TDIS WP 14 PRR Manufacture and Inspection Plan

TDIS WP 14 PRR Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) TDIS PRR meeting 2018/03/08

TDIS PRR meeting Agenda § § Manufacture and Inspection Plan Procedures Specifications Drawings Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 2

TDIS PRR meeting § Manufacture and Inspection Plan – Proto Sub-assemblies Assembly Process Vacuum Tanks Transitions Ion Pumps / NEG cartridges Sector valves Girder Jacks Manufacturing Metrology Inspection RGA test Leak test Shipping to CERN Components manufacturing Metrology Inspection Shipping to CERN Components manufacturing Valves assembly Metrology Inspection Shipping to CERN Components manufacturing Girder assembly Metrology Inspection Shipping to CERN Components manufacturing Resources Ion Pumps Cinel EN-MME Vacuum Tanks Transitions SAES GETTERS VAT Girder BSB Industry Jacks CERN warehouse NEG Cartridges Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 3

TDIS PRR meeting § Manufacture and Inspection Plan – Proto Sub-assemblies Assembly Module supports Mechanical tables Jaw RF screen Complete Module Process Components manufacturing Support assembly Metrology Inspection Components manufacturing Metrology Inspection Endurance test (1 table) Components manufacturing Jaws assembly Metrology Inspection Components manufacturing RF screen assembly Metrology Inspection Assembly Resources Ext. suppliers EN-MME Mechanical tables Ext. suppliers EN-MME Ext. suppliers EN-STI EN-MME EN-STI RF screens Jaws Manufacture and Inspection Plan Procedures, specifications and drawings Module supports David Carbajo Perez (EN-STI-TCD) 4

TDIS PRR meeting § Manufacture and Inspection Plan – Proto Sub-assemblies • Elements to keep an eye on: Component Roller screws Affected systems Remarks TDIS HRMT TDIS Prototype Delivery date tight although reachable. A close follow-up of the x x production is advisable Ti clamps Cooling system TZM stiffener x X x x Manufacture and Inspection Plan Procedures, specifications and drawings Clamps for HRMT module -> machining by EN-STI. For TDIS prototype -> machining outsourced (Cinel, to be confirmed) Outsourcing shifted to Cinel (with large experience in cooling systems for the collimators) since current supplier not confident in achieving requested pipes flatness by machining Trials ongoing at supplier to improve requested back-stiffener flatness. One piece produced so far but flatness requirement not fulfilled (part to be used for HRMT, where stiffener flatness is not critical) David Carbajo Perez (EN-STI-TCD) 5

TDIS PRR meeting § Inspection Plan – Proto/Hi. Rad. Mat Sub-assemblies System/Component RF-screen Cooling pipes Ti clamps Ti-6 Al-4 V blocks Cu. Cr. Zr blocks Graphite blocks TZM stiffener Mechanical Roller table screws Vacuum vessels Girder Ion Pumps/NEG cartdriges/Valves Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties NDT Ultrasound inspection SEM X-ray Vacuum analysis inspection tests Pressure test x x Dimensional report to be prepared by CERN x x x Radiographies of the radius areas after bending x x x x x x x x x x Mechanical properties measured @RT and @300°C x x x x SEM analysis before/after cycling test x x x x Leak test, RGA to be conducted by supplier (Cinel) Inspection done by supplier (BSB industry) Validation tests on vacuum, dimensions and materials done in the past for other units. Not requested for this batch. Jaw Sector valves Remarks Manufacture and Inspection Plan Procedures, specifications and drawings Material analysis/NDT done by raw material supplier (HWN) Material analysis/NDT done by raw material supplier (Albaksan) Vacuum tests to be done at CERN after vacuum firing treatment David Carbajo Perez (EN-STI-TCD) 6

TDIS PRR meeting § Inspection Plan – Proto/Hi. Rad. Mat Sub-assemblies Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties System/Component Jaw TZM stiffener x x x NDT Ultrasound inspection x SEM X-ray Vacuum analysis inspection tests x Pressure test Remarks Mechanical properties measured @RT and @300°C EDMS 1897213 Metrology analysis of Hi. Rad. Mat TZM stiffener Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 7

TDIS PRR meeting § Inspection Plan – Proto/Hi. Rad. Mat Sub-assemblies System/Component Jaw Ti clamps Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties x x x NDT Ultrasound inspection x x SEM X-ray Vacuum analysis inspection tests Pressure test Remarks Material analysis/NDT done by raw material supplier (HWN) EDMS 190689 Metrology analysis of the first produced titanium clamp Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 8

TDIS PRR meeting § Inspection Plan – Proto/Hi. Rad. Mat Sub-assemblies System/Component Jaw Cu. Cr. Zr blocks Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties x x x NDT Ultrasound inspection x SEM X-ray Vacuum analysis inspection tests Pressure test Remarks Material analysis/NDT done by raw material supplier (Albaksan) EDMS 1894119 Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 9

TDIS PRR meeting § Inspection Plan – Proto/Hi. Rad. Mat Sub-assemblies System/Component RF-screen Graphite Jaw blocks Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties NDT Ultrasound inspection SEM X-ray Vacuum analysis inspection tests Pressure test x x x x Manufacture and Inspection Plan Procedures, specifications and drawings Remarks Dimensional report to be prepared by CERN Vacuum tests to be done at CERN after vacuum firing treatment David Carbajo Perez (EN-STI-TCD) 10

TDIS PRR meeting § Inspection Plan – Proto Sub-assemblies System/Component Jaw Cooling pipes Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties x x x NDT Ultrasound inspection x SEM X-ray Vacuum analysis inspection tests x Pressure test x Remarks Radiographies of the radius areas after bending Samples produced to verify the feasibility of the geometry EDMS 1808269 Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 11

TDIS PRR meeting § Inspection Plan – Proto/Hi. Rad. Mat Sub-assemblies System/Component Mechanical table Roller screws Material properties analysis Dimensional Chemical inspection composition Mechanical Thermal properties x x x NDT Ultrasound inspection SEM X-ray Vacuum analysis inspection tests x Pressure test Remarks SEM analysis before/after cycling test Endurance test of one mechanical table foreseen to validate design. Roller screws supplier already validated for collimators Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 12

TDIS PRR meeting § Manufacture and Inspection Plan – HRMT schedule HRMT 45 Beam Time 6 th – 10 th August Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 13

TDIS PRR meeting ü ü § Procedures for the development phase HL-LHC baseline documentation vs systems life-cycle (EDMS 1361462) ü Documents available in EDMS for the TDIS WP 14 (status: in work) ! Documents to be created (2 Q 2018) Manufacture and Inspection Plan Procedures, specifications and drawings ü ü ü ! David Carbajo Perez (EN-STI-TCD) 14

TDIS PRR meeting § Procedures Foreseen activities for TDIS considered by LS 2 coordination team in their app PLAN (code 10015). All tasks confirmed ü Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 15

TDIS PRR meeting § Procedures Full TDIS structure to be created in MTF application. Items available for some components already. Absorber Module TDIS Beam Absorber for Injection Segmented Motorization Module support Electrical motor Roller screw Linear bearing Sliding table Mechanical table frame Shaft Bracket support Cooling circuit assembly support Base plate Electrical junction box Protection cover Keys Absorber block Clamp Back-stiffener Cooling pipe Jaw Compression spring Pipes support plate Springs support plate Support plate Ion pump NEG pump Vacuum system VGRB gage VGPB gage RF screen Impedance Hardware RF ferrite tile Transversal RF finger Longitudinal RF finger LVDT PT 100 probe Instrumentation Flow meter Temperature sensor (cooling) Vessel Flange Vacuum chamber Bellow Transition Manufacture and Inspection Plan Procedures, specifications and drawings Support assembly Sector valve assembly Transition Girder Jacks Sector valve 16

TDIS PRR meeting § Specifications EDMS 1905241 EDMS 1865250 Excel list with all requirements included in functional specification and the corresponding studies/tests intended to verify that they are fulfilled Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 17

# Page Chapter Requirement description Value 1 Minimum gap (anti-collision) 1. 0 mm 2 3 Maximum gap Maximum individual jaw position Minimum individual jaw position across axis 110. 0 mm ± 55. 0 mm Surface flatness ± 0. 10 mm Single jaw position precision ± 0. 05 mm 7 Single jaw setting reproducibility ± 0. 01 mm 8 Minimum step size 0. 01 mm 9 Maximum angle at each module ± 2 mrad 10 Maximum retraction between modules 20 mm 4 5 6 5 3. 1 ± 5. 0 mm Relevant calculation/study/ mechanism available Documentation Result analysis (OK/NOK) Jaw movement range in operation and setting precision Anti-collision switch / Mechanical stoppers Drawing mechanical table Mechanical stoppers integrated in LHCTDIS_0011 mechanical tables Tolerance Analysis Jaw block flatness (EDMS 1906421) Motor and roller Precision given by roller screw technical thread pitch and motor step specifications Measurements Given by design from collimators mechanical tables Motor technical Given by motor step specifications Design verified Linking bar between mechanical Report to be tables constraints max. angle prepared Tolerance calculation Limited by software Software program Remarks Relevant verification testing Report Result verification (OK/NOK) OK OK OK TDIS prototype validation test program To be created OK OK TDIS Performance vs MKI failure cases 11 6 3. 2 Charging failure - no damage 288 x 2. 0 e 11 BCMS (inj. ) protons on TDIS Fluka simulation + FEA thermomechanical simulations IP 8 Large impact parameter study Manufacture and Inspection Plan Procedures, specifications and drawings FEA calculations reports (EDMS 1851379) OK Most critical Hi. Rad. Mat HRMT 45 component: to reproduce the To be TZM back-stiffener worst-scenario created and cooling pipes conditions David Carbajo Perez (EN-STI-TCD) 18

TDIS PRR meeting § Drawings Manufacture and Inspection Plan Procedures, specifications and drawings David Carbajo Perez (EN-STI-TCD) 19

Thanks for your attention Content Input from Antonio Perillo Marcone, Chiara Braco, Luca Gentini, Hector Garcia Gavela David Carbajo Perez (EN-STI-TCD) 20