The HL-LHC project: info day for industry

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1 The HL-LHC project: info day for industry Lucio Rossi Project Coordinator *** Marcello Losasso Industrial Relations *** Isabel Bejar Alonso HL-LHC Technical Coordinator *** Boi-Lan Nguyen Lemoine Procurement Procedures *** F. Savary Magnet Components and Assemblies The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement

2 Impact: accelerators in Science, Industry and Society system built Ion implantation E-beam material processing E-beam irradiation NDI Neutron Generator Radioisotope production Ion Beam Analysis Synchrotron Radiation 70 companies involved, accelerator in the world, (more than if medical are included) 1100 new systems deployed every year for about US$ 2.2B. (if medical therapy is included, the bottom line figure will increase by 1 $B more) 2

3 3 Goal of High Luminosity LHC (HL-LHC) as fixed in November 2010 From FP7 HiLumi LHC Design Study application The main objective of HiLumi LHC Design Study is to determine a hardware configuration and a set of beam parameters that will allow the LHC to reach the following targets: A peak luminosity of L peak = cm -2 s -1 with levelling, allowing: An integrated luminosity of 250 fb -1 per year, enabling the goal of L int = 3000 fb -1 twelve years after the upgrade. This luminosity is more than ten times the luminosity reach of the first 10 years of the LHC lifetime. Concept of ultimate performance recently defined: L ult cm -2 s -1 and Ultimate Integrated L int ult 4000 fb -1 LHC should not be the limit, would Physics require more

4 4 Run I Run II Run III Run IV, V cm -2 s ns bunch high pile up cm -2 s ns bunch pile up cm -2 s ns bunch pile up 60 Technical limits to lumi increase (Machine & Experiments) ns

5 5

6 Andere benadering voor Hi Lumi CERN wil voor geavanceerd werk graag met kleine bedrijven samenwerken Het prototype van de 11T-magneet is een pilot Ze doen de assemblage zelf onderdelen in kleine tenders tussen 50K en 200k CHF De Projectleiding onderschat coördinatie Inkoop niet, en is blij met ons voorstel Nederlandse bedrijven staan hoog aangeschreven Er is een niet nader genoemde achterstand De komende 10 jaar grote business kansen Bedrijven die meteen instappen hebben de grootste voordelen (en profiteren vanaf dag één) L. HL C&S Review - 9 March

7 AIM: to connect CERN with all these potential industrial partners, fostering collaboration, technical exchange, deployment of EU commercial potential. Providing a structured environment for debate, communication and exchange on information and ideas on important topics of the Hi-Lumi project. Developing a dialog between all stakeholders. Investigating bridging solutions between industrial, scientific and commercial concerns to be included in our future CfT Disseminating technical requirements on components and equipment's object of the project scope. M.Losasso cern fp/kt 7

8 Many points around the ring 8

9 HL- LHC Project needs ( ) Magnets 11-T Magnet RF Cavities Collimators Cryogenics Vacuum Cold Powering (HTS superconducting links, power converters) Machine Protection & Magnet QPS Collider-Experiment Interface Energy Deposition & Absorber Beam Diagnostics Radiation resistant solid state switches for kicker magnets Integration and (de-)installation Hardware commissioning Infrastructure, Logistic and Civil Engineering

10 HL-LHC Technologies Precision and cryogenic mechanics Advanced manufacturing techniques Surface and heat treatment Large equipment and tooling Tooling like oven for heat treatment, impregnation under pressure Power and rad-hard electronics New material development Advanced «robotics» (or telemanipulation) Mechatronics OC, 12/11/2014

11 11 Technical Infrastructure Metallic structures, cooling, ventilation, electrical distribution, handling, tooling, controls, logistics

12 Industry Make or buy 12

13 Our objective The High Luminosity project seeks industrial suppliers and collaborations to start the construction phase and make the High Luminosity upgrade. CERN aims at fostering R&D collaborations and knowledge exchange also with SMEs, a perfect opportunity to match their capacity with the requirements of HiLumi. Next 4 years there will be intensive prototyping and the production of some of the first series of components. Understanding our needs is the first step to tender successfully. Understanding your capabilities and the know how that could come from industry is the best way to specify equipment that can be built by industry 13

14 Procurement needs now->2018 Some examples

15 Procedures by purchase value Value Who How Transmission < CHF Quote requested by Users Automatic PO sent by fax < CHF 3 quotes requested by Users or procurement CHF and < CHF CHF and < CHF CHF and above Procurement sends Price Enquiries to 3 up to 5 suppliers Procurement sends Price Enquiries sent to 3 up to 5 suppliers by procurement. Market Surveys (MS) & Invitations to Tender (IT) issued by Procurement E-Tendering ILO informed E-Tendering ILO informed Signed PO sent by post Signed PO sent by post Signed PO sent by post Signed PO / contract sent by post HiLumi LHC goes to Industry, 26 June 2015, Procurement Procedures

16 The Magnets for HL-LHC OC, 12/11/2014

17 Technology for new magnets: precision machines, with automatized movements Rotating winding machine for coil up to 3 meters of length SC coil with specially machined insulators (5-axis machine) Accuracy of the winding: 20 µm! curing presses : tooling precise at 20 µm and 200 C. collaring presses. Precision mechanics under large forces with high pressure precision hydraulics, precision sensor, automatization 14

18 SC magnet factory 50,000 tons Repair, spare manufacturing LHC SC magnets Prototyping of new magnets for LHC upgrades (Nb 3 Sn) (Large) tooling and magnet components Logistics and mechanical workshop Operation, repair, spare manufacturing, new magnets for all projects requiring resistive magnets Tooling and magnet components Magnet workshops and test stations (including radioactive magnets) 18

19 Large Magnet Facility: Opportunities for companies - Manufacturing of components tools - Welded/mobile structures - - Machined precision components

20 LMF: Opportunities for companies - Machining of precision components - Manufacturing of handling tools (CE marking) - Design/modification of complex systems and machines HOIST HINGED SUPPORT TILTING SUPPORTS

21 High homogeneous magnetic fields can be achieved in superconducting magnets Superconducting magnet technology relies on the ability to produce superconducting materials in the form of high current cables In superconducting magnets the field is generated by a suitable distribution of current, properly arranged around the beam aperture OC, 12/11/2014

22 IP2 - DS collimators ions 11 T (LS2-2018) IP7 DS collimators in the betatron cleaning(ls3) T Nb 3 Sn

23 New technology Nb 3 Sn 11T Dipole Single aperture model Twin aperture model Nb3Sn cable Insulation for 700 C Automatized precision tooling with advanced sensoring OC, 12/11/2014

24 HiLumi LHC goes to Industry Magnets Main HiLumi-LHC Magnet Features Type Material Field/Gradient (T) / (T/m) Aperture (mm) Length (m) Units (-) Q1,Q3 Q2 D1 D2 Q4 DS 11T Single aperture Single aperture Twin aperture Two-in-one aperture Two-in-one aperture Nb 3 Sn 11.4 / x x (½ LARP, ½ CERN) Nb-Ti (KEK) Nb-Ti (INFN) Nb-Ti 6.0 / (CEA) Nb 3 Sn x (32) (CERN)

25 11T Dipole 3 phases TODAY Graph showing nominal upgrade parameters fb -1 would be reached in 2036 HiLumi LHC goes to Industry Magnets

26 HiLumi LHC goes to Industry Magnets T Dipole scope in numbers Models Prototypes Series baseline Phase 1 LS2, all RRP Phase 2 LS3 Phase 3 LS4 MBHSM101 (done) MBHSP101 (done) MBHSP102 (done) In addition: 3 x 1-in-1 2 x 2-in-1 P1: MBH_P001 First of a kind 1 x (2 MBH + 1 BPC 1 ) PIT (new X-section): 4 x 1-in-1 2 x 2-in-1 RRP (new X-section): 2 x 1-in-1 1 x 2-in-1 P2: MBH_P002 [PIT] P3: MBH_P003 [RRP] 2 in IP2 + 2 in IP7 or 4 in IP7 tbc 4 x (2 MBH + 1 BPC) None Same design as for LS3 To complete IP7 or in IP2 2 x (2 MBH + 1 BPC) Series spares x (2 MBH + 1 BPC) Option - - IP1-IP5 Max. 8 x (2 MBH + 1 BPC) 1. BPC stands for By-Pass Cryostat

27 The Nb 3 Sn is in the detail 14 strands, 1.25 mm PIT Winding Instrumentation Ready for assembly OC, 12/11/2014 Reacted Instrumented Impregnation

28 Technology for new magnets: precision machines, with movements, automatized, 3 Rotating winding machine for coil up to 3 meters of length OC, 12/11/2014

29 Coil Curing OC, 12/11/2014

30 Magnet Assembly 2 collaring presses. Precision mechanics under large forces with high pressure precisom hydraulics, precision sensor, automatization OC, 12/11/2014

31 Precision pieces (+700 to -270 C use) Titanium alloy pole pieces (700 C) Austenitic steel winding mandrel (700 C) Austenitic steel end spacers (700 C), 5 axis machining Collars compressing the coils (10 µ m profile) OC, 12/11/2014

32 3D printing Head spacer for new prototype made with the 3D printer are impregnated with the cyanate ester resin and reinforced with glass fiber to obtain the desired mechanicals properties due to the thin wall thickness Titanium 3D printed OC, 12/11/2014

33 Vacuum for HL-LHC OC, 12/11/2014

34 Interconnects Accommodate the different apertures (octagonal, circular, hypodrome) RF screening and low impedance A typical LHC interconnection LHC plug-in-module (PIM) V. Baglin HiLumi goes to Indutry CERN 34

35 Cold warm transitions Accommodate the different apertures (octagonal, hypodrome, circular) RF screening, low impedance, thermally anchored A typical LHC cold warm transition (CWT) V. Baglin HiLumi goes to Indutry CERN 35

36 Room Temperature Vacuum System ~ 6 km length Bake able vacuum system Relies on TiZrV getter film pumping after activation at ~ 200 deg Combined sector in both side of each experiment Both beams circulates in the same beam pipe Twin sector Beams circulate in different beam pipes V. Baglin HiLumi goes to Indutry CERN 36

37 Warm Modules Modular system ~ in the LHC ring Bellow shielding to optimise beam impedance RF bridge with several shapes (circular/elliptical) Ag coated CuBe fingers Rh coated insert Allow thermal expansion during bakeout (+/- 20 mm stroke) Can accommodate instrumentation ports V. Baglin HiLumi goes to Indutry CERN 37

38 Vacuum Chambers Cu, Stainless steel Cu plated Circular, elliptical, transitions Specific chambers e.g. Y chamber Supports V. Baglin HiLumi goes to Indutry CERN 38

39 Cristal collimators Rotational stage: closed loop controlled, piezo based Range: +/- 10 mrad Accuracy: +/- 0.5 urad Piezo shutter with the small mirrors to initialise the Interferometer sensor heads Insert 3D interferometer View of the sensor piezo rotational stage + mirror + shutter + sensor heads Piezo rotational stage based on flexure structure OC, 12/11/2014

40 Hollow Electron Lenses An electron beam guided by strong axial magnetic field overlaps with the circulating LHC beam. With axisymmetric electron distribution the beam core is unperturbed whereas the halo gets a smooth tuneable transverse kick. This device is a complement of the collimation system and will increase its efficiency. Design of the cryostat housing the 5T superconducting coils OC, 12/1/20

41 OC, 12/11/2014

42 HL-LHC Collimators and High Temperature Materials Alessandro Bertarelli, CERN (EN/MME) On behalf of the LHC Collimation Team (BE-ABP, EN-STI, EN-MME) HiLumi LHC Goes To Industry Workshop CERN, Geneva, Switzerland 26 June, 2015

43 Collimation System for HL-LHC IR1 + IR5: New tertiary collimators and physics debris absorbers Completely new layouts Novel materials IR7 : DS collimators + 11T dipoles IR2 (Ion physics debris): DS collimators + 11T dipoles Where are Collimators? Total of 118 collimators presently installed ~10 different design! 108 Movable units No less that 40 units to be replaced for HL-LHC A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June 2015 IR7: Low impedance collimators New design, novel advanced materials 43

44 A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June Horizontal Collimator Layout Overall length: 1480mm Tank width: 260mm Collimator assembly What are Collimators? Beam axis Adjustable (Horizontal) Stand (Al Alloy) Plug-in system (integrates mechanical, hydraulic and electrical quick connections) Fixed Support (Stainless Steel)

45 LHC Secondary Collimator (TCSG) The collimator and its jaws are expected to maintain their functionality after the impact of 288 SPS bunches at 450 GeV (1+ kg TNT) Jaw Assembly (1.2 m long) Up to 15 kw per jaw in regular operation Jaw Block (2D Carbon-Carbon) 1 m long 40 µm flatness in operation What is a Collimator? Jaw Cooling system Cu-Ni Pipes Actuation system 35 mm stroke 10 µ m repeatability High radiation compliant Vacuum Vessel Stainless steel EB welded A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June

46 A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June Jaw assembly Design How is a Collimator made? Vacuum Brazing (Cu-Ni to Glidcop)

47 A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June TCSPM Jaw Prototype How is a Collimator made? BPM Button pickup Molybdenum Graphite Tapering Copper Diamond Blocks

48 Actuation System Design Each jaw is actuated by two independent actuators and supported on two axles. Hybrid stepper motors are used to drive the system The system must operate for ~20 years in a harsh environment (15 MGy) with virtually no maintenance How is a Collimator made? Fixed table Hybrid Stepper motor Return spring To ensure auto-retraction Mobile table 35 mm stroke Roller screw assembly 2 mm lead/rev A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June

49 A. Bertarelli HiLumi LHC Goes To Industry CERN 26 June Actuation System Design How is a Collimator made? Roller screw assembly High efficiency High precision (6 µm/135 mm) Radiation hard lubrication Stainless steel shaft Linear Ball Bearing High precision Radiation hard lubrication

50 Superconducting RF Crab Cavities Marco Garlaschè CERN EN/MME On behalf of the Crab Cavities Team HiLumi LHC Goes To Industry Workshop CERN, Geneva, Switzerland 26 June, 2015

51 Crab Cavities: Why? Currently in LHC, at a given experiment Collision Point 2φ the AIM to increase the number of collisions between the two LHC beams by reducing the crossing angle φ HiLumi 2 Industries - Garlaschè 26/06/

52 Crab Cavities: Why? the ANSWER Superconducting Radio-Frequency Cavities, a.k.a. CRAB Cavities 26/06/2015 HiLumi 2 Industries - Garlaschè 52

53 Crab Cavities: What? a Module is Cryostat embedding o 2x CRAB cavities o auxiliary systems 80 K > T > 2 K 2 K 2 K BEAM 300 K > T > 80 K 26/06/2015 HiLumi 2 Industries - Garlaschè 53

54 Bottom-Up View: Cavities RFD Cavity DQW Cavity 2x designs! Highly non-axialsymmetrical Niobium cavities Technologies Involved: o Forming of 3 4mm-thick Niobium sheets non axisymm. shapes, high aspect ratios, profile tolerance ~ 0.5mm o EB-welding (strict requirements ): Nb/Nb & Nb/NbTi o Brazing (or other) of Nb to S.Steel Interest for Suppliers Not Needed Much Welcome Needed 26/06/2015 HiLumi 2 Industries - Garlaschè 54

55 Manufacturing R&D with companies CRABS Initial tests qualification of forming and RF SPL Project forming & welding of Cu Nb Nb/SS CERN CERN 26/06/2015 HiLumi 2 Industries - Garlaschè 55

56 HOMs & FPCs 1 Al2O3 200 mm Cu Nb SS 620 mm Input/Output systems for power management inside cavities Technologies Involved: o Mix turning + milling + assembly of Cu and Nb parts (assembly profile ~0.3mm) o Brazing of vacuum-air interfaces embedding Ceramic + Cu + S.Steel 1 High Order Mode Dampers, Fundamental Power Couplers 26/06/2015 HiLumi 2 Industries - Garlaschè 56

57 Magnetic Shieldings & He Vessel T SHIELD = 80K 300K T SHIELD = 2K Magnetic Shielding alloy: o Forming + assembly o Annealing treatment Helium Vessel: o Machining (Titanium Gr.2) o Assembly + Titanium TIG welding o Supply of Titanium bellows 26/06/2015 HiLumi 2 Industries - Garlaschè 57

58 Cryostat Manufacturing of Cryostat and Auxiliary systems Sheet metal working of tank (precision interfaces) 1700 mm Cryo Line (welds tight at 2K) Ti/S.Steel direct transitions 2K) SS Bellows and vacuum equip. Thermal shielding with Helium cooling + MLI 2900 mm HiLumi 2 Industries - Garlaschè 26/06/

59 Not Forgetting Passive/active Tuning System (ref. Kurt Artoos) Actuation FSI 1 Alignment System (ref. Mateusz Sosin) 1 Frequency Scanning Interferometry 26/06/2015 HiLumi 2 Industries - Garlaschè 59

60 Not Forgetting Active SPS Test: motorized & remotelycontrolled supporting systems 26/06/2015 HiLumi 2 Industries - Garlaschè 60

61 Technology for SC RF cavities 26/06/2015 HiLumi 2 Industries - Garlaschè 61

62 Polymer laboratories activity for which we may require industrial partnership Electrostatic paint The epoxy paint have an insulation and radiation protection of 30KV for 0.5mm thickness 15

63 Needed for cryogenic devices in special insulation materials (accuracy 0.1 mm) Several different pieces made on the 3 D printer and impregnated were used to check the design 16

64 and let light shining over LHC many years more 64

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