ILC TRANSPORT AND INSTALLATION

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ILC TRANSPORT AND INSTALLATION

Presentation to CES meeting 8 April 2009

• ILC Beam height explanation,• Transport implications of sloping access tunnels• Discussion of buggy-type solution• Info on CLIC module transport

Acknowledgements: • Jerry Leibfritz, FNAL• Atsushi Enomoto, KEK• David Smekens, CERN• Caterina Bertone, CERN

Keith Kershaw, EN-HE CERN CES 08 April 2009

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Reason for the (relatively high ) height of the ILC cryomodules above the floor (1)

(860mm clearance underneath cryomodules)

Response from Jerry Leibfritz, FNAL (1)• This is what is used at DESY for FLASH and CMTS, and

also at the Fermilab ILCTA. • It is based on the large support girder that sits

underneath the first and last cryomodules of a string to counteract the large vacuum load and prevent movement of the cryomodule. The support stand sits on top of this girder.


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Picture of the first cryomodule on its green support girders at Fermilab.

( cryogenic components not installed )


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Beam tunnel and service tunnel


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Reason for the (relatively high) height of the ILC cryomodules above the floor (2)

Response from Jerry Leibfritz, FNAL (continued)• The cryogenic feedbox and endcaps are designed for this elevation and it

would have been too expensive for us at Fermilab to redesign this, so we used basically the same design as DESY.

• When we were initially laying out the ILC tunnel, we tried to maximize the use of space, so we set the elevation of the cryomodule to be in the widest part of the diameter of the tunnel, allowing us to move it as close to the wall as possible.

• For a machine as big as the ILC, these components could be redesigned, so the cryomodule sits lower, but it would require some engineering effort.

TRANSPORT NOTE: THE CURRENT BEAM POSITION IS HIGH ENOUGH TO ALLOW THE USE OF TRANSPORT VEHICLES WHICH INCLUDE THEIR OWN TRANSFER CAPABILITY; IT IS THEREFORE INTERESTING TO LEAVE IT WHERE IT IS


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LHC Buggies can move at 180 deg to transport direction


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DESY Dwarsloeper During Transfer (height 1m)


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Access ramps to tunnel

• CLIC• ILC Asian site


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CLIC longitudinal section


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CLIC access ramp tunnel summary

Figures based on CLIC Longitudinal section drawing data.

Access Point Number 11 5 3

upper height (m) 425 395 391

lower height (m) 358.7 350 350

delta h (m) 66.3 45 41

slope (%) 8 7 8

length (m) 829 643 513


11Keith Kershaw, EN-HE CERN CES 08 April 2009

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Transport implications of access ramps instead of shafts

Need to consider special vehicles (e.g. cryo-modules) and standard vehicles (e.g. services).

Effect of slope on vehicle design:• Need more traction force (more driven wheels)• Need more braking force (more braked wheels)• Cooling of motors (for long slopes)• Cooling of brakes / motors for braking→Bigger vehicle (integration)


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Some notes on slope effects

Standard electric vehicles • Typically 1.5-2% slope for continuous use at full rated

loadwith increased slope the load capacity or the use factor reduces. (see performance chart)

Encyclopedie de la Manutention• “rampe ≥ 7% = problème délicate” (this is with

unbraked trailers)• Effect of 2% slope is to double traction force needed

compared with horizontal surface.


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Example on effect of slope

• In the example a tractor with a nominal towing capacity of 20 tonnes can be used on a 10% slope to tow a 6 tonne trailer a maximum of 1600m in one hour.


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Other transport/slope experience at CERN

Buggies for LHC warm magnet installation:• Designed for max slope 8%.• During testing on 7% slope (several passes)

overheated after approx 1hour.Special purpose fork lift:• Customized for 14% slope (needed continuous

forced ventilation for brakes and motors)• Difficult to find supplier willing to do this.


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Slope general comments

at this stage:• 1.5 - 2% slope means can use standard vehicles (lowest cost

most reliable solution)• Up to 7 or 8% slope achievable by reducing standard vehicle

capacity to approx one third of nominal (space issues?).• Any steeper slopes will mean that it becomes more difficult

to use standard equipment –this will have cost and reliability implications.

• In any case equipment for installing cryomodules will be specially designed and built - but what about other equipment?


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Discussion - Buggies• The 860mm clearance below cryomodules allows the use of a combined

transport and transfer vehicle such as the LHC buggies.• The LHC buggies were designed for slope of 8% but did overheat after

intensive use on slopes• The transfer using buggies is carried out by rotating the wheels through 90

degrees . The space between ends of LHC warm magnets when being installed is approx 7cm – longitudinal alignment relied on the operators’ skill and care.

• The space between the ends of ILC cryomodules is approx 2cm – this would lead to risk of damage using buggy –type solution relying on operator skill for large numbers (1600) modules unless some additional precise alignment is provided.

• The LHC buggies were used for transporting warm magnets – less delicate than cryomodules.


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Buggy concept adaptation for ILC including access ramps

• The LHC buggies are 560mm high: for ILC the 860mm clearance underneath cryomodules will allow incorporation of cradles, load suspension, additional cooling and precise positioning tables to allow accurate longitudinal alignment during lateral transfer onto jacks.

• Buggy width closer to cryomodule width than outline vehicle shown in ILC cross section (slide 4)


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Next steps

• Next step for CLIC at this stage was small amount of designer work to look into dimensions of vehicle integrated in tunnel and then consider transfer process, as well as vehicle entry into main tunnel .


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CLIC transport

Slides from CLIC workshop in Oct 2008


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Transport envelope in cyan – 1125 x 1150 x 2100Lifting points according to the worst case, i.e. on top of the transport envelope.Intergirder support acceptable assumption for the moment.

R. Nousiainen 04092008Keith Kershaw, EN-HE CERN CES 08 April 2009

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3 cable trays 520mm

2 CV pipes 600mm

2 CV pipes 250mm

Drive beam

Drive beam

Main beam

Main beam

Safe passage

Transport train

Turnaround loop

RIGHT VIEWTYPICAL CROSS SECTION CLIC TUNNEL

Monorail


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3 cable trays 520mm

2 CV pipes 600mm

2 CV pipes 250mm

Drive beam

Drive beam

Main beam

Main beam

Safe passage

Transport train

Turnaround loop


Monorail


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3 cable trays 520mm

2 CV pipes 600mm

2 CV pipes 250mm

Drive beam

Drive beam

Main beam

Main beam

Safe passage

Transport train

Turnaround loop


Monorail


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3 cable trays 520mm

2 CV pipes 600mm

2 CV pipes 250mm

Drive beam

Drive beam

Main beam

Main beam

Safe passage

Transport train

Turnaround loop


Monorail


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3 cable trays 520mm

2 CV pipes 600mm

2 CV pipes 250mm

Drive beam

Drive beam

Main beam

Main beam

Safe passage

Transport train

Turnaround loop


Monorail


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Shaft

Jonction chamberwith shielding

Loading area

Maintenance area

Services area

10t Crane

Based on Civil Engineering drawings prepared in 2007

Proposal for module lowering and tunnel access


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Asian site


ILC TRANSPORT AND INSTALLATION

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