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The use of pressurized bladders for stress control of superconducting magnets was firstly proposed at Lawrence Berkeley National Laboratory in the early 2000s. Since then, the so-called ‘bladders and keys’ procedure has become one of the reference techniques for the assembly of high-field accelerator magnets and demonstrators. Exploiting the advantages of this method is today of critical importance for Nb$_{3}$Sn-based accelerator magnets, whose production requires the preservation of tight stress targets in the superconducting coils to limit the effects of the strain sensitivity and brittleness of the conductor. The present manuscript reports on the results of an experimental campaign focused on the optimization of the ‘bladders and keys’ assembly process in the MQXFB quadrupoles. These 7.2 m long magnets shall be among the first Nb$_{3}$Sn cryomagnets to be installed in a particle accelerator as a part of the High Luminosity upgrade of the LHC. One of the main practical implications of the bladders technique, especially important when applied to long magnets like MQXFB, is that to insert the loading keys, the opening of a certain clearance in the support structure is required. The procedure used so far for MQXF magnets involved an overstress in the coils during bladder inflation. The work presented here shows that such an overshoot can be eliminated thanks to additional bladders properly positioned in the structure. This optimized method was validated in a short model magnet and in a full-length mechanical model, becoming the new baseline for the series production at CERN Furthermore, the results are supported by numerical predictions using finite element models. The use of pressurized bladders for stress control of superconducting magnets was firstly proposed at Lawrence Berkeley National Laboratory (LBNL) in the early 2000s. Since then, the so-called “bladders and keys” procedure has become one of the reference techniques for the assembly of high-feld accelerator magnets and demonstrators. Exploiting the advantages of this method is today of critical importance for Nb3Sn-based accelerator magnets, whose production requires the preservation of tight stress targets in the superconducting coils to limit the effects of the strain sensitivity and brittleness of the conductor. The present manuscript reports on the results of an experimental campaign focused on the optimization of the “bladders and keys” assembly process in the MQXFB quadrupoles. These 7.2 m long magnets shall be among the frst Nb3Sn cryomagnets to be installed in a particle accelerator as a part of the High Luminosity upgrade of the LHC. One of the main practical implications of the bladders technique, especially important when applied to long magnets like MQXFB, is that to insert the loading keys, the opening of a certain clearance in the support structure is required. The procedure used so far for MQXF magnets involved an overstress in the coils during bladder infation. The work presented here shows that such an overshoot can be eliminated thanks to additional bladders properly positioned in the structure. This optimized method was validated in a short model magnet and in a full-length mechanical model, becoming the new baseline for the series production at CERN. Furthermore, the results are supported by numerical predictions using Finite Element models. The use of pressurized bladders for stress control of superconducting magnets was firstly proposed at Lawrence Berkeley National Laboratory (LBNL) in the early 2000s. Since then, the so-called bladders and keys procedure has become one of the reference techniques for the assembly of high-field accelerator magnets and demonstrators. Exploiting the advantages of this method is today of critical importance for Nb3Sn-based accelerator magnets, whose production requires the preservation of tight stress targets in the superconducting coils to limit the effects of the strain sensitivity and brittleness of the conductor. The present manuscript reports on the results of an experimental campaign focused on the optimization of the bladders and keys assembly process in the MQXFB quadrupoles. These 7.2 m long magnets shall be among the first Nb3Sn cryomagnets to be installed in a particle accelerator as a part of the High Luminosity upgrade of the LHC. One of the main practical implications of the bladders technique, especially important when applied to long magnets like MQXFB, is that to insert the loading keys, the opening of a certain clearance in the support structure is required. The procedure used so far for MQXF magnets involved an overstress in the coils during bladder inflation. The work presented here shows that such an overshoot can be eliminated thanks to additional bladders properly positioned in the structure. This optimized method was validated in a short model magnet and in a full-length mechanical model, becoming the new baseline for the series production at CERN. Furthermore, the results are supported by numerical predictions using Finite Element models.

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 arcs of the Large Hadron Collider (LHC) will contain around 1700 main superconducting dipoles and quadrupoles. The long and heavy magnets are placed on fragile composite support posts inside a cryostat to reduce the heat in-leak to the magnets super fluid helium bath. The presence of such fragile components like the support posts, the beam position monitors and the corrector magnets make the cryo-magnets very difficult to handle and transport. Furthermore, keeping the geometry of the cryo-magnets unchanged (in the range of 0.1 mm) throughout the various transports and handling is essential for the good functioning of the future LHC. A detailed dynamic analysis was performed to determine the behavior of the cryo-magnets under all the handling and transport conditions and to choose the related optimum parameters. The results of finite element modal calculations as well as experimental modal analyses are presented and compared. The maximum accelerations admissible during transport with several types of vehicle were computed. The accelerations experienced by both types of cryo-magnets were measured during real transport with different vehicles. The dynamic deformation of the support posts in the cryo-dipole was also measured. The methodologies of these analyses and their results are reported as well as the resulting specification for the transport during the LHC installation.

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.