The Assembly of the LHC Short Straight Sections at CERN: Work Organization, Quality Assurance and Lessons Learned

After 4 years of activity, the assembly of approximately 500 Short Straight Sections (SSS) for the LHC has come to an end at the beginning of 2007. This activity, which was initially foreseen in European industry, was in-sourced at CERN because of the insolvency of the prime contractor. While the quadrupole cold masses were produced in industry, the assembly within their cryostats was transferred to CERN and executed by an external company under a result-oriented contract. CERN procured cryostat components, set up a dedicated 2000 m2 assembly hall with all the specific assembly equipment and tooling and defined the assembly and testing procedures. The contractor took up responsibility for the delivery, on time, of assemblies according to the required quality. A dedicated CERN production and quality assurance team was constituted. A specific quality assurance plan was set up involving 2 additional contractors responsible for weld inspections on a total of about 20'000 assembly welds and the execution of about 3300 leak detection tests. This paper presents the organizational aspects of the activity and the experience gained throughout the production. The learning curves and statistics by type of non-conformities detected and general quality assurance aspects are presented and discussed. The main lessons learnt are summarized, in an attempt to draw some conclusions which could be useful in making strategic choices for the cryostat assembly in future large-scale accelerators

Thermal Performance of the LHC Short Straight Section Cryostat

The LHC Short Straight Section (SSS) cryostat houses and thermally protects in vacuum the cold mass which contains a twin-aperture superconducting quadrupole magnet and superconducting corrector magnets operating at 1.9 K in superfluid helium. In addition to mechanical requirements, the cryostat is designed to minimize the heat in-leak from the ambient temperature to the cold mass. Mechanical components linking the cold mass to the vacuum vessel such as support posts and an insulation vacuum barrier are designed to have minimum heat conductivity with efficient thermalisations for heat interception. Heat in-leak by radiation is reduced by employing multilayer insulation wrapped around the cold mass and an actively cooled aluminium thermal shield. The recent commissioning and operation of two SSS prototypes in the LHC Test String 2 have given a first experimental validation of the thermal performance of the SSS cryostat in nominal operating conditions. Temperature sensors mounted in critical locations provide a temperature mapping which allows a crosscheck with the calculated temperature values and thermal performance. Moreover the measurements allowed a validation of the efficiency of the employed thermalisations. This paper presents the experimental results for the thermal performance of cryostat components and gives a first comparison with the design values

Leak-Tight Welding Experience from the Industrial Assembly of the LHC Cryostats at CERN

The assembly of the approximately 1700 LHC main ring cryostats at CERN involved extensive welding of cryogenic lines and vacuum vessels. More than 6 km of welding requiring leak tightness to a rate better than 1.10-9 mbar.l.s-1 on stainless steel and aluminium piping and envelopes was made, essentially by manual welding but also making use of orbital welding machines. In order to fulfil the safety regulations related to pressure vessels and to comply with the leak-tightness requirements of the vacuum systems of the machine, welds were executed according to high qualification standards and following a severe quality assurance plan. Leak detection by He mass spectrometry was extensively used. Neon leak detection was used successfully to locate leaks in the presence of helium backgrounds. This paper presents the quality assurance strategy adopted for welds and leak detection. It presents the statistics of non-conformities on welds and leaks detected throughout the entire production and the advances in the use of alternative leak detection methods in an industrial environment

Models and experimental results from the wide aperture Nb-Ti magnets for the LHC upgrade

MQXC is a Nb-Ti quadrupole designed to meet the accelerator quality requirements needed for the phase-1 LHC upgrade, now superseded by the high luminosity upgrade foreseen in 2021. The 2-m-long model magnet was tested at room temperature and 1.9 K. The technology developed for this magnet is relevant for other magnets currently under development for the high-luminosity upgrade, namely D1 (at KEK) and the large aperture twin quadrupole Q4 (at CEA). In this paper we present MQXC test results, some of the specialized heat extraction features, spot heaters, temperature sensor mounting and voltage tap development for the special open cable insulation. We look at some problem solving with noisy signals, give an overview of electrical testing, look at how we calculate the coil resistance during at quench and show that the heaters are not working We describe the quench signals and its timing, the development of the quench heaters and give an explanation of an Excel quench calculation and its comparison including the good agreement with the MQXC test results. We propose an improvement to the magnet circuit design to reduce voltage to ground values by factor 2. The program is then used to predict quench Hot-Spot and Voltages values for the D1 dipole and the Q4 quadrupole.Comment: 8 pages, Contribution to WAMSDO 2013: Workshop on Accelerator Magnet, Superconductor, Design and Optimization; 15 - 16 Jan 2013, CERN, Geneva, Switzerlan

Mechanical Design Analysis of MQXFB, the 7.2-m-Long Low-β Quadrupole for the High-Luminosity LHC Upgrade

As part of the High-Luminosity Large Hadron Collider (LHC) Project, a set of Nb Snquadrupoles are being developed, aiming to enhance the performance of the inner triplets. The new magnets, identified as MQXFA and MQXFB, will share the same cross section with two different lengths, 4.2 and 7.2 m, respectively. During the magnet development, three short models were tested, along with a number of mechanical models, demonstrating the capability of the magnet cross section to achieve the specified performances. The same performances are now required for the full-length magnets. To ensure this, the authors studied the impact of the magnet length on the capability of the structure to provide an adequate support to the coils. Finite element and simplified analytical models were used to evaluate the impact of the magnet length on the stresses in the magnet ends and coil elongation during powering. The models were calibrated using the results from the short model tests, and used to provide an indication on the required prestress and its foreseen impact on the magnet performance.

Mechanical Performance of Short Models for MQXF, the Nb3Sn Low-β Quadrupole for the Hi-Lumi LHC

In the framework of the Hi-Lumi LHC Project, CERN and U.S. LARP are jointly developing MQXF, a 150-mm aperture high-field Nb3Sn quadrupole for the upgrade of the inner triplet of the low-beta interaction regions. The magnet is supported by a shell-based structure, providing the preload by means of bladder-key technology and differential thermal contraction of the various components. Two short models have been produced using the same cross section currently considered for the final magnet. The structures were preliminarily tested replacing the superconducting coils with blocks of aluminum. This procedure allows for model validation and calibration, and also to set performance goals for the real magnet. Strain gauges were used to monitor the behavior of the structure during assembly, cool down and also excitation in the case of the magnets. The various structures differ for the shell partitioning strategies adopted and for the presence of thick or thin laminations. This paper presents the results obtained and discusses the mechanical performance of all the short models produced up to now

Overview of the Quench Heater Performance for MQXF, the Nb3Sn Low-β Quadrupole for the High Luminosity LHC

In the framework of the high-luminosity upgrade of the Large Hadron Collider, the U.S. LARP collaboration and CERN are jointly developing a 150 mm aperture Nb Sn quadrupole for the LHC interaction regions. Due to the large stored energy density and the low copper stabilizer section, the quench protection of these magnets is particularly challenging, relying on a combination of quench heaters attached to the coil surface and coupling loss induced quench (CLIQ) units electrically connected to the coils. This paper summarizes the performance of the quench heater strips in different configurations relevant to machine operation. The analysis is focused on the inner layer quench heaters, where several heater strips failed during powering tests. Failure modes are discussed in order to address the technology issues and provide guidance for future tests.

Optimizing the use of pressurized bladders for the assembly of HL-LHC MQXFB magnets

The use of pressurized bladders for stress control of superconducting magnets was firstly proposed at Lawrence Berkeley National Laboratory (LBNL) in the early 2000s. Since then, the so-called bladders and keys procedure has become one of the reference techniques for the assembly of high-field accelerator magnets and demonstrators. Exploiting the advantages of this method is today of critical importance for Nb3Sn-based accelerator magnets, whose production requires the preservation of tight stress targets in the superconducting coils to limit the effects of the strain sensitivity and brittleness of the conductor. The present manuscript reports on the results of an experimental campaign focused on the optimization of the bladders and keys assembly process in the MQXFB quadrupoles. These 7.2 m long magnets shall be among the first Nb3Sn cryomagnets to be installed in a particle accelerator as a part of the High Luminosity upgrade of the LHC. One of the main practical implications of the bladders technique, especially important when applied to long magnets like MQXFB, is that to insert the loading keys, the opening of a certain clearance in the support structure is required. The procedure used so far for MQXF magnets involved an overstress in the coils during bladder inflation. The work presented here shows that such an overshoot can be eliminated thanks to additional bladders properly positioned in the structure. This optimized method was validated in a short model magnet and in a full-length mechanical model, becoming the new baseline for the series production at CERN. Furthermore, the results are supported by numerical predictions using Finite Element models