1. OLAV3 Engineering Integration and installation of experimental beam pipes: the case of LHC 7/8/20111P.Lepeule for VSC group

2. OLAV3 7/8/2011P.Lepeule for VSC group2

3. Outline ATLAS CMS & TOTEM ALICE LHCb Engineering & integration (1 & 2) – Transformation process Installation – Main issues – Installation Conditions – ATLAS,CMS,ALICE,LHCb pictures CERN approach Unexpected situations What we learnt 7/8/20113P.Lepeule for VSC group

4. ATLAS 7/8/20114P.Lepeule for VSC group

5. CMS 7/8/20115P.Lepeule for VSC group

6. ALICE 7/8/20116P.Lepeule for VSC group

7. LHCb 7/8/20117P.Lepeule for VSC group

8. Engineering & integration 1 Inputs – Final design results from more than 15 years discussion between experiment collaboration, experiment integration team, Vacuum group and machine experts. – Contradictory request between machine (Impedance, safety buckling factor) and experiment collaboration (mass to be minimized) has made decision sometimes tricky and longer than planned. – Formal design review, production review, installation review were important milestones to freeze parameters in order to be ready on time. 7/8/20118P.Lepeule for VSC group

9. Engineering & integration 2 Design, manufacture & quality – Individual specifications for raw material was an important issue for final quality of UHV experimental pipes (magnetic permeability, porosity, weldability…) – Process of transformation was much longer than for LEP: Beryllium and fully machined optimized conical pipes + VSC lab qualification + CU coating + NEG deposition, increased drastically the delivery time for each segment. – Dedicated tooling was developed for each segment and each phase of manufacture or conditioning i.e Cu coating, NEG Deposition and RF bridges integration for sharp transition (CMS hf ct2 case) – It was identified at an early stage that extensive Lab tests would be needed to prevent any non- conformities during very tight installation windows. 7/8/20119P.Lepeule for VSC group

10. Transformation process metrolgie 7/8/2011P.Lepeule for VSC group10 machining E.B welding Global metrology Cu coating

11. Transformation process 7/8/2011P.Lepeule for VSC group11 RF bridge integration Sub-assembly + leak test Bake-out + Cu coating testPreparation for NEG coating

12. Installation Main issues – 35 segments to install and 27 different environment which impose 27 different accurate studies, tests and types of tooling – Limited access time & distance between cavern sites – No access after installation – Mandatory in-situ leak test after each segment connection – Keep integrity of pipes after installation Detector closing Access of collaboration teams nearby fragile beam pipes – Full in-situ bake-out at end of first installation – Keep good control of alignment during detector closing – Follow up day by day cavern experiment activities to define any risk for integrity of beam pipes till complete detector closure – Mandatory flexibility of staff 7/8/201112P.Lepeule for VSC group

13. Installation Installation conditions – A total of 35 beam pipe segments were installed (without taking into account injection lines) in the 4 different experimental caverns with many changes during installation planning. – Installation was strongly coupled with sub-detector delivery time, test and installation – Uncertainty or changes in LHC machine date completion led the experiments to sometimes believe they had more time than originally planned. – Beam pipes installation was often on critical path of 2008 LHC start up due requirement for full bake-out for NEG activation after beam line closing. 7/8/201113P.Lepeule for VSC group

14. ATLAS pipes installation 7/8/2011P.Lepeule for VSC group14 Insertion of C.pipe with pixel in detector VJ installation Detector closing

15. CMS pipes installation 7/8/2011P.Lepeule for VSC group15 Forward pipe sub-assemblyCentral pipe insertion Lowering of HF/CT2 assembly End Cap pipe lowering

16. Cms pipes installation sequence 7/8/2011P.Lepeule for VSC group16

17. ALICE pipes installation 7/8/2011P.Lepeule for VSC group17 RB 26/3 insertion RB 26 4-5 insertion Heating shells on C.pipe RB 26 4-5 insertion

18. LHCb pipes installation 7/8/2011P.Lepeule for VSC group18 Ux 85-1 completion S.Steel Ux 85.4 lowering Ux 85-1 & 2 installed with protection Ux 85-1 & 2

19. CERN approach Solutions to issues – Identification of critical assembly sequence or insertion to be tested in laboratory on dedicated test stands or mock-up with experiment integration teams. – Minimum half length of ATLAS and CMS was installed and baked in simulated mechanical environment with dedicated test bench structure. – Extensive tests during manufacture phase and then in Laboratory were done to avoid any repair or removal from a pit during detector assembly: x ray control & leak test of each weld Bake out followed by a global leak test Cu Coating adhesion (if required) NEG performance analysis Check leak tightness of optimized flanges with real seals (thermal cycling) 7/8/201119P.Lepeule for VSC group

20. CMS CP tested insertion 7/8/2011P.Lepeule for VSC group20

21. bake-out & mechanical test 7/8/2011P.Lepeule for VSC group21 ½ length bake-out with 42 m test benchCms /Alice bake-out shells insertion Atlas guiding ring and support testCms HF/CT2 insertion test

22. Unexpected situations on spot 7/8/2011P.Lepeule for VSC group22

23. Unexpected situations on spot 7/8/2011P.Lepeule for VSC group23

24. Unexpected situations 7/8/2011P.Lepeule for VSC group24

25. What we learnt – Take care about pipes integrity after installation takes a lot more time than planned and needs additional resources with induced additional stress…. – Capability for staff to work at high, overtime, in a safe way is an important issue to cope with sometimes difficult working conditions. – Decisions on the spot are often necessary in collaboration with the experiments, and flexibility and stamina of staff are a main quality. – Organization as a common project led to significant cost savings, flexibility with staffing, good feedback and quality from one installation to another. 7/8/201125P.Lepeule for VSC group

26. END 7/8/2011P.Lepeule for VSC group26 THANK YOU