D. Delikaris, TE-CRG, LSC 25th Meeting Page 2 October 18 th, 2013 LS1 Committee (LSC)- 25 th Meeting D. Delikaris, TE-CRG Cryogenics activities report

D. Delikaris, TE-CRG, LSC 25th Meeting Page 3 Agenda Update on Cryogenic Activities: Preventive Maintenance - Major overhauling Helium Cold Boxes repairs in LHC P2-P8-P6 cryoplants QRL compensator bellows (Headers C & D) DFBA splice consolidation DFBA gimbal bellows

D. Delikaris, TE-CRG, LSC 25th Meeting Page 4 Preventive maintenance C199 contract for Preventive & Corrective maintenance activities Investigation launched to understand the “baseline vs work orders vs work progress” issue: Work progress on schedule wrt to LS1 planning; shifted with respect to the original CRG baseline (non-adapted to real work progress tracking) Discrepancy between work progress & work orders (WO) completion: due to open WO that can only be closed at a later stage & dates Remaining actions: Work order line to be completed wrt expected milestones for closure A new version of the baseline will be defined

D. Delikaris, TE-CRG, LSC 25th Meeting Page 5 Major overhauling; Dashboards Helium screw compressors 3.3 kV electrical motors Everything on track Delayed delivery of Kaeser compressors caused by additional corrective maintenance task (rotors replacement)

D. Delikaris, TE-CRG, LSC 25th Meeting Page 6

D. Delikaris, TE-CRG, LSC 25th Meeting Page 7 Major overhauling (compressors & 3.3 kV motors) Reception from manufacturer and… …installation, coupling and alignment at LHC P6

D. Delikaris, TE-CRG, LSC 25th Meeting Page 8 P2 18 kW LHC cold box repair Leak repaired on medium pressure He circuit to insulation vacuum (heat exchanger) First tightness testing: done Reinstallation of MLI: underway Closing of the vacuum jacket: w Vacuum pumping: w 46 Final testing: w Matter removal for two stage welding Intermediate stage Final stage Excellent work from Fives Cryogenie (FR)

D. Delikaris, TE-CRG, LSC 25th Meeting Page 9 P8 18 kW LHC cold box repair Leak repaired on N2 circuit of to insulation vacuum (pre-cooling heat exchanger) First tightness testing: done Reinstallation of MLI: underway Closing of the vacuum jacket: w Vacuum pumping: w 46 Final test: w 47 Leak observed Matter removal Final welding

D. Delikaris, TE-CRG, LSC 25th Meeting Page 10 P6 18 kW LHC cold box repair - Leak to be repaired on SS/AL transition, He to insulation vacuum - Spare ordered (Japan), expected mid Nov. - Order done; repair to be done by Linde end of Nov. Aluminium to Stainless Steel transition DN400 HP LP MP

D. Delikaris, TE-CRG, LSC 25th Meeting Page 11 QRL Headers C & D compensator x-rays status

D. Delikaris, TE-CRG, LSC 25th Meeting Page 12 QRL Headers C & D compensator repair status Header D in the LS1 planning Additional information: - Header D in 14L2: external envelope was open, dedicated spare testing is underway - Header D: 4 additional spares available - Header E: 31/64 (LHC all sectors) compensators checked and OK (partially visible on line C x-ray) - Headers C & E new spares: 3 offers requested mid August, only one feedback from Witzenmann received, order will be sent next week with 12 weeks of delivery time for 30 DN100 and 15 DN80

D. Delikaris, TE-CRG, LSC 25th Meeting Page 13 DFBA 13 kA splices consolidation Schedule shift caused by: - Extra time for repair of non conformities (quality checks, geometrical) for DFBAN & DFBAO - Discovery of damaged bellows in DFBAO - Personnel illness (one) Forecast: - Disturbance due to disconnection (same team as splices) of DFBAK (for repairing the bellows) will add 1-2 weeks - Training of additional personnel (existing) for recovery

D. Delikaris, TE-CRG, LSC 25th Meeting Page 14 DFBA gimbal bellows Following the discovery of a damaged bellow in the DFBAO by using a double endoscope inspection technique, a global inspection of the bellows is being carried out: to be completed by end of the w 43 on all DFBAs Current status (4/32; 12.5 %): 2 DFBAs with upper bellows damaged (DFBAK collapsed & probably leaking, DFBAO damaged but not leaking) 2 DFBAs with lower gimbal damaged; not leaking (DFBAI & DFBAF) First inspection of DFBAO Double endoscope inspection of DFBAO upper bellows Lower bellows

D. Delikaris, TE-CRG, LSC 25th Meeting Page 15 DFBA gimbal bellows: repair strategy - Lower bellows: in-situ repair, 3 weeks each for DFBAI and DFBAF respectively (patching solution) - Upper bellow DFBAK: workshop repair, bellows replacement, learning form opening - Develop local internal solution for DFBAO by drilling the inner layer of the 2-layer bellow thus eliminating the helium accumulation issue and reinforce the mechanical resistance of the bellow by encapsulating it in an epoxy shell. Decision for DFBAO in 6 weeks. DFBAK closed 24/02/2014 DFBAO closed, if local repair, 17/01/2014 DFBAO closed, if workshop repair, 09/04/2014

D. Delikaris, TE-CRG, LSC 25th Meeting Page 16 Conclusions Preventive Maintenance - Major overhauling C199: Discrepancy on baseline/work progress/work orders clarified and to be closely followed; major overhauling of helium compressors and 3.3 kV electrical motors on schedule Helium Cold Boxes repairs in LHC P2-P8-P6 cryoplants Very good progress; P2-P8 completed; P6 on schedule QRL compensator bellows Damaged bellow on header D in the repair planning compliant to LS1; Header C bellows repair work ahead of schedule; spares procurement for all bellow’s type on going DFBA splice consolidation Despite additional resources work progress remains constantly shifted from the baseline (originally expected to recover by end of 2013) due to geometrical non-conformities, personnel illness and the discovery of a 4 th damaged gimbal interfering with teams load. Training of additional personnel scheduled DFBA gimbal bellows On going cross-check by double endoscopy of all DFBAs bellows; DFBAI, DFBAF: in-situ repair (patching) DFBAK: workshop repair (bellows replacement) DFBAO: development of dedicated local technical approach for in-situ repair prioritized; final decision in 6 weeks, if negative, workshop repair (bellows replacement)