HRM Technical BoardApril 28th, 2015 Fausto Lorenzo Maciariello, on behalf of many colleagues: F-X Nuiry, V. Kain, J. Uythoven, O. Aberle, R. Folch, R. Losito, G.E. Steele, M. Butcher, A. Lechner, R. Ferriere.

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Outline• Motivations

• The Experimental Set Up

• On-Line Instrumentation Monitoring

• List Of Materials

• Preparation & Installation Phase

• Operational Phase

• “Short-Term” Cool-Down & Storage

• Post-Irradiation Phase & Failure Scenarios

• RP Related Hazard Inventory & Radiation Level

• Disposal Risk Analysis

• Conclusions

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Motivations

1. Assess the Integrity of Graphite for TCDIs and TDIs during Run 3. The goal is to reproduce the worst accidental scenario that the TCDI and the TDI can see during their life time.

2. Test New Promising Materials for BIDs

3. Benchmark Simulations• Temperature and Displacement Measurements foreseen.

Beam Intensity Sig X[mm] * Sig Y[mm]

Peak per Primary

[GeV/cm3]

Max Temperature

[°C]

M-C Safety Factor*

Run 3 BCMS 5.76 E13 0.320*0.511 0.436 1450 0.8

HiRadMat 3.46 E13 0.313*0.313 0.663 1342 0.7

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The Experimental Set UpActive Part Materials:

• Upper Jaws Stroke: +/- 30mm. The upper jaws will begin at z=400mm.

• Lower Jaws Stroke: +/- 30mm. The upper jaws will begin at z=0 mm.

• Tank Stroke (5th axis): +/- 60mm.• Instrumentation Stroke (6th axis): +/- 60mm.

400mm

On-Line Instrumentations

5th Axis

Collimator Feet

Plug-In System

Jaws

Beryllium Beam Window

Tank

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On-Line Instrumentation Monitoring150mm

80mm

X

ZY

* Detailed Simulations on expected thermo-mechanical loads are contained in the Safety file.

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List of Materials

Boron Nitride (1.9g/cm3)

Graphite (1.83g/cm3) 3D C/C (Wrapping Process Technnique,1.7g/cm3)

3D C/C (Plane Process Technique,1.7g/cm3)

Aluminum AW-6082

T6

Collimator support feet 77 600

Aluminum AW-6082

T6

5th axis 132 160

Aluminum AW-6082

T6

Plug-in 32 215

Stainless Steel Vacuum tank 363 112

Stainless Steel Collimator jaw housing

and stiffener

71 33

Material Components Estimated Weight

[Kg]

Approximate

distance to the

beam axis [mm]

Brass LVDTs axis 0.1 290

Beryllium Vacuum Windows 0.012 On BeamRad-Hard Glass Optical windows 1.5 80

Stainless Steel 316L Bellows 0.5 78

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Layout

TT61 Side

TNC Side

Table Position 2

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List of Materials - Instrumentation

Instrumentation

Tank & HRM Table

Position

Optomet LDV passive head Inside the tank

140mm from the beam

Pyrometer Passive Head Inside the tank

140mm from the beam

Radiation Hard Camera Outside the tank

Instrumentation

TT61

Position

Optomet LDV Acquisition System In The TT61 bunker. Connected to the

Optomet LDV passive head through TT61-

TNC feedthroughs.

Pyrometer Acquisition System In The TT61 bunker. Connected to the Polytec

passive head through TT61-TNC

feedthroughs.

Camera Acquisition System In The TT61 bunker. Connected to RadHard

camera

Beam(TNC Side)

Instrumentation Location

Table B Location (TNC Side)

• Main part of the instrumentation and equipment connected through the standard HRM table .

• Additional cabling not present on HRM table will be connected through TT61-TNC feedthroughs

• *Detailed List of Instrumentation in the Safety File

TT61 Side

TT61 Side

TNC Side

Instrumentation Location

Beam

Table B

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Preparation & Installation Phase1) Experiment Integration and Assembly• Manufacturing of the tank and Collimator jaw housing by EN/MME.

• Collimator feet, plug-in, 5th axis, instrumentation and equipment: EN/STI.

• All parts assembled, instrumented and tested in EN/STI bldg. 867 and at bldg. 272.

• BPKG support, tank and in-tank instrumentation alignment in Metrology Lab.

2) Integration in SPS-BA7 – estimated time ~ 3 weeks• Integration of the experimental tank interface plate on to the HRMT lifting table.

• Alignment cross-check of the LDV and pyrometer head(s).

• Integration of the electrical connectivity.

• First testing of the acquisition system and of the remote control system of the online systems.

• Connection and installation of the rad-hard cameras to the test-bench.

3) Installation in TNC estimated time ~ 1 week• Transported to the TNC HiRadMat area via a trolley transport system, vertical lift and then remotely

controlled crane.

• Connection of the instrumentation feed-throughs via the TNC/TT61 holes.

• Alignment cross-check of the experimental set-up.

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Operational PhaseAlignment Procedure to be followed before impacting Jaws:

1. Establish trajectory – collimator open2. Set up interlock thresholds3. Copy settings to high intensity cycle4. Set up collimator

• 0.5 sigma steps with nominal bunch: scan gap. [Small gap]

Operational Phase5. Move collimators out: calculate

jaw setting with defined beam center.

6. Verification with fast 12 bunch shot: check trajectory.

7. Move in jaw: impact 1.5 sigma8. Verification shot with 12 bunch

shot. Check beam loss signal, check position on BPKG (Vertical Alignment accuracy: +/-0.5σ)

9. Alignment Instrumentation with the beam, scanning the jaw with few 12 bunch individual shots (Horizontally) using the 5th axis (best Horizontal alignment accuracy= beam Jitter).

10.288 Bunch Shot

5th Axis

Instrumentation

The same procedure has to be done for the lower jaws, while for the upper ones there is no need of instrumentation-beam alignment (n. 8). Type of beam: Trajectory indiv.

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Operational PhaseThe goal is to reproduce the worst accidental scenario that the TCDI and the TDI can see during their life time.

Mohr-Coulomb Safety factor as INDICATOR of material survival. The material survives if M-C > 1.

Each jaw will see: • 2 pulses @ 1.5 sigma impact parameter. Allowing

enough cool-down between the two (>10minutes)• Intensity per pulse: 1.2 E11 protons/bunch • Number of bunches: 288• Sigma X*Sigma Y= 0.313*0.313

Dependency of M-C safety factor and maximum energy density on impact parameter (in σ) for a round beam with a σ=0.295mm. For a round beam with a different beam

spot size will be expected the same behavior.

• As already mentioned, the induced stresses are affected by the distance to the next free surface. Hence the proposal of having two opposite jaws in order to perform a high-precision alignment

◦ Scanning the beam with a small gap◦ Detecting induced showers with BLMs

• Expected beam deviation accuracy Vertically: +/-0.5σ

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“Short-Term” Cool-Down & Storage

1. After the experiment, the tank-pump line is closed with a valve and the vacuum is broken (0.8-1bar).

2. The experimental set-up will need to remain at the experimental area for ~1 month for radiation cool-down. Then, fast disconnection of services not included in standard HRMT table (<1 mSv/h tank wall).

3. Remote transport with the crane to the cool-down storage area downstream in TNC tunnel.

4. 6 months of cooling at the storage area downstream in TNC tunnel ,radiation dose rate drops to levels below 200μSv/h at contact with the tank wall.

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“Short-Term” Cool-Down & Storage: EnvelopeThe test-bench exceeds the limits of the default space available to experimental hardware. Discussion and approval by the HRM Technical Board is needed.

BTV, on going design

About 42mm inside the “forbidden area”. Cooling pipes NOT used !!

600mm

230mm

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Failure Scenarios1. Global deformation that makes the flatness larger than 100 μm.

2. Cracks on fragile materials (Graphite and BN) can be really dangerous and not acceptable. On 3D C/C “small” cracks (not affecting the surface flatness requirements and not affecting the block integrity) can be accepted due to its ductility.

Expected results are based on material static limits (displacement rate 0.02mm/s) while we are under dynamic load conditions (2000 mm/s)

• *Mohr-Coulomb safety factor should be larger than 1 as an indicator for the material survival (Criterion to be applied to fragile materials as graphite)

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Post-Irradiation Phase1. Ultrasounds (CERN, MME Lab)

• Detectable defects: 1mm on 25mm thickness, 2mm on 50mm thickness

2. Microscopy Inspection (CERN, MME Lab)

3. Metrology Control (Bldg. Metrology, 72)

<<Analysis that are not performable in a radioactive workshop need to be performed in a delimited (by RP)

“radioactive zone”>> (M. Widorski, DGS-RP-AS)

Microscopy Inspection on Graphite.Defects detectable 10 to 50 microns.Depends on the chosen magnification.

Sound Wave direction

No Defects bigger than 1.5mm (resolution) detected in the material.

Difference in the intensity of the ultrasound crossing the block. Inhomogeneous material, due to:• Micro porosity,

• Micro defects smaller than the resolution,• Grain size

*Detailed Metrology report EDMS 1497604, Detailed Ultrasound report EDMS 1504923.

Detectable deformations less than 1mm. Depends on the chosen sampling.

4. Micro-Tomography (RX SOLUTIONS, Annecy)5. X-Ray

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RP Related Hazard Inventory & Radiation Levels

• Simulations were performed with the following assumptions:• The full total of 8 high intensity shots all impacted

one jaw in exactly the same position, thus maximizing the activation for both the jaw and the downstream tank.

Cooling time Residual dose jaw

Residual dose tank

Residual dose 0.4m from tank

1 hour 7900mSv/hr 2300mSv/hr 21mSv/hr

1 day 7mSv/hr 13mSv/hr 0.6mSv/hr

1 week 2mSv/hr 4mSv/hr 80μSv/hr

1 month 0.6mSv/hr 0.9mSv/hr 23μSv/hr

6 months 85μSv/hr 0.1mSv/hr 5μSv/hr

1 year 26μSv/hr 40μSv/hr 1μSv/hr

Radiation dose at contact of the tank wall. Conservative Approach

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Disconnection By Hand, Cabling not on HRM Table

• 2 x LDV fibres

• 1 x Pyrometer fibre

• 1 x Radhard camera cable

• 1 x Miniature camera feedthrough (2 screws)

Each Disconnection: 30 s

Total Exposure Time: 3 min

Radiation Dose: 1month (at contact with tank wall), <1 mSv/hr

Total Radiation Dose: 50 μSv

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Disposal & Jaw Extractions

Disassemble at BA7 surface of the tank, BPKG and HRM table. HRM table, BPKG and collimator

feet are sent to radioactive disposal, building 953.

2.1.

Full assembly after 6 months of storage at TNC

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Disposal & Jaw Extractions

Opening the tank and extracting jaws in 867. Radioactive Workshop.

• Time Needed: 2min (multiple people holding the clamps)

• Radiation Dose: < 200 μSv/hr

• Total Radiation Dose: 6.6 μSv

• Time Needed per jaw: 4 min

• Radiation Dose: < 200 μSv/hr

• Total Radiation Dose: < 53.3 μSv (4 Jaws)

4.1

3.

4.2

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Disposal & Jaw Extractions

Jaw extraction in 867. Radioactive Workshop.

5.

• Time: 20 s/screw (6screw to tight) + 2 min target extraction

• Radiation dose: < 200 μSv/hr• Total time per Jaw ≈ 4min• Total Radiation Dose: < 53.4

μSv (4 Jaws)

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Disposal & Jaw Extractions

• Total Exposure Time ≈ 35 min

• Expected Activation (Contact on tank surface): < 200 μSv/hr

• Cumulated Radiation Dose ≈ 120 μSv

• Number of People needed for the Operation: 6

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Risk AnalysisEvent Description Hazard Measures/Precautions

Installation and AssemblyManual Handling Work to be done during the

assembly

Injury due to lifting heavy objects Several handles for single component,

to facilitate the lifting by multiple

people (e.g. tank door).

Modular design easy to mount and

dismount

Use of crane/lift

DismountingRadiation exposure during the disconnection of cable

After the experiment some cables need to be disconnected manually from the HRM table

Exposure to ionizing radiation Checking the radiation level.Minimizing time for the operation in TNC with test before the actual experiment (practice the procedure).

Activation of the tank and jaws

Extracting the irradiate materials Exposure to ionizing radiation Design made to facilitate the jaw extraction and reducing the dismounting timeTools for dismounting procedure further from the activated components

Post Irradiation PhaseMetrology tests Radiation exposure during PIE of

irradiated targetsExposure to ionizing radiation PIE carried out only after RP

greenlight in a delimited “radioactive” are or radioactive workshopUltrasound tests

Microscopy InspectionsMicrotomography tests Exposure to ionizing radiation

Exposure to ionizing radiation and Shipping the targets externally

*A detailed list of risks is given in the safety file.

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Conclusion

• We will REPRODUCE the worst case scenario for the thermo-mechanical stresses and assess the TCDI & TDI survival.

• The design and the instrumentation integration is progressing.

• Simulations on expected thermo-mechanical loads and radiation levels were done (detailed information in the Safety File)

• Post Irradiation Analysis will be able to detect material failure.

• Safety aspects represent a major priority during all the phases of the experiment.

• 6 months cool down period in TNC will be sufficient for residual dose rate to fall down <200 μSv/h at contact with the tank wall.

Thank For Your Attention !!!

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Risk AnalysisEvent Description Hazard Measures/Precautions

Installation and AssemblyManual Handling Work to be done during the assembly Injury due to lifting heavy objects Several handles for single component, to

facilitate the lifting by multiple people (e.g. tank door).Modular design easy to mount and dismountUse of crane/lift

Electrical connections Working with electrical connections Electrical shock Insulated wiring/low voltage

Pre-existing activation of the experimental area

Exposure during the installation phase Ionizing radiation Minimizing time for the operation in TNC with test

Vacuum Vacuum inside the tank Ropture of the Window Calculations to choose the needed thicknessExcessive bow Calculations to choose the needed thicknessInstrumentation misalignment The final alignment will be done with vacuum

(for the pre-alignment procedure and the alignment with the real beam)

Testbench lift Positioning on Position 2 in TNC Fall of heavy loads Verification Crain maximum lifting weigth> total testbench weight

TransportTest bench transportation The test-bench needs to be transported

from BA7 to TNCFall of heavy loads Slower transport and verification of maximum

weights Transport Vibration occurring during the transport Loosing of jaw/instrumentation alignment After the pre-alignment on the BA7 surface

anotheer one is foreseen in TNC with the pilot beam.

Experimental PhaseFire Ignition of componets Potential release of radioactive material All the component are under vacuum and the

max temperature for the target is much below the max service temperature (under vacuum). Risk of ignition is totally eliminated

Experiment diagnostic Measurements to be done in a high radioactive area

High activate environment Remote diagnostic onlyExpensive electronic devices to be placed on the bunker (TT61) protected by the shielding

On-line instrumentation alignment Need of very accurate precision (0.2mm) Not measuring temperature and displacement at the correct location

Scanning the jaw surface, in order to find the location with the strongest signal given by the LDV, while the pilot beam is impacting the jaw.

DismountingRadiation exposure during the disconnection of cable

After the experiment some cables need to be disconnected manually from the HRM table

Exposure to ionizing radiation Checking the radiation level.Minimizing time for the operation in TNC with test before the actual experiment.

Activation of the tank and jaws Extracting the irradiate materials Exposure to ionizing radiation Design made to facilitate the jaw extraction and reducing the dismounting timeTools for dismounting procedure further from the activated components

Post Irradiation PhaseMetrology tests Radiation exposure during PIE of

irradiated targetsExposure to ionizing radiation PIE carried out only after RP greenlight in a

delimited “radioactive” are or radioactive workshop

Ultrasound testsMicroscopy InspectionsMicrotomography tests Exposure to ionizing radiation

Exposure to ionizing radiation and Shipping the targets externally

Jitter

Beam Spot Size

Trajectory

X

Y

Z

Z: Beam Direction

Sensors Position Accuracy

Pilot and or Medium Intensity

Beam

 Nominal Beam

Min[mm]

Max[mm]

Min[mm]

Max[mm]

BEAM SPOT SIZE 0.3 0.3

VERTICAL BEAM DEVIATION “x”

-0.2 +0.2

HORIZONTAL BEAM DEVIATION “y”

-5 +5

VERTICAL JITTER “x” -0.06 0.06

HORIZONTAL JITTER “y” -0.075 0.075

Beam Axis Distorsion compared to Z

Angle= ???°

BPM Accuracy -0.2 +0.2

Instrumentation Alignment precision

(without 6th axis)…?       1 Sigma

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Dynamic Behavior of Graphite

Under Dynamic Stress load the graphite limit is higher.

Elastic Strain Limit= 0.0051Elastic Limit≈58 MPa

Max Pic Stress=43 MPa

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INFO NEEDED

• Beam Spot Size Accuracy:

• Jitter Accuracy:

• Trajectory Accuracy:

• BPM accuracy:

Geometric Center of the jaw given by the Geometers. Accuracy:

ALL THESE INFO NEEDED FOR EACH DIRECTION: X, Y, Z.

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2 h of stability data taking with 1e+11. 2mm fp2• P2p: ~ 1 mm

• One strong horizontal mode

The error scales like: 0.3 mm/2 mm = 0.15. Only 0.15 of the 1 mm for our optics.