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CERN-SLAC meeting June, 15-17 1 The LHC Collimator Project LHC Collimators for Phase 1 CERN-SLAC meeting – June, 15-17 2005 Palo Alto, Ca Alessandro Bertarelli.

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Presentation on theme: "CERN-SLAC meeting June, 15-17 1 The LHC Collimator Project LHC Collimators for Phase 1 CERN-SLAC meeting – June, 15-17 2005 Palo Alto, Ca Alessandro Bertarelli."— Presentation transcript:

1 CERN-SLAC meeting June, 15-17 1 The LHC Collimator Project LHC Collimators for Phase 1 CERN-SLAC meeting – June, 15-17 2005 Palo Alto, Ca Alessandro Bertarelli – CERN Geneva Mechanical design and engineering for the LHC Collimators

2 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 2 Outline Focus on … Main geometrical constraints Mechanical general layout Supporting system Mechanical design Equivalent heating test Thermo-mechanical calculations Nominal cases (steady and transient) Accident cases (dynamic)

3 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 3 Geometrical Constraints Typical tunnel cross-section (IR7) Beam axis inter-distance 224 mm Reserved for survey Reserved for transport Reserved for ventilation Second beam pipe (Ø84mm)

4 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 4 Geometrical Constraints Main constraining dimensions 503 618 522 354 950 1406

5 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 5 Supporting system Fixed base (pre- installed) Adjustable base (pre-installed) Adjustment rods (3) (for in-tunnel alignment – tilt and slope) Mechanical plug-in (top and bottom parts) Plug-in support plate Pivoting cradle (manual adjustment +/-10º)

6 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 6 Supporting system Cradle Bracket Stepper-motor and gearbox (+/-10 mm) Linear guide-way slots Sliding Plate (+/-10mm) Survey Sight Support (counter-pivoting) Jaw actuation system

7 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 7 Mechanical design 1. Jaw actuated by 2 stepper-motors via a roller screw (10  m/step) 2. Return spring for semi - automatic pullback and play recovery 3. Rack-pinion system to prevent misalignments (max  3 mm) 1 1 2 2 3

8 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 8 Design Principles 1. Jaws in C/C or graphite 2. Cooling Cu-pipes (2 x 3 turns) and plate pressed against the jaw, brazed to the bar. 3. Main GlidCop® support bar Low thermal contact resistance (P=3 bar) Differential thermal expansion allowed Good cooling capacity (5 l/min per pipe) Deformations minimized (compensation) 3 2 1

9 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 9 Heating test set-up Test conditions 1 m long C/C jaw (65x25mm) Up to 4kW heat flux (2x2000W) Up to 6 bar clamping pressure Up to 5 l/min water flow (per tube) 11 ºC water inlet temperature Reflecting screen Vacuum Chamber Ceramics insulator Heater Cartridge

10 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 10 Heating Test & Calculations Experimental results versus numerical calculations (2500W) … 31.1º 24.9º 21.9º 17.8º 30.8º 24.0º 17.4º 21.3º 2300 W 100 W … material properties and thermal conductance model confirmed !!!

11 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 11 Thermo-mechanical Analysis A large number of FE simulations, complemented by analytical calculations, were carried out: Nominal conditions: 3-D coupled steady-state analysis of 1h beam lifetime case (0.8e11 p/s at 7 TeV) Nominal conditions: 3-D “quasi-static” coupled analysis of 0.2h lifetime case (4e11 p/s at 7 TeV over 10 s) Abnormal conditions: 2-D transient coupled analysis of injection error (3.2e13 p at 450 GeV during 7.2  s) Abnormal conditions: 2-D transient coupled analysis of asynchronous beam dump (9.1e11p at 7 TeV during 200ns)

12 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 12 Thermo-mechanical Analysis Nominal conditions 0.8e11p/s - data inputs: Initial temperature:27 ºC Water inlet temperature:27 ºC Water flow rate (per pipe):5 l/min (2.95m/s) FLUKA Energy depositions: Nominal Conditions 6.2kW at 0.8e11p/s V.V. 13.01.04 (symmetric)TCS.B2 from TCP3 Nominal Conditions (worst case equiv.) 4.5kW at 0.8e11p/s. V.V. Sept. 04 (non-symmetric)TCSG.A6.L1 Spring preload (avg. pressure):3 bar Materials: AC150K 2-D C/C (properties as experimentally measured) R4550 Isotropic Graphite (properties as experimentally measured)

13 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 13 Thermo-mechanical Analysis FEM Model for 3-D analysis (nominal conditions) Coupled thermal-structural analysis (SOLID5 main elements) Temperature-dependent material properties Mapped power density distribution (HGEN load) Contact elem. (Friction + thermal conductance) Preloaded Spring (LINK elements) Convection (12360W/m2/K) with linearly increasing water temperature Deposited power (W/m 3 )

14 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 14 Thermo-mechanical Analysis Nominal conditions: 0.8e11p/s 7TeV Steady-state Symmetric Power Density Distribution (simplified based on Primary coll. calculations) Unsymmetric Power Density Distribution (to be updated with new FLUKA runs!)

15 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 15 Thermo-mechanical Analysis Mechanical properties of C/C and Graphite (excerpts) AC150K C/C 2D (z direction) R4550 Graphite CTE @ RT α [°K^-1] -1.5e-64.3e-6 Young Modulus E [GPa] 76.8411.5

16 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 16 Thermo-mechanical Analysis AC150 C/C 2D R4550 Graphite Symmetric Power Density Distribution 48[°C]52[°C] Unsymmetrical Power Density Distribution 43[°C]47 [°C] Thermal analysis Nominal conditions: 0.8e11p/s 7TeV - Steady-state

17 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 17 Thermo-mechanical Analysis Thermal analysis - Nominal conditions: steady-state AC150 jaw with unsymmetrical power distribution

18 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 18 Thermo-mechanical Analysis Displacement analysis – Nominal conditions: Steady-state R4550 graphite R4550  Max ≈ - 20  m R4550  Max ≈ 45  m Symmetric Power Distribution Unsymmetric Power Distribution

19 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 19 Thermo-mechanical Analysis Displacement analysis – Nominal conditions: Steady-state AC150K 2D C-C AC150  Max ≈ 32  m AC150  Max ≈ 55  m Symmetric Power Density Distribution Unsymmetric Power Density Distribution

20 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 20 Thermo-mechanical Analysis Nominal conditions (4e11p/s) - data inputs: Initial temperature:resulting from steady-state runs Water data:as for steady-state FLUKA Energy depositions: Nominal Conditions 31kW at 4e11p/s V.V. 13.01.04 (symmetric)TCS.B2 from TCP3 Nominal Conditions (worst case equiv.) 22.5kW at 4e11p/s V.V. Sept. 04 (non-symmetric)TCSG.A6.L1 Spring preload (avg. pressure):3 bar Materials:as for steady-state

21 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 21 Thermo-mechanical Analysis AC150 C/C 2D R4550 Graphite Symmetric Power Density Distribution 123[°C]128[°C] Unsymmetrical Power Density Distribution 105[°C]109 [°C] Thermal analysis Nominal conditions: 4e11p/s 7TeV – after 10 s (Tmax)

22 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 22 Thermo-mechanical Analysis Maximum displacement history– Nominal conditions: 10s spike R4550 graphite with symmetric power distribution

23 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 23 Thermo-mechanical Analysis Maximum displacement history– Nominal conditions: 10s spike R4550 graphite with non-symmetric power distribution

24 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 24 Thermo-mechanical Analysis Maximum displacement history– Nominal conditions: 10s spike AC150K 2D-C/C+CuNi pipes with non-symmetric power distribution

25 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 25 Thermo-mechanical Analysis Accident conditions - Data inputs: Initial temperature:27 ºC Water inlet temperature:27 ºC Water flow rate (per pipe):5 l/min (2.95m/s) FLUKA Energy depositions: Nominal Conditions 6.2kW at 0.8e11p/s V.V. 13.01.04 (symmetric)TCS.B2 from TCP3 Nominal Conditions (worst case equiv.) 4.5kW at 0.8e11p/s. V.V. Sept. 04 (non-symmetric)TCSG.A6.L1 Spring preload (avg. pressure):3 bar Materials: AC150K 2-D C/C (properties as experimentally measured) R4550 Isotropic Graphite (properties as experimentally measured)

26 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 26 Thermo-mechanical Analysis Abnormal condition - Data inputs: Initial temperature:27 ºC FLUKA Energy depositions: Injection error M. Magistris June 2004 Asynchronous beam dump V. Vlachoudis June 2003 (new simulations in progress..) Materials: AC150K 2-D C/C (properties as experimentally measured) R4550 Isotropic Graphite (properties as experimentally measured)

27 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 27 Thermo-mechanical Analysis FEM Model for 2-D analysis (abnormal conditions) Coupled thermal-structural analysis (PLANE13 main elements) Plane strain assumption - Most highly loaded cross-section Deposited power (W/m 3 )

28 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 28 Thermo-mechanical Analysis Transient thermal analysis – Asynchronous beam dump (to be updated …) AC150 T max = 756º R4550 T max = 698º

29 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 29 Thermo-mechanical Analysis Transient stress analysis – Asynchronous beam dump (to be updated …) AC150  ymax = 58.1 MPa

30 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 30 Thermo-mechanical Analysis Transient stress analysis – Asynchronous beam dump (to be updated …) R4550  ymax = 20.7 MPa

31 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 31 Thermo-mechanical Analysis Transient thermal analysis – Injection error (updated) AC150 T max = 389 ºC

32 CERN-SLAC meeting June, 15-17 A. Bertarelli CERN 32 Thermo-mechanical Analysis Transient stress analysis – Injection error AC150  ymax = 24.8 MPa

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