Series-produced Helium II Cryostats for the LHC Magnets: Technical Choices, Industrialisation, Costs

Assembled in 8 continuous segments of approximately 2.7 km length each, the He II cryostats for the 1232 cryodipoles and 474 Short Straight Sections (SSS housing the quadrupoles) must fulfil tight technical requirements. They have been produced by industry in large series according to cost-effective industrial production methods to keep expenditure within the financial constraints of the project and assembled under contract at CERN. The specific technical requirements of the generic systems of the cryostat (vacuum, cryogenic, electrical distribution, magnet alignment) are briefly recalled, as well as the basic design choices leading to the definition of their components (vacuum vessels, thermal shielding, supporting systems). Early in the design process emphasis was placed on the feasibility of manufacturing techniques adequate for large series production of components, optimal tooling for time-effective assembly methods, and reliable quality assurance systems. An analytical review of the costs of the cryostats from component procurement to final assembly, tests and interconnection in the machine is presented and compared with initial estimates, together with an appraisal of the results and lessons learned.