LIU-SPS, 29 April 2015 Paul Cruikshank1 Variants today: Starting point: Assume same boundary conditions as 15/4/2015 presentation Analysis is for SPS arc and ds only. Assume 8 months aC duration (as before) Coat only MBB dipoles Consider 6 sextants partial aC in 8 months Consider 1 sextant partial aC in 8 months With/without QD, QF, SSS aC coating. With/without impedance reduction. LIU-SPS, 29 April 2015 Paul Cruikshank2 aC & impedance partial treatment (sextant or machine) Remove all SSS, all QD, zero MB (3 of 12 components/period) LIU-SPS, 29 April 2015 Paul Cruikshank3 MBB MBA QFSSSMBASSSQDMBB MBA SSSQF In-situ MBBMBA QFSSSMBASSSQDMBB MBA SSSQF MBB MBA QFSSSMBASSSQDMBB MBA SSSQF aC + Impd (aC) + Impd (aC) + Impd (aC) + Impd MBB In-situ Ex-situ Impd aC aC coat MBB, QD, (SSS & QF optional). Impedance improvement on SSS + QD ex-situ and QF in-situ (aC) + Impd Cost for aC options (update with partial & sextant): Preliminary totals to be checked by experts LIU-SPS, 29 April 2015 Paul Cruikshank4 Impedance reduction during partial aC LIU-SPS, 29 April 2015 Paul Cruikshank5 Impedance solution for 6 sextants: SSS/QD = 1116 kCHF, SSS/QF = 844 kCHF (~ 120 kCHF less if isolation not required) Impedance reduction for sextant: SSS/QD = 186 kCHF, SSS/QF = 141 kCHF aC cost estimate details and variants LIU-SPS, 29 April 2015 Paul Cruikshank6 aC coating, MBB in-situ, SPS 4 day aC cycle Insert cathode, pump, coat 1, coat 2, cathode cooling, demount Goal 3 MBB/day or 12 MB/4 days MB string (2 x MBB) together, so 6 strings/4 days Working space to insert cathode train is SSS + QD = 5.4 m Coating MB strings = 6 coating stations 2 pumping group with gas inj, RGA, pc2 x 70 kCHF 1 cathode trains (13.2m) with 150 mm linear drive1 x 50 kCHF Total 6 stations1140 kCHF aC coating manpower (8 months) 4 FSU (coating - 2 x 2 teams)312 kCHF 1 staff eng + 1 staff tech 1 FSU (sample measurements)78 kCHF Considerations No MB transport or alignment required. Requires removal of SSS and QD only Implies plasma cleaning LIU-SPS, 29 April 2015 Paul Cruikshank7 MBB MBA QFMBAMBB MBA aC coating, MBB in-situ, sextant 4 day aC cycle Insert cathode, pump, coat 1, coat 2, cathode cooling, demount Goal 0.5 MBB/day or 2 MB/4 days MB string (2 x MBB) together, so 1 strings/4 days Working space to insert cathode train is SSS + QD = 5.4 m Coating MB strings = 1 coating stations 2 pumping group with gas inj, RGA, pc2 x 70 kCHF 1 cathode trains (13.2m) with 150 mm linear drive1 x 50 kCHF Total 1 stations190 kCHF aC coating manpower (8 months) 2 FSU (coating - 1 x 2 teams)156 kCHF 1 staff eng + 1 staff tech 1 FSU (sample measurements)78 kCHF Considerations No MB transport or alignment required. Requires removal of SSS and QD only Implies plasma cleaning LIU-SPS, 29 April 2015 Paul Cruikshank8 MBB MBA QFMBAMBB MBA Plasma cleaning MB in-situ, SPS Under vacuum cleaning O 2 injection and plasma discharge Consider 1 day plasma cleaning cycle for 2 MBB string Goal 3 MBB/day or 15 MBB/week, so 7.5 cleaning cycles/week Plasma cleaning MB strings = need 2 stations 2 pumping groups with gas inj, RGA, pc2 x 70 kCHF 1 anode train (13.2m)1 x 30 kCHF Total 2 stations340 kCHF Plasma cleaning manpower (8 months) 4 FSU (cleaning & tunnel logistics - 2 x 2 teams)312 kCHF Considerations: Requires removal of SSS and QD Requires tunnel logistics LIU-SPS, 29 April 2015 Paul Cruikshank9 Plasma cleaning MB in-situ, sextant Under vacuum cleaning O 2 injection and plasma discharge Consider 1 day plasma cleaning cycle for 2 MBB string Goal 0.5 MBB/day so 1 cleaning cycle every 4 days Plasma cleaning MB strings = need 1 stations 2 pumping groups with gas inj, RGA, pc2 x 70 kCHF 1 anode train (13.2m)1 x 30 kCHF Total 1 stations170 kCHF Plasma cleaning manpower (8 months) 2 FSU (cleaning & tunnel logistics 1 team shared with coating)0 kCHF Considerations: Requires removal of SSS and QD Requires tunnel logistics LIU-SPS, 29 April 2015 Paul Cruikshank10 LIU-SPS, 29 April 2015 Paul Cruikshank11 Thanks for your attention ! (presentation 15/4/2015 slides follow as back-up) LIU-SPS, 29 April 2015 Paul Cruikshank12 In the beginning. First slide that Brennan gave me everything decided ! LIU-SPS, 29 April 2015 Paul Cruikshank13 Recall: Starting point: Extensive work already made by SPS-U and SPS-LIU teams J.Bauche, B.Goddard, V.Mertens, M.Taborelli, P. Costa-Pinto, P. Chiggiato Recent discussions with above, plus C.Bertone, P.Bestmann, J.Ferreira, J.Perez- Espinos, Experience of 16 MB and 5 Quad aC coated chambers in SPS handling, performance, ageing, etc. General assumptions for activity: LS2 activity and 5 working days/week. 8 months aC duration ( 1m ramp-up + 6m cruise + 1m ramp down) Chamber is coated in the magnet Machine components returns to initial slot Consider arc and DS machine components only (for now): aC coat all 744 dipoles = 6 dipoles/working day aC coat all 192 quads = 1.5 quads/day (new scope) aC coat all 192 SSS = 1.5 SSS/day (new scope) LIU-SPS, 29 April 2015 Paul Cruikshank14 Scope today aC coating Dipole (74% SPS ) Baseline update Variants aC coating Quads & SSS (15 % SPS ) additional aC scope - without/with impedance reduction Doesnt (yet) address aC for LSS components Doesnt (yet) address other consolidation needs Doesnt (yet) address impact on other LS2 activities LIU-SPS, 29 April 2015 Paul Cruikshank15 Cells% SPSChamber type X-section (mm) FormUnits /cell Chamber (mm) Chamber /cell % cell% SPS Arc+DS 88.9 MBA152 x 36.5Rect MBB129 x 48.5Rect QF mag152 x 38.3Elipse QD magDia 83Round QF SSS152 x 36.5Ellipse QD SSSDia 83Round Radiation considerations Extensive SPS radiation campaign Feb 2013 for LS1: MB range cm Quad & SSS range cm Need to make detailed assessment for each MB, Quad, SSS to coat Dose cost for each item to aC coat list to compile Public road limitations < 5 uSv/hr otherwise transport containment required Avoid road transport LIU-SPS, 29 April 2015 Paul Cruikshank16 aC activity 1 hr, 1 MB aC activity 1 hr, 744 MB aC activity 1 hr, 192 Quad 1 40 cm1 uSv744 uSv cm10 uSv1920 uSv Sextant 5 (best) Sextant 1 (worst) Costs the existing numbers Baseline: (J.Bauche 2009/2010) Consider 744 MB in ECX/EXA5 6 dipoles/day in 124 days 3957 kCHF APT: LIU e-cloud study Considers 744 MB and studies kCHF ( ) LIU-SPS, 29 April 2015 Paul Cruikshank17 aC factory options LIU-SPS, 29 April 2015 Paul Cruikshank18 BA2 lift BA3 lift BA6 lift BA4 crane BA5 crane Transit aC ex-situ factory ECX/ECA5 TCC6 Other ? aC in-situ factory aC ex-situ factory BHA5 Other ? aC ex-situ factory B867 via BA3 & road P1.8 via BA6 & road B?? via road Other ? 192 SSS 192 Quad 744 MB Tunnel transport Surface transport Underground activity Surface activity aC typical sequence: Disconnect (vac + mech) Transport Clean + aC coat Transport Survey (x,y,z,tilt) Reconnect (vac + mech Survey (smoothing) Baseline Adjacent quads cant be simultaneously removed Underground to surface: MB, Quad, SSS to surface: BA1 nothing. BA2 lift, requires mobile crane + crane driver for loading65k BA3 lift, usual exit point, coactivity with cavity works BA4 crane, requires opening ECX4 wall & extr.septum removal???k BA5 crane, coactivity new dump, requires opening of ECX5 wall100k BA6 lift, coactivity with P1 (LHC & ATLAS) ground logistics Handling team at (each) surface location130k Lorry driver(s) if aC factory is elsewhere65k Handling team at (each) aC factory130k BA3 exit gives access to Prevessin infrastructure BA6 exit gives access to P1.8 infrastructure BA2 exit would block 1 of the 2 CERN mobile cranes (plus road trans) Several exit points create flexibility (C.Bertone) Night shift will add 50% to manpower costs For cost estimate, consider 1 exit point MB, 1 exit point Quad & SSS Many constraints ! LIU-SPS, 29 April 2015 Paul Cruikshank19 Ex-situ v in-situ aC coating LIU-SPS, 29 April 2015 Paul Cruikshank20 Ex-situ benefits: Working environment Radiation constraints Access Combined consolidations In-situ benefits: Transport & logistics needs Building space needs Disconnection needs Realignment needs To avoid too many combinations in cost estimate consider: All Dipoles ex-situ or in-situ aC All Quadrupoles + SSS ex-situ aC only All Quadrupoles + SSS ex-situ aC only, with impedance reduction Cost estimates and considerations: TE/VSC aC coating, MB ex-situ aC coating, MB in-situ Wet cleaning, MB ex-situ Plasma cleaning, MB ex-situ Plasma cleaning, MB in-situ Impedance reduction variants for Quad & SSS EN/SU P.Bestmann MB ex-situ, MB re-alignment MB in-situ, Quad & SSS re-alignment EN/HE C.Bertone Underground to surface MB transport & logistics Quad & SSS transport & logistics TE/MSC & DG/SCR From 2010 cost estimates LIU-SPS, 29 April 2015 Paul Cruikshank21 Cost for aC options: Preliminary totals to be checked by experts Excludes on-going TE/VSC works to validate: Long hollow cathode solutions eg 13 m Plasma cleaning as pre-treatment to aC coating Plasma cleaning with p.port shields not removed LIU-SPS, 29 April 2015 Paul Cruikshank22 aC cost estimate details and variants LIU-SPS, 29 April 2015 Paul Cruikshank23 aC coating MB ex-situ (baseline) 3 day aC cycle, 6 MB/day = 18 MB in work pumping, coating, cathode cooling Coating in MB pairs = 9 coating stations (+1 reserve) 1 pumping group with gas inj, RGA, pc70 kCHF 2 cathode trains (6.6m) with 150 mm linear drive2 x 30 kCHF Total 10 stations1300 kCHF aC coating manpower (8 months) 4 FSU (coating - 2 x 2 teams)312 kCHF 1 FSU (sample measurements)78 kCHF Surface of 360 m2 (15 x 24 m) 10 Coating stations = 2 x MB length + footpath 2 transit stations Min spacing between MB = 1 metre LIU-SPS, 29 April 2015 Paul Cruikshank24 aC coating, MB in-situ 5 day aC cycle Insert cathode, pump, coat 1, coat 2, cathode cooling, demount Goal 6 MB/day or 30 MB/5 days MB string (4 x MB) together, so 7.5 strings/5 days Adjacent quads cannot be removed so working space is 2m Coating MB strings = 8 coating stations 2 pumping group with gas inj, RGA, pc2 x 70 kCHF 2 cathode trains (13.2m) with 150 mm linear drive2 x 50 kCHF Total 8 stations1920 kCHF aC coating manpower (8 months) 4 FSU (coating - 2 x 2 teams)312 kCHF 1 staff eng + 1 staff tech 1 FSU (sample measurements)78 kCHF Considerations No MB transport or alignment required. Requires removal of SSS and Quads Remove all SSS Remove alternate quads coat MB reinstall quad realign quad remove adjacent quad. Implies plasma cleaning LIU-SPS, 29 April 2015 Paul Cruikshank25 Wet cleaning MB ex-situ (baseline) 0.5 d wet cleaning cycle, 6 MB/day = 3 MB in work create a table (acetone, detergent, rinse, dry) 3 cleaning stations (+ reserve) ~3 m3 demin rinsing water/MB Recirculating pumps, tanks, heaters, blowers100 kCHF Rinsing water tanks (30)10 kCHF Hand/foot contamination detector20 kCHF Dose rate monitors + balisette??40 kCHF Total 4 stations170 kCHF Cleaning manpower (8 months) 2 FSU (60 CHF/hr)156 kCHF Surface of 120 m2 (6 x 20m) 4 Cleaning stations = MB length + protection zone 4 transit stations Min spacing between MB = 1 metre Independent wet zone Considerations Remove/clean/reinstall RF shielding with wet cleaning156 kCHF Local system to cleaning, rinse, dry30 kCHF LIU-SPS, 29 April 2015 Paul Cruikshank26 Plasma cleaning MB ex-situ Under vacuum cleaning O 2 injection and cold plasma discharge to remove hyrocarbons + System built to remove aC coating - As aC pre-treatment, to validate. + No pumping shield removal- With p.port shielding to validate + No waste water- No dust removal + No contamination transfer 0.5 d plasma cleaning cycle, 6 MB/day = 3 MB in work Sequence insert anode train, pump, plasma clean, extract train. Plasma cleaning in MB pairs = 2 stations ( 1 reserve) 1 pumping group with gas inj, RGA, pc70 kCHF 2 anode trains (6.6m) 2 x 15 kCHF Total 2 stations200 kCHF Plasma cleaning manpower (8 months) 2 FSU (60 CHF/hr)156 kCHF Surface of 60 m2 (15 x 4m) Plasma cleaning station = 2 x MB length + footpath Min spacing between MB = 1 metre LIU-SPS, 29 April 2015 Paul Cruikshank27 Plasma cleaning MB in-situ Under vacuum cleaning O 2 injection and plasma discharge Consider 1 day plasma cleaning cycle for 4 MB string Goal 6 MB/day or 30 MB/week, so 7.5 cleaning cycles/week Plasma cleaning MB strings = need 2 stations 2 pumping groups with gas inj, RGA, pc2 x 70 kCHF 2 anode trains (13.2m)2 x 30 kCHF Total 2 stations400 kCHF Plasma cleaning manpower (8 months) 4 FSU (cleaning & tunnel logistics - 2 x 2 teams)312 kCHF Considerations: Requires removal of SSS and Quads (special sequence) Requires tunnel logistics Requires set-up (2 x SPS dipole) to validate in 2015 LIU-SPS, 29 April 2015 Paul Cruikshank28 MB underground transport + aC logistics (baseline) Underground transport to ECX5 4 hrs x 3 FSU per MB = ~ 800 CHF* x kCHF Remove-transport to ECX5-return transport-reinstall If over night activity add 50% coefficient292 kCHF Underground logistics in ECX5 & ECA5 for 8 months 2 FSU for cleaning & aC coating factory130 kCHF 50 m2 for transit handling (6 magnets) Additional handling infrastructure: 1 Dumont250 kCHF 1 Volk tractor80 kCHF 1 trailer30 kCHF Other handling tooling20 kCHF Total 380 kCHF Other underground aC options? TCC6 tunnel (demount 100m of TI2, TT60 for 170 m2 area) LIU-SPS, 29 April 2015 Paul Cruikshank29 Quad & SSS transport to surface Underground transport to lift (BA2, BA3, BA6) Sequence: Remove-transport to surfacereturn from surfacereinstall Manpower 585 kCHF for 744 dipoles, so.. For 372 Quad & SSS (really 384)292 kCHF 50% coefficient for night shift146 kCHF Surface logistics: Handling team per location130 kCHF Additional tunnel infra for SSS: 1 Pratt side-loader renovation70 kCHF 1 small trailer20 kCHF Additional tunnel infra for quad if MB are removed 1 Dumont (quad config)250 kCHF 1 Volk tractor80 kCHF 1 trailer30 kCHF If MB coated in-situ, no additional infrastructure0 kCHF LIU-SPS, 29 April 2015 Paul Cruikshank30 MB aC ex-situ MB alignment Inputs & constraints: Consider MB must return to initial position Is this essential? field quality, geometry, pumping port, other. Tilt alignment before vacuum connections (on-line) Alignment in transport passage (need HE & SU decoupling!) SU request 0.5 d for 4 MB string (8 MB/day capacity) Manpower needs: 2 FSU for 8 months MB & smoothing 156 kCHF Equipment needs: Laser tracker, small tooling30 kCHF LIU-SPS, 29 April 2015 Paul Cruikshank31 MB aC in-situ Quad alignment Inputs & constraints: Returning quad aligned wrt to quad neighbours Tilt alignment before vacuum connections No SSS reinstallation until QF & QD realigned Alignment in trans passage (need HE & SU decoupling) 6 MB/day = 1.5 Quads/day & 1.5 SSS/day SU request 0.5 d for 2 quads & 0.5 d for 2 SSS Manpower needs: 2 FSU for 8 months Quad, SSS & smoothing 156 kCHF Equipment needs: Laser tracker, small tooling30 kCHF LIU-SPS, 29 April 2015 Paul Cruikshank32 Impedance reduction during aC LIU-SPS, 29 April 2015 Paul Cruikshank33 Inputs from J.Perez-Espinos: 192 Quads, 192 SSS of arc & DS, Where applicable includes cutting/demounting/remounting/welding, All transport costs in aC estimate, Additional building surface needs for max and intermediate solutions to do, Max = 2896 kCHF, min = 0 kCHF Summary Updated costs: aC variants - to be checked by experts Impedance variants ( kCHF) to be checked by experts Next steps Radiation cost per magnet TE/VSC Developments (long hollow cathode, plasma for aC, etc) Add LSS components to aC cost estimate Check compatibility of aC variants with other LS activities Find opportunity to make aC pilot run on significant zone of SPS (with fixed budget), to validate procedures & process, measure performance, gather knowledge for SPS deployment and other CERN needs. LIU-SPS, 29 April 2015 Paul Cruikshank34 Thanks for your attention !