1. Transport and Handling (T&H) considerations for HL-LHC
I. Ruehl – CERN / EN-HE
Standards and Best Practices Workshop
CERN 13th June 2014

2. HL-LHC Standards and Best Practices Workshop
Outline
General issues
Surface T&H
Surface → LHC underground transfer
LHC underground T&H
Your input
Conclusion
HL-LHC Standards and Best Practices Workshop

3. HL-LHC Standards and Best Practices Workshop
General Issues
Need to consider all phases
Delivery of components
Assembly
Test
Storage
Transfer to shaft
Lowering (crane or lift ?)
Loading underground
Transport along tunnel (co activities)
Unloading / Transfer onto supports
Removal for repair
Integration
Space for transport, unloading and transfer / installation
Allow for guidance error margin
Allow co-activity (passage next to transport zone)
Space for loading lowered items
Consider logistics (parking and passing places)
Integrate T&H requirements into equipment and infrastructure design as early as possible – saves time and money; avoids conflicts & increases SAFETY!!!
Saves time, money and conflict potential and increases SAFETY
HL-LHC Standards and Best Practices Workshop

4. General Issues – Space → INTEGRATION!
HL-LHC Standards and Best Practices Workshop

5. Road transports
≤ 44 tons
Dimensions: 25 m length x 4m wide (incl. truck and trailer)
(second category – permanent authorization for CERN during LHC construction)
>44t ≤ 55 tons
Dimensions upon limitation of roads and local infrastructure
(third category – special request/authorization)
> 55 tons
Dimensions as for ≤ 55 tons
need specialized company
CERN road transport equipment
Charges divisibles : PTRA 44 TONNES MAXIMUM
Camion
Remorque
Poids total roulant
PTRA
CHARGE
(à vide)
UTILE (kg)
409
536
12950
40000
27050
417
537
20800
44000
23200
410
538
20250
23750
412
535
33300
10700
541
30500
13500
542
29750
14250
415
28300
15700
25500
18500
24750
19250
Charges indivisibles
UTILE (kG)
96000
55000
95000
(61700)
41000
75000
46700
HL-LHC Standards and Best Practices Workshop

6. Road / Surface T&H equipment
Mobile crane 220t
Cranes:
2 mobile cranes for loads up to 220t (30t at 100m deep)
1 pick and carry crane  16t
Telescopic forklift  12t
Straddle carrier 37t
345 EOT cranes up to 280t
Forklifts:
25 diesel forklift up to 6t
1 diesel diesel  12t
13 electrical forklifts up to 4t
Trailers, MEWP etc.
Mobile crane 55t
Pick & carry 16t
Straddle carrier 37t
Forklift - Diesel
Forklift - Electrical
MEWP
HL-LHC Standards and Best Practices Workshop

7. Surface – LHC underground transfer: Cranes
PM45
PX54
PM65
PX45
PX65
PM25
PX85
PX25
PM85
PMI2
PX15
PMI5
HL-LHC Standards and Best Practices Workshop

8. HL-LHC Standards and Best Practices Workshop
Surface – LHC underground transfer: Cranes
Figure shows list of cranes by point with capacity and ‘horizontal’ load dimension.
Maximum dimensions can be increased on case by case study.
Standard shaft zone
SHAFTS
SWL
Length
Width PM
PM15
20t
5.5m
1.5m
PM25
10t
4.5m
PM45
PM65
PM85
PMI2
40t
20m PX
PX25
65t
9.5m 1m
PX45
80t
PX65
PX85 8m
PX15
16t 7m
PX54
HL-LHC Standards and Best Practices Workshop

9. HL-LHC Standards and Best Practices Workshop
Surface – LHC underground transfer: Cranes
Example of technical spec:
PR T SX6-PX65-UX65
HL-LHC Standards and Best Practices Workshop

10. Surface – LHC underground transfer: PM shafts
HL-LHC Standards and Best Practices Workshop

11. Surface – LHC underground transfer: Lifts
Point
Pitch
Cabin
Doors
Range
Max. load
Nb of persons
Speed
Manufacturer
Depth
Width
Height
Access
transported
Unit mm - m Kg
m/s 1
PM15
2700
1850
2 (1)
82.481
3000 33
1.6
Schindler
PM18
1550
1450
2000
1200 2
81.7
1000 12
0.6
Alimak
PX15
2650
1750
3 (1)
91.81
AS Ascenseurs
PM25
45.35
PX24 (L1)
1400
1100
2500
800
51.34
630 8
PX24 (L2)
5 (1) 24 13 3
PZ33
2100
2200
900
99.25
PM32
1300
1275
67.4
1125 15
0.55 4
PM45
138.31
PZ 45
143.64
2.5 5
PM54
4 (1)
97.05
PM56
1950
1050
2 (2)
90.015 6
PM65
94.845
PZ65
100.57 7
PM76
96.432
PM85
99.596
PZ85
104.24
European norms EN81 (Oct 77 Bruxelles)
& normsSIA 370/10 (79 - Zurich edition)
(1) Acess from same side
(2) Acess from oppposite side
HL-LHC Standards and Best Practices Workshop

12. HL-LHC Standards and Best Practices Workshop
LHC underground T&H
Volume reserved for transport
HL-LHC Standards and Best Practices Workshop

13. HL-LHC Standards and Best Practices Workshop
LHC underground T&H: Standard solutions
Pefra
Trans-Lift 2.5t
Fenwick-Linde 6t
Mafi 20t
Volk 30t
Mobilev 2t
HL-LHC Standards and Best Practices Workshop

14. LHC underground T&H: Specific solutions
LHC cryo-magnet T&H equipment
Advantages
Allows installation with very limited clearance (250 to 300 mm) underneath the cryo-module
Transfer tables allow small longitudinal corrections during resp. after lateral movement
Disadvantages
Very sophisticated, complex and consequently maintenance intensive
Tunnel almost entirely blocked during transport operation
LHC ‘warm’ magnet T&H equipment
Advantages
All-in-one solution for longitudinal transport and lateral transfer
No longitudinal offset when wheels turn 180°
Operates on slopes up to 7%
Operator friendly
Disadvantages
Require considerable clearance (>500 mm) underneath the machine components
Requires exact positioning since jacks can only compensate for a very slight misalignment
Tunnel almost entirely blocked during transport operation
HL-LHC Standards and Best Practices Workshop

15. LHC underground T&H: Cryo-magnets Courtesy K. Artoss
3 trailer types : CTU, MCTU, STU
MCTU (LSS and dipoles)
Removable support points (3)
Lateral distance: 432, 530, 630 mm
LHCHMUMV0042 and 43

16. LHC underground T&H: Specific solutions Courtesy JL. Grenard
Trailer-Crane unit for remote handling of Collimators 1t
Collimators designed with automatic service connections
Integrated mechanical guiding system
Boom collision detection
Power connected to the monorail
Motorized lifting spreader
Shielding at each extremity
Side collision detection
Recovery manual hydraulic control

17. Your input T&H study specification sheet
Equipment description / characteristics / drawings / specifications indicating:
Length / Width / Height
Weight
Support / Fix point(s)
Lifting point(s)
Center of gravity
Maximum acceleration limits
Vibration limits
Temperature limits
Natural frequencies
Quantities to be transported & installed
Additional equipment weight & dimension if required for transport e.g. spreader beam
Interconnection details
Cross section drawing of equipment in tunnel …
HL-LHC Standards and Best Practices Workshop

18. HL-LHC Standards and Best Practices Workshop
Conclusion
Available T&H means at CERN covers some (most?) of HL-LHC requirements BUT
new cryo-magnet layout/dimensions may require a complete new set of equipment for T&H operations
inner triplet (a.o.) replacements needs in-depth studies
We need your input to define our WPs
integrate T&H requirements into equipment and infrastructure design as early as possible
Smart design solutions / layouts to be applied whenever possible and in particular when remote handling becomes necessary (radiation level; ALARA principle)
→ see presentation by K. Kershaw
Please provide a certified spreader / lifting beam with your supply
HL-LHC Standards and Best Practices Workshop

19. HL-LHC Standards and Best Practices Workshop
Contacts
For more details, questions etc. please contact either or
HL-LHC Standards and Best Practices Workshop

20. HL-LHC Standards and Best Practices Workshop
¿QUESTIONS?
HL-LHC Standards and Best Practices Workshop