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The assembly of the approximately 1700 LHC main ring cryostats at CERN involved extensive welding of cryogenic lines and vacuum vessels. More than 6 km of welding requiring leak tightness to a rate better than 1.10-9Â mbar.l.s-1 on stainless steel and aluminium piping and envelopes was made, essentially by manual welding but also making use of orbital welding machines. In order to fulfil the safety regulations related to pressure vessels and to comply with the leak-tightness requirements of the vacuum systems of the machine, welds were executed according to high qualification standards and following a severe quality assurance plan. Leak detection by He mass spectrometry was extensively used. Neon leak detection was used successfully to locate leaks in the presence of helium backgrounds. This paper presents the quality assurance strategy adopted for welds and leak detection. It presents the statistics of non-conformities on welds and leaks detected throughout the entire production and the advances in the use of alternative leak detection methods in an industrial environment.

The series production of the LHC SSS has started in the beginning of 2004 and is foreseen to last until end 2006. The production consists in the assembly of 474 cold masses housing superconducting quadrupoles and corrector magnets within their cryostats. 87 cold mass variants, resulting from various combinations of main quadrupole and corrector magnets, have to be assembled in 55 cryostat types, depending on the specific cryogenic and electrical powering schemes required by the collider topology. The assembly activity features the execution of more than 5 km of leak-tight welding of stainless steel and aluminium cryogenic lines, designed for 20-bar pressure, according to high qualification standards and undergoing severe QA inspections. Some 2500 leak detection tests, using He mass spectrometry, are required to check the tightness of the cryogenic circuits. Extensive electrical control work, to check the integrity of the magnet instrumentation and electrical circuits throughout the assembly of the SSS, is also carried out. This paper presents the current status of production, the assembly facilities at CERN, work organisation and Quality Assurance issues, and the acquired assembly experience after one and a half years of production.

The recent commissioning and operation of the LHC String 2 have given a first experimental validation of the global thermal performance of the LHC lattice cryostat at nominal cryogenic conditions. The cryostat designed to minimize the heat inleak from ambient temperature, houses under vacuum and thermally protects the cold mass, which contains the LHC twin-aperture superconducting magnets operating at 1.9 K in superfluid helium. Mechanical components linking the cold mass to the vacuum vessel, such as support posts and insulation vacuum barriers are designed with efficient thermalisations for heat interception to minimise heat conduction. Heat inleak by radiation is reduced by employing multilayer insulation (MLI) wrapped around the cold mass and around an aluminium thermal shield cooled to about 60 K. Measurements of the total helium vaporization rate in String 2 gives, after substraction of supplementary heat loads and end effects, an estimate of the total thermal load to a standard LHC cell (107 m) including two Short Straight Sections and six dipole cryomagnets. Temperature sensors installed at critical locations provide a temperature mapping which allows validation of the calculated and estimated thermal performance of the cryostat components, including efficiency of the heat interceptions.