The Cryostat Integration into ILD

11

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

44

insertion of other vacinsertion of other vac--tank / CMCtank / CMC


55

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


66

HCAL prepared for insertion / CMSHCAL prepared for insertion / CMS


77

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


88

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


99

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


1010

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


1111

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


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


1515

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


1616

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°


1717

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


- 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


1919

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


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


2222

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


2323

• 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


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


2525

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


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


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

The Cryostat Integration into ILD

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