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The Cryostat Integration into ILD
Stromhagen, Richard / DESY-Hamburg / - ILD Integration Workshop 2010 - DESY
22
Table of contentTable of content
1.0 Cryostat assembly overview .…………………………………………………………………………1.0 Cryostat assembly overview .…………………………………………………………………………………..1………..1--77
2.1 The 2.1 The ILDILD Cryostat structure proposal ………………………………………………………..............Cryostat structure proposal ………………………………………………………...................... 882.1.1 2.1.1 ILDILD Cryostat production schedule proposal ………………………………………………………….Cryostat production schedule proposal …………………………………………………………. 992.1.2 Applied and resulting force, deflection line …………………2.1.2 Applied and resulting force, deflection line ………………………………………………………….10……………………………………….102.1.3 FEM Simulation for Cryostat Segment End…………………………………2.1.3 FEM Simulation for Cryostat Segment End………………………………………………………11……………………11--1313
3.1 Solenoid assembly completion in 3.1 Solenoid assembly completion in ILDILD central barrel, with methodcentral barrel, with methodsimilar to CMS ……………………………………………………………………………….........similar to CMS ………………………………………………………………………………..........................14.................14
4.0 Operations schedule for Cryostat completion in 4.0 Operations schedule for Cryostat completion in ildild central barrelcentral barrel-- installation of adjustable integral key installation of adjustable integral key -- ………………………………………………….15………………………………………………….15
4.1 Lifting of outer vacuum vessel off jacks and final adj4.1 Lifting of outer vacuum vessel off jacks and final adjustment in ustment in ILDILD Central BarrelCentral Barrel-- alternative: each support is fitted individually and then weldealternative: each support is fitted individually and then welded to barrel…………..16 d to barrel…………..16
4.2 Bracket after adjustment and tack welding, final weldi4.2 Bracket after adjustment and tack welding, final welding ……………………………………..17ng ……………………………………..17
5.0 Cryostat integration in Central Barrel, final installation…5.0 Cryostat integration in Central Barrel, final installation……………………………………………….. 18…………………………………………….. 18
6.0 6.0 ILDILD Central Barrel Central Barrel –– structural force …………………………………………………………………………19structural force …………………………………………………………………………19--2020
7.0 Calculation for Screws of Barrel, 7.0 Calculation for Screws of Barrel, –– DIN 18800…………………………………………….................DIN 18800……………………………………………................. 21217.1.1 Appraisal and interpretation of result …………………………………7.1.1 Appraisal and interpretation of result ……………………………………………………………………………………………………… 22227.1.2 Recalculation for screw interconnection ………………………………7.1.2 Recalculation for screw interconnection ……………………………………………………………….………………………………. 23237.1.3 Result for screw DIN EN ISO 4014 7.1.3 Result for screw DIN EN ISO 4014 –– M36 x 140 M36 x 140 –– 10.9 / 10.9 /
washers DIN 6916 washers DIN 6916 –– 37 ………………………………………………………………………………………..37 ……………………………………………………………………………………….. 24247.1.4 Screw and washers lost of tension ………………………………………………7.1.4 Screw and washers lost of tension ………………………………………………………………………..………………………..2525
8.0 Conclusions ……………………………………………………………………………………………………………………8.0 Conclusions …………………………………………………………………………………………………………………… 2626
9.0 References …………………………………………………………………………………………………………………….9.0 References ……………………………………………………………………………………………………………………. 2626
33
CERN CMS Solenoid schematic
Richard Stromhagen / DESY
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insertion of other vacinsertion of other vac--tank / CMCtank / CMC
Richard Stromhagen / DESY
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the CMS centre part of the compact the CMS centre part of the compact muonmuon solenoid barrel solenoid barrel
with the vacuum tankwith the vacuum tank
Richard Stromhagen / DESY
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HCAL prepared for insertion / CMSHCAL prepared for insertion / CMS
Richard Stromhagen / DESY
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the centre part of the compact the centre part of the compact muonmuon solenoid barrel with solenoid barrel with
the vacuum tank, HCAL, ECAL, TPC and all connections the vacuum tank, HCAL, ECAL, TPC and all connections
Richard Stromhagen / DESY
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2.1 the ild cryostat structure proposal / all welded 2.1 the ild cryostat structure proposal / all welded
end flange
outer vacuum vessel
inner vacuum vessel
reinforcement
spacer
eye for radial suspension
- weight ~ 70 t
- weight ~ 56 t
- weight ~ 5t
J x-x = 1,82 x10¹²
- weight ~ 136 t
suspension points for radial tier
solenoid vents
inner rails for HCAL
horizontal tie rod
to be done
to be done
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2.1.1 2.1.1 ILDILD Cryostat production schedule proposal Cryostat production schedule proposal
Outer-, and inner- vacuum vessel-sheet 4 or 8 (max. 13610 mm x 3905 mm, s= 30 mm) segment rolled and welded
outer vacuum vessel
inner vacuum vessel- sheet 4 or 8 rolled and outside scaffold - aligned and welded
- lodge inner vv in outer vv, align rims and weld
- welding of end plate
to be done
assembly cryostat to ovv- solenoid completion and fixture
- prepared edge lined up and welded- rotation symmetrical pilot hole diameter (ø 40 mm)- outer reinforcements clamped to barrel and held in place by outer support - aligned axis of ovv and barrel- fixed ovv and welded brackets to the central barrel
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2.1.2 Applied and resulting force, deflection line of Cryostat2.1.2 Applied and resulting force, deflection line of Cryostat
--manual calculationmanual calculation--
F ovv ~ 0,05 mm
f ovv ~ 0,5 mm
f oief ~ 0,3 mm
f ovv ~ 0,5 mm
f oief ~ 0,3 mm
7810
207428682868
1. outer vacuum vessel (ovv)
- weight ~ 70 t
- section modulus J x-x = 9,57 x 10¹¹outer ø 8680 / s = 30
2. outer + inner + end-flanges (oief)
- weight ~ 136 t
- section modulus J x-x = 1,82 x10¹²(stainless steel)
inner ø 6880 / s = 40
3. cryostat weight total ~ 360 t
4. HCAL, ECAL, TPC ~ 710 t
∑ ~ 1200 t
FR ~ 6000 kN
FL ~ 6000 kN
FA ~ 6000 kN
FB ~ 6000 kN
f oief ~ 0,03 mm
(active force) (active force)
(active force)
(active force)
reaction force,
reaction force,reaction force
supportsupport
resetting fixing
resetting fixing
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2.1.3 2.1.3 ILDILD Cryostat IDEAS FEM simulationCryostat IDEAS FEM simulationonly end half part 2868 lg. / F = 3000 kN constant offonly end half part 2868 lg. / F = 3000 kN constant off--circumferencecircumference
Richard Stromhagen / DESY
J x-x = 2,35518 x 10¹¹
23 t
F hand cal. ~ 0,5 mm
F max ~ 5,4 mm
σ ~ 160 N / mm²
1212
ILDILD Cryostat with “Cryostat with “ANSYSANSYS” FEM simulation” FEM simulation
All deformation without + 30% safety factor,
- to be inaccuracy meshing.
max. deformation 1,3 mm
1313
ILDILD Cryostat total stress “Cryostat total stress “ANSYSANSYS simulation”simulation”
max. stress ~ 50 N/mm²
1414
3.1 Solenoid assembly completion in 3.1 Solenoid assembly completion in ILDILD Central BarrelCentral Barrel-- method similar to CMS method similar to CMS --
1. outer vacuum vessel (75 T.) with barrel after installation on turn table, primary alignment
path of insertion
2. assembly and completion of the solenoid ( ~ 225 T)- rotate inner vacuum vessel into horizontal position => welded radial tiers and end flange
- vertical assembly of the inner vacuum vessel
- rotation of the Inner vacuum vessel in horizontal position
75 T
path of insertion
outer VV
suspended from crane
75 T
solenoid suspended from crane ~ 225 T
inner vessel
60 T
spacer and belts
rotate end towards Barrel
rotate end towards Barrel
- welding radial tiers and end flange
Step 3 Step 4
rotate end towards barrel
Step 1
Step 2
Richard Stromhagen / DESY
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4.0 Operation schedule for Cryostat completion in 4.0 Operation schedule for Cryostat completion in ILDILDcentral barrelcentral barrel
-- installation of adjustable integral key with 3 DEG angle installation of adjustable integral key with 3 DEG angle bracket footings bracket footings --
Installation of “jacking up to line” keys with hardened plate to primary alignment (integral key ~ 3deg), shown in position (8 units)
integral key, slope 3deg
hardened plateF max ~ 150 t / 2
adjustment distance
allowable pressure
S235JR (St37) RmN ~ 360 N/mm²
yield point Rp0,2N ~ 235 N/mm²
σdB ~ F / A ~ 75 000 0 N / 8 x 500 (mm) ~ 188 N/mm²
without preparatory work, full yield settling ~ 0,8 mm
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4.1 Lifting outer vacuum vessel off jacks and final alignment in4.1 Lifting outer vacuum vessel off jacks and final alignment inILDILD Central BarrelCentral Barrel
-- alternative: each support is fitted individually and then weldealternative: each support is fitted individually and then welded to Barreld to Barrel --
-after primary alignment
- tack weld each bracket to barrel
individually,
- from point to point to fit and tack
- fit screw between barrel and ovv
- all bracket to barrel tack welding
- remove circular 6° ovv from barrel
- all bracket end welding
(alternative: welding without removal of ovv)
6°
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Fmax ~ 300 kNM bending moment ~ 19500Nm
F axial ~ 150 kN
σ normal stress ~ 152 N/mm² < σ tol. ~ 195 N/mm²
Reference is data sheet DVS 0705 / DIN 18800
150 kN
150 kN
4.1.2 Bracket after adjustment- and tack welding,
- bracket after tack and final welding -
welding seam: aw ~ 35 mm,
l = 80 mm, Aw = 2800 mm²
steel: S235JRG2Rm ~ 360 N/mm²Re ~ 215 N/mm²
σ II ~ 18 N/mm²σ ┬ ~ 32 N/mm²ح II ~ 32 N/mm²ح ┬ ~ 32 N/mm²σ exist ~ 48 N/mm² < σw ~ 207 N/mm² (St37) (factor ~ 4)
stress reference value
Richard Stromhagen / DESY
- after tack weld bracket to barrel,end welded (without ovv)
- alternative: end welded with ovv
1818
5.0 Cryostat integration in central barrel, final installation - outer vacuum vessel end fixing in central barrel -
fix with friction bolt DIN 1481 - ø 50 x 240 lg. hexagon head bolts with large head (HV) DIN 6914 – M30 x 300 comply with washersand nuts
Assembly boring of ø 50H¹² mmbracket in combination withCryostat eye
friction bold DIN 1481 shearing force max ~ 1685000 N Account: 20 friction bold to lift 1200 t
Fr theory ~ 600000 N Fr applied under 600000 N! Surface pressure 65 N/mm²
Fa ~ 300000 N Fb ~ 300000 N
shear stress factor ~ 2,5 (1,2 is ok) surface pressure 125 N / mm²
S235JR ~ 235 N/mm² > 125 N/mm²
pressure factor ~ 1,8 (1,2 is ok)
tightening screw condition: hydraulically operated insequence for 24 boldDIN 6914 – M30 x 300M ~ 1650 Nm, Fv ~ 350 kN
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FG
FC
FBFA
f1, l1
f9, l9Fp
Fs
FR
1900
6.0 structural force / staticManual calculation with neutral line (“Fp”) in parallel key to
barrel segment
FG centre of gravity = 11250 kN
FC cryostat = 12000 kN / 2 = 6000 kN
FA = 4300 kN
FB = 13000 kN
Ma moment = 6000 kNm
FS = 12000 kN
FR resulting force = 17000 kN
FP fictitious pressure point (Roloff / Matek Kap.8.4.5)
FR = 16300 kNF2 = 15700 kNF3 = 4200 kN
Parallel key (Fp)
FR
F2F3
0
Ma
Richard Stromhagen / DESY
Shows the Simplified
external force acting on barrel and connecting
screws
2020
6.1 The location of the neutral line from keys to barrel6.1 The location of the neutral line from keys to barrelthe FEM simulation with CAD IDEAS and manual calculation the FEM simulation with CAD IDEAS and manual calculation
-- 6.0 continues neutral line area “6.0 continues neutral line area “FpFp” ” --
Transverse force support,
Bolt DIA 60 mm,
Assembly bore positioning
“Fp”
max. deformation 2mm
force neutral line “Fp”
force neutral line
pressure
tension
2121
7.0 Calculation for screw of Barrel, DIN 188007.0 Calculation for screw of Barrel, DIN 18800: :
method: bracket connection (Roloff / Matek 8.4.5)method: bracket connection (Roloff / Matek 8.4.5)force, factors and dimension list (show 6.0) force, factors and dimension list (show 6.0)
externalexternal force force FsFs = 11917027 N= 11917027 Ntorque arm torque arm La La = 2400 mm= 2400 mmnumber of threads number of threads n n = 44= 44number of engaged threads number of engaged threads z z = 28= 28number of crack number of crack m m = 1= 1minimumminimum thickness thickness t min t min = 65 mm= 65 mm
(part) safety factor (part) safety factor -- tensile strength tensile strength SM SM = 1.2= 1.2
(part) safety factor (part) safety factor –– shear force shear force SMq SMq = 1.2= 1.2
(part) friction factor (part) friction factor µ µ = 0,8 = 0,8 ((Roloff / Mattek cap 4.1 / TB 4Roloff / Mattek cap 4.1 / TB 4--1)1)
preload screw preload screw Fv Fv = 560000 N= 560000 N
property mind. class property mind. class = 10.9 (d > M16)= 10.9 (d > M16)
tensile strength tensile strength Rm Rm = 1040 N/mm= 1040 N/mm² ²
yield strength yield strength Re Re = 940 N/mm= 940 N/mm²²
allowable flange pressure allowable flange pressure σσ zulzul = 540 N/mm= 540 N/mm²²
clearance (L) of tensile load screw to center of pressureclearance (L) of tensile load screw to center of pressure
L1 = 1900;L1 = 1900; L2 = 1750; L3 = 1600; L4 = 1450; L5 = 1130; L6 = 980; L7 =L2 = 1750; L3 = 1600; L4 = 1450; L5 = 1130; L6 = 980; L7 = 830; L8 =830; L8 = 680; L9 = 510680; L9 = 510
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7.1.1 Appraisal7.1.1 Appraisal and and interpretationinterpretation of of resultsresults-- the screw calculation utilizes data from 7.0 the screw calculation utilizes data from 7.0 --
1. required bolt diameter 1. required bolt diameter = M 36= M 362. mean diameter 2. mean diameter ØØ = 36,00 mm= 36,00 mm3. minor diameter 3. minor diameter ØØ = 33.40 mm= 33.40 mm4. core diameter 4. core diameter ØØ = 31,09= 31,095. applied shear stress 5. applied shear stress דדa a == 332332 N / mmN / mm²²6. applied flange pressure for t6. applied flange pressure for tmin min = 65 mm = 65 mm σσl l = 116 N / mm= 116 N / mm²²7. bending moment bench mark center of pressure 7. bending moment bench mark center of pressure Mb Mb = 28600000 Nm= 28600000 Nm8. max. traction for bolt at distance l8. max. traction for bolt at distance l11 Fo Fo max max = 129526 N= 129526 N9. max. tensile strength for bolt at distance l9. max. tensile strength for bolt at distance l11 σσz z = 159 N / mm= 159 N / mm²²
10. applied bolt shearing force 10. applied bolt shearing force Fq Fq existexist = 270842 N (not = 270842 N (not
mechanical characteristics of bolt M 36mechanical characteristics of bolt M 36 interpretationinterpretation
nominal tensile strength nominal tensile strength σσz z max.max. = 693 N / mm= 693 N / mm²² ≥≥ σσz z existingexisting = 159 N / mm= 159 N / mm²²nominal nominal shear stress shear stress דד a max. a max. = 381 N / mm= 381 N / mm²² ≥≥ == a a existing existingדד 332332 N / mmN / mm²²nominal applied flange pressure nominal applied flange pressure σσl l max.max. = 540 N / mm= 540 N / mm²² ≥≥ σσl l existingexisting = 116 N / mm= 116 N / mm²²maximum bold friction grip / shear force F maximum bold friction grip / shear force F max. max. = 324638 N = 324638 N ≥≥ Fq Fq existexist = 270841 N= 270841 Nfor 10 bolt at l1 for 10 bolt at l1 FFR max. R max. = 2839941 N = 2839941 N ≥≥ FFR existing R existing = 1169545 N= 1169545 N
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• Recalculation for screw DIN ISO 4014 - M36 x 140 – 10.9 / set VDI 2230 • washers DIN 6916 - 37
tightening screw condition: hydraulically operated
Steel grade: Part 1. S235 JRG1 = 65 mm thicknessPart 2. S235 JRG1 = 100 mm thickness
max. shear resistance fBM = 0.59 max. seating part stress factor fG = 1,44 (VDI Tab. 5.5/1)max. seating washers stress factor fG = 0,87washers average surface roughness Rz = 0,5µfor screw elastic limit ~ 90% min. friction factor screw connecting surface µK = 0,14for screw elastic limit ~ 90% min. friction factor screw thread µG = 0,14friction grip / part friction factor 0,8 µ (connection with force transmission by friction)
stress cone inside slit ~ Ø 100 mmstress cone outside slit ~ Ø 110 mm existing bearing pressure
distance pre-stressing area from transmission of screw force ~ 35 mm (Fd) existing shear stress
operating temperature ~ 20°C shearing strain force
35 mm Fd
0,8 µ
fBM, fBM,
Rz
µK
Mt
Mt
Fa
Fa
Fq
Fq
Fs
Mb
43,71
Richard Stromhagen / DESY
7.1.2
2424
7.1.3 Result for screw DIN EN ISO 4014 7.1.3 Result for screw DIN EN ISO 4014 –– M36 x 140 M36 x 140 –– 10.9 and 10.9 and washers DIN 6916 washers DIN 6916 –– 37 37
Ma Ma -- locking torque = locking torque = 4,5 kNm4,5 kNm
Fv Fv -- max. screw axial force = max. screw axial force = 420 kN420 kN
tol. screwtol. screw--in depth = in depth = 44 + 4 mm44 + 4 mm
surface pressure surface pressure mounting operating after settling, mounting operating after settling, -- fz = fz = 8,50 µ8,50 µ
screw connecting surface = 830 screw connecting surface = 830 N/mmN/mm²² = = 821 N/mm821 N/mm²²
washers connecting surface = 453 N/mmwashers connecting surface = 453 N/mm²² = = 448 N/mm448 N/mm²²
safety coefficient anti safety coefficient anti surface pressuresurface pressure
screw connectingscrew connecting surface surface = 1,05 = = 1,05 = 1,061,06
washers connectingwashers connecting surface surface = 1,08 = = 1,08 = 1,091,09
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screw and part deformation
fs ft
Fvz
Fvr
FMmax / MA
f (mm)
F (N)
min. thread length
2
4
6
8
10
12
1410 20 30 40 %
loading force in thread length %
Number of thread
loss of tension / loading force in thread length
Fv
45 mm
65 mm
stress concentration prevention
Richard Stromhagen / DESY
screw
part
0,01
screw operation force
7.1.4 Screw and washers lost of tension
2626
8.0 conclusion8.0 conclusion
In this note is described the status of the integration cryostaIn this note is described the status of the integration cryostat in central barrel.t in central barrel.
The design is only proposal, in detail with all calculation reqThe design is only proposal, in detail with all calculation required and realistic.uired and realistic.
Insertion of Insertion of ildild cryostat in central barrel is adequate to CMS cryostat.cryostat in central barrel is adequate to CMS cryostat.
strength analysis assumes “openstrength analysis assumes “open--door design” (good safety factor)door design” (good safety factor)
A lot of studies need to be performed:A lot of studies need to be performed:design of cryostat supporting systemdesign of cryostat supporting system-- all geometrical parametersall geometrical parameters
-- finish cryostat constructions conceptfinish cryostat constructions concept-- cryostat quench scenarios cryostat quench scenarios -- cabling conceptcabling concept-- power supply connection designpower supply connection design-- cryostat safety instruction sheetcryostat safety instruction sheet-- scaffoldingscaffolding-- gasgas--, cables, cables--, water, water--, power, power--connectionconnection-- escape rotesescape rotes-- safety periphery and risk assessment analysesafety periphery and risk assessment analyse-- collaboration with other international collaboration with other international ildild interacting groupsinteracting groups-- peripheries transport equipment and devicesperipheries transport equipment and devices
Richard Stromhagen / DESY
References:
CMS Technical Design Report - ISBN 92-9083-101-4
Roloff / Matek Maschinenelemente - ISBN 978-3-8348-0262-0
Schrauben Vademecum - ISBN 978-3-935326-46-7