installation review march ‘03 l.simonetti – infn torino 1 its - fwd - beam pipe installation ...

Installation Review

March ‘03

L.Simonetti – INFN Torino1

ITS - FWD - beam pipe installation

Elements considered ITS (=SPD+SDD+SSD), FWD (=V0R, T0R, FMD-Si1, FMD-Si2), CS (=Central Section

of beam pipe (4.82 m long))

Topics Major

constraints Tests prior to

installation Installation

sequence Planning Man power CERN

infrastructure use

Fault tolerance

RB24 side RB26 side

PMD FMD-Si3 FMD-Si2 FMD-Si1

FrontAbsorber

SPDT0L T0RV0L V0RSDD SSD

beam pipe Central Section

RFvalve

Installation Review

March ‘03


ITS - FWD - beam pipe installation

Major constraints Presence of -absorber on RB26 side: forces asymmetric installation Small clearance SPD – CS-pipe (5 mm): forces specific assembly of

SPD (no SPD sliding over beam pipe) Minimum material budget: all services have to be connected at both

ITS ends

ConsequencesComplex and rather long installation procedureSeveral installation approaches have been studied during three

years. The present solution is being pursued by: testing the details on a full-scale installation mock-upregular discussions within ALICE and with the beam pipe group

AT/VAC has the responsibility of all the operations on the pipe and on its support and bakeout shell

Installation Review

March ‘03


Pre-installation and functional tests

Tests prior to installationMechanical

With the installation mock-upWith the final ITS+FWD+pipe mechanics and tools, with the

actual detectors weights, and with the real TPC: final test in SLX2 between July and December 2004Space requirement : a ~6-8 m long area corresponding to the RB24

side for the (dummy) beam pipe installationTools requirements: dummy beam pipe with accessories (bellows,

flanges, valve); dummy front absorberElectrical / electronics / cooling

Individual sub-detectors test upon arrival at CERN ITS re-tests will be performed in the Si-lab in Meyrin (build. 186)

with individual sub-detectors and with SPD+SDD+SSD assembled together (final effectiveness test of grounding scheme and of sub-detectors EM screens)Space requirement : for the detectors (4x4 m2 for each SPD, SDD,

SSD); for the the racks (power supplies, cooling, DCS, shoe-boxes); for the computing (2 workstations per detector); in total about 75 m2

Installation Review

March ‘03


Installation step 1. (6 days) (all durations assuming 1 shift / day)

Assumptions before starting ITS installation:The beam pipe in the Front Absorber (RB26) is already leak-tested and refilled with

N2; its flange is available at the nominal coordinates out of the Front AbsorberThe TPC is at 4.5 m from the

int. point (IP) on the RB24 side (opposite to the absorber)

The 4 fixation plates (C1…C4) of the ITS rails on the TPC are pre-assembled so that they will become aligned when the ITS will be coaxial with the TPC at the end of the installation.

First installation stepInstall and align (survey) the

ITS rails so that they are 1 mm below the nominal beam axis (to minimize the displacement of beam-pipe bellows while linking ITS to TPC)

On the absorber: rails held by remotely actionable jaws TPC/C1

TPC/C2

TPC/C3

TPC/C4

L3

4.5

m

IPFront

absorber

ITS rails

jaws

Installation Review

March ‘03


Installation step 1.

C1

C2

C3

C4

Rail for ITS

Rail for beam pipe

Rails for ITS services

C4

C3

Installation Review

March ‘03


slide ITS through the TPCResponsibility ALICESlide up to 1.56 m from the IP

(place for FWD & SPD)

IP

1.56

m

Install beam pipe on ITS railsResponsibility AT/VAC5 m long temporary support

needed on RB24 sideAlign beam pipe with rails

Slide beam pipe to absorberResponsibility AT/VACSurvey beam pipeConnect to absorber flangeBakeout and leak test (9 days) Refill with clean gas (N2)

Install outer ITS (=SDD+SSD) on railsCrane lowers ITS underground; align it to the rails (and/or external references),

Installation step 2. (a) (13 days)

Installation Review

March ‘03


Section 1

Beam Pipe

Support Structure

Section 3

Section 2

Section 4

Installation step 2. (b)

beam pipe linked to front absorber flange

adjustment tools to compensate sagging

The 4 sections of the support and bakeout shell supports and protects the beam pipe Central Section (Be) during the different installation steps

CMS experiment bakeout shell

Beam pipe

Section 1

Section 2

Section 4

Section 3

Beam pipe support

RF valve support

RF valve

Installation Review

March ‘03


Installation step 2. (c)Section 1

Section 2

Beam pipe

Beam pipe support

RF valve support

RF valve

Section 1

Section 2

Section 3

Section 4

Installation Review

March ‘03


Section 1

Installation step 3. (4 days)

Install V0 and T0 on RB26 Responsibility ALICE Each half V0 and half T0 are pre-

assembled together to save time during installation in pit.

V0 and T0 are fixed to the absorber

T0

V0

V0

T0

beam pipe bellows

T0 V0

Remove section 1 of beam pipe support Responsibility AT/VAC 45

º45

º

Cabling and test of V0 & T0

TPC/C4

SDD

SSD

Installation Review

March ‘03


Install temporary support It’s made of 2 halves; the upper

one is brought into position through rotation about axis “A” (to avoid risks for the beam pipe)

It has 4 flaps (“B”) at ±45º for fixation of beam-pipe and SPD supports prior to transfer their load to ITS

Align (survey) temporary support to the beam pipe

A

BInstallation step 4.

(3 days)

A

Installation Review

March ‘03

L.Simonetti – INFN Torino11Dummy 3rd cone

FMD – Si1

Installation step 5. (4 days)Fix support for beam pipe and

FMD (“3rd cone”) to temporary support The 3rd cone is made of two

halves containing the FMDs lifting tools allow for slow and

accurate positioning of 3rd cone Spoke structure reduces

material in front of FMDs and allows for visual inspection

Test FMDs FMDs have pigtails up to the

outer edge of the 3rd cone

Lifting tool

Remove 3rd cone lifting tools

Installation Review

March ‘03



Lifting tool

First Beam Pipe Support

Mount and adjust monitoring system of bellow movements Responsibility ALICE Non-touching capacitive

sensors are proposed

Bellows

Flanges

Detectors

Beam Pipe Support Adjustment

Third cone FA

Mount and adjust 1st support to the beam pipe Responsibility AT/VAC Survey

Installation Review

March ‘03


Section 2

Install the two SPD half-cylinders (Resp. ALICE) Two half cylinder/cones Specific installation tools

are being designed SPD services (cables,

fibres & capillaries) are pre-assembled in the cones

SPD services

Remove section 2 of beam pipe support (Resp. AT/VAC)


Fix the two, coupled, SPD half-cylinders to temp. support, above the 3rd cone, using a 2nd series of bolts & precision plugs

SPD fixed in cantilever mode to temp. support, SPD pigtails on RB24 side unconnected

3rd cone

SPD cone

Temporary support

Installation Review

March ‘03


Slide outer ITS onto SPDs (Responsibility ALICE) Transfer load of SPD and 3rd cone (beam pipe) from temporary support to ITS


Mount and adjust 2nd support to the beam pipe (resp. AT/VAC) Survey

Outer ITS, SPD & beam pipe are now an integral unit

TPC/C4

Temp.Support

SPD

SDD

SSD

Connect SDD and SSD on RB26 sideFinal fixation of SPD pigtails on RB24

side to ITS cone

Installation Review

March ‘03


The dedicated support structure is being designed, to fix FMD-Si2 to ITS The temporary support used on the RB24 side can also be used on the RB26

one for the installation of FMD-Si2

FMD detecotorFMD detector


Remove section 3 of beam pipe support (Resp. AT/VAC)

Section 3

Install FMD-Si2 Also FMD-Si2 detector rings are made of top and bottom halves

FMD-Si2

Installation Review

March ‘03



Install chariot for ITS services on RB24 Assemble the two half-

cylinders of composite material, having the ITS services on them

CS beam pipe with its chariot

Patch panels for ITS and FMD-Si2

TPC Service Supp. Wheels

ITS service chariotCS beam pipe with its chariot


TPC Service Supp. Wheel

ITS-TPC links devices

Slide them through TPC while monitoring beam pipe bellows on RB24

connect ITS & FMD-Si2 services at the patch panels

Installation Review

March ‘03


Installation step 11. (0.5 days)

Lift ITS by 3 mm to prepare for TPC sliding to interaction point (using a contact sensor and viewed by camera during operation)

Remote control tools to operate the ITS lift tools on both rails in parallel

ITSITS lift tool

ITS

ITS –TPC link device

TPC

Installation Review

March ‘03



CS beam pipe with its chariot


TPC Service Supp. Wheels

ITS service chariot

Slide TPC over ITS to interaction point Simulation of the TPC sliding showed

that vertical displacements are expected during this operation

Constant monitoring of the TPC absolute alignment and of the displacement of the beam pipe bellows on RB26 is required

Lifting tools are foreseen in the TPC to re-align TPC position to the nominal beam axis (see T.Meyer talk)

Removal of C4 link point between TPC and ITS rails when TPC reaches the Front Abs.

TPC/C4removed

TPC/C1TPC/C2TPC/C3

TPC/C4

ITS

TPC SSW

TPC ServiceSupport Weels

Installation Review

March ‘03


Installation step 13. (0.5 days)

Link ITS to TPC, so that TPC, ITS and CS beam pipe become an integral unit ITS is appended to TPC from its top; end-position of TPC sliding is detected by

appropriate electrical contacts ITS is lowered to the nominal position, i.e. one mm higher than the rails a plug at ITS bottom on RB24 side blocks ITS angular movements The link-devices allow for galvanic insulation of TPC from ITS

TPC

ITS

ITS –TPC link device connected on both TPC sides (top)

Installation Review

March ‘03



Bend ITS+FWD services and temporarily fix them to TPC service wheel ; remove terminal half-cylinders of service chariot (not shown) (Responsibility ALICE)

ITS servicechariot

TPC service wheel Remove section 4 of beam pipe

support and bakeout shell Mount and adjust 3rd support to

the beam pipe (Resp. AT/VAC) The support is connected to TPC Survey needed

Remove beam pipe chariot

Installation Review

March ‘03


Installation step 15. (5 days)Lift ITS-service chariot from the ITS rails

Mount conical sections to the ITS-service chariot (to preserve PMD acceptance) and chariot lifting tools

Hang ITS-service chariot to the TPC Service Support Wheels (SSW) on RB24

Conical sections

Chariot lifting tools

Remove ITS rails

Free ITS rails on front abs.by opening the remotely

controllable jaws

Installation Review

March ‘03


Summary of installation schedule

In the present planning the ITS – FWD – beam-pipe installation starts on middle June 2006

Assuming one shift per day, and without parallelization of tasks, the present estimate indicates a overall duration of 15 weeks.

Installation Review

March ‘03


Commissioning

All the concerned detectors and sub-systems (power, cooling, monitoring) will be thoroughly tested during the construction phase After the construction, the ITS barrels will be operated for final

debugging for about 4-8 weeks ITS and FWD commissioning (sub-systems included) has to be

performed during the installation: no time to re-open the detectors for reparations. After FWD installation and after ITS installation, tests with pulser

will be performed The ITS will be tested after the RB24 service chariot has been slid

to the final position (turn-on requires the cooling system to be functional)

Some monitoring of individual subdetectors is possible during installation (e.g. during nights), to ensure regular operation, without increasing the already long installation time. The appropriate temporary connections are currently under study

Any intervention to the FEE and the detectors is excluded

Installation Review

March ‘03


Survey and alignment

Survey of the working position See installation sequence before For all the sub-detectors: whenever the positioning capability of the

installation tools cannot guarantee the knowledge of the detector positions within ± 0.1 mm (Still to be defined )

Monitoring during the installation and operation Monitor of the beam pipe bellows on the RB26 side : continuously since

the installation of the 1st CS beam pipe support Monitor of the clearance SPD – beam-pipe : continuously since the

installation of the half-cylinders Monitor of the TPC absolute position: continuously since its sliding-in to

the interaction point Monitor of the ITS-TPC relative position: continuously since the arrival of

the TPC on the interaction point

Installation Review

March ‘03


Maintenance and access in the future

Accessibility of the various elements All the considered detectors can be accessed only after the removal of the

TPC (operation which implies several weeks) Time estimates for various exchanges/repair of critical elements

Careful intervention ITS / Forward detectors during shutdown 3 months would allow sufficient time for major repair operation

Access for bake-out - Alice detector fully operational 5 to 6 weeks (depends on the extent of commissioning)

Fast access for bake-out - Alice detector not operational 2 to 3 weeks possibly even faster

Fault tolerance ITS sub-detectors are rather highly segmented for both the power supplies and

the cooling system (each segment corresponds to few% of the acceptance), so in case of fault leading to shutdown of one element the loss in acceptance would be tolerable

FMDs, particularly the FMD-Si1, will embody as much redundancy as possible. All the sub-detectors have spare parts ranging from 10% to 20% The monitoring tools installed within the TPC body will have redundancy.

Installation Review

March ‘03


Personnel and resources

Personnel from the ALICE Institutes will be present during the pre-installation mechanical test (about 13 weeks for installation and 8 weeks for removal, from 7/2004) for the movements of the sub-detectors, their connections (cabling, cooling), etc.

Additional personnel from the ALICE Institutes will be present during the installation (about 15 weeks from 6/2006) for the functional tests & commissioning.

Personnel from the ALICE DCS, DAQ and trigger groups is needed during the installation for the first setup of the detector DAQ/trigger branches and then on-call

Personnel for the external cooling systems (ST/CV) is needed for the first setup of the detector cooling control system and then on-call

Installation Review

March ‘03


CERN infrastructure use

Road Transport In principle ITS needs only one transport, at the start of installation, from

the Si-Lab in Meyrin (build.186) to SLX2 :on a vibration-free vehicle for the barrelOn standard CERN transportation trucks for the several racks (power

supply, cooling, etc.) The total weight of the ITS barrel is about 100 kg

Cranes usage and survey CERN personnel for the survey and the crane operation is needed on

the basis of a detailed schedule that has to be prepared; Present very preliminary estimates for the survey indicate a need for

20% of the time both during the pre-installation mechanical test (13 weeks from 7/2004) and during the installation (15 weeks from 6/2006).

Need of the crane should be limited to few days during the same period

installation review march ‘03 l.simonetti – infn torino 1 its - fwd - beam pipe installation ...

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