The Large Hadron Collider (LHC) is presently under installation at CERN, Geneva. The approximately 4000 superconducting corrector magnets required by the machine are powered through copper-stabilized Nb-Ti busbars. To interconnect the magnets along the machine, about 50 000 joints between superconducting cables rated at 600 A have to be performed in-situ during the interconnection activities. An ultrasonic welding technique has been developed and optimised by CERN which led to the development of a dedicated machine which was qualified during the assembly of the STRING II, a 110-m chain of cryomagnets assembled as a prototype of the LHC. The realization of the "series" interconnections together with the procurement of the tooling based on functional specifications have been contracted to a consortium of firms. Qualification tests and acceptance criteria in terms of electrical contact resistance, mechanical resistance, reliability and reproducibility have been defined by CERN. This paper presents the tests and some results of the qualification process relevant to the industrialized tooling provided by the contractor. Results of pre-series junctions done in the LHC tunnel are presented together with the perspective for the continuation of the work.
The main components of the LHC, the next world-class facility in high-energy physics, are the twin-aperture highfield superconducting cryomagnets to be installed in the existing 26.7-km long tunnel. After installation and alignment, the cryomagnets have to be interconnected.
The numerous complex activities required to prepare the cryomagnets for the installation in String 2 are described. These include the configuration of the mechanical interfaces, the conditioning of the beam tubes, the installation of beam screens and the instrumentation as well as the final checks. The preparation of the cryomagnets for String 2 has been a dress rehearsal for the preparation that the cryomagnets will undergo before their installation in the tunnel. After a description of the interconnection procedures of the components for String 2, the tests carried-out to release the String for operation are described. A brief account of the lessons learnt is also given.
Abstract-The final interconnections of the LHC superconducting magnets in the underground tunnel are performed by a contractor on a result-oriented basis. A consortium of firms was awarded the contract after competitive tendering based on a technical and commercial specification.The implementation of the specific technologies and tooling developed and qualified by CERN has required an important effort to transfer the know-how and implement the follow-up of the contractor.This paper summarizes the start-up phase and the difficulties encountered. The organization and management tools put in place during the ramping-up phase are presented. In addition to contractual adaptations of the workforce, several configuration changes to the workflows were necessary to reach production rates compatible with the overall schedule and with the different constraints: availability of magnets, co-activities with magnets transport and alignment, handling of non-conformities, etc. Also the QA procedures underwent many changes to reach the high level of quality mandatory to ensure the LHC performance.The specificities of this worksite are underlined and first figures of merit of the learning process are presented.
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