one is foreseen in TNC with the pilot beam. Experimental Phase FireIgnition of componetsPotential release of radioactive materialAll the component are under vacuum and the max temperature for the target is much below the max service temperature (under vacuum). Risk of ignition is totally eliminated Experiment diagnosticMeasurements to be done in a high radioactive area High activate environmentRemote diagnostic only Expensive electronic devices to be placed on the bunker (TT61) protected by the shielding On-line instrumentation alignmentNeed of very accurate precision (0.2mm)Not measuring temperature and displacement at the correct location Scanning the jaw surface, in order to find the location with the strongest signal given by the LDV, while the pilot beam is impacting the jaw. Dismounting Radiation exposure during the disconnection of cable After the experiment some cables need to be disconnected manually from the HRM table Exposure to ionizing radiationChecking the radiation level. Minimizing time for the operation in TNC with test before the actual experiment. Activation of the tank and jawsExtracting the irradiate materialsExposure to ionizing radiationDesign made to facilitate the jaw extraction and reducing the dismounting time Tools for dismounting procedure further from the activated components Post Irradiation Phase Metrology testsRadiation exposure during PIE of irradiated targets Exposure to ionizing radiationPIE carried out only after RP greenlight in a delimited “radioactive” are or radioactive workshop Ultrasound tests Microscopy Inspections Microtomography testsExposure to ionizing radiation Exposure to ionizing radiation and Shipping the targets externally 26

27. Jitter Beam Spot Size Trajectory X Y Z Z: Beam Direction Sensors Position Accuracy Pilot and or Medium Intensity Beam Nominal Beam Min [mm] Max [mm] Min [mm] Max [mm] BEAM SPOT SIZE 0.3 VERTICAL BEAM DEVIATION “x” -0.2+0.2 HORIZONTAL BEAM DEVIATION “y” -5+5 VERTICAL JITTER “x” -0.060.06 HORIZONTAL JITTER “y” -0.0750.075 Beam Axis Distorsion compared to Z Angle= ??? ° BPM Accuracy -0.2+0.2 Instrumentation Alignment precision (without 6 th axis) …? 1 Sigma

28. Dynamic Behavior of Graphite 28 Under Dynamic Stress load the graphite limit is higher. Elastic Strain Limit= 0.0051 Elastic Limit≈58 MPa Max Pic Stress=43 MPa

29. INFO NEEDED Beam Spot Size Accuracy: Jitter Accuracy: Trajectory Accuracy: BPM accuracy: Geometric Center of the jaw given by the Geometers. Accuracy: ALL THESE INFO NEEDED FOR EACH DIRECTION: X, Y, Z. 29

30. 2 h of stability data taking with 1e+11. 2mm fp2 P2p: ~ 1 mm One strong horizontal mode 30 The error scales like: 0.3 mm/2 mm = 0.15. Only 0.15 of the 1 mm for our optics.