Tracker cooling plant refurbishment Project status Revised plan Financial impact

F.Raffaelli2 Tracker cooling plant activities Lines leak search from the distribution cabinet to the tracker. Fabrication of the distribution and control lines Implementation of the air purging system Insertion of additional sensors for better plant monitoring/operation Implementation of the remote refilling system Preparation for a further implementation, the draining and the disposal system. Activities list:

F.Raffaelli3 Leak rate test from cabinet to the Tracker draining campaign is on going a manifold with 6 sensors ready; Labview software prepared- tables & recording system in preparation

F.Raffaelli4 Reconstruction of the distribution and control lines A new distribution line was designed to improve the tightness, the cleanness and the maintenance. Robust Metallic sealing connection, welded flow regulation valves and an improvement on the existent isolation valves were adopted. Doing this operation we are removing all dirt present on the plane which is a potential danger for plugging the tracker cooling lines. The new lines can be dismounted and have a further modification if needed. A qualification control plan has been adopted to provide the high quality of all the produced components.

A new welded regulation valve and metallic sealing F. Raffaelli5 U Bellow valve VCR Joint Full inspection outside/ inside 30% of X-rays will be done all assembled lines are going to be leak tested before mounting Work is taking place at CERN and It is going to end in a month

New transition Stainless steel-Copper These transitions will replace the leaking joints New transitions A section of the joint are made for validating the soldering penetration.

E.Focardi7

shut-off valves They have been tested in vacuum in Pisa. We have a concern on the quality for a long term application. For this reason we tested in various conditions and we will try to improve them. Furthermore in the future we could remove them and eventually replace F. Raffaelli8

F.Raffaelli9 SOLYRO VALVE COMMENTS: Spring load is not enough to compress packing Seats has a spherical contact – Conical shape could be better IMPROVEMENT: Change packing with a energized polyurethane seal All this valves need to be cleaned

E.Focardi10 Manifold at the plant An inspection has been done after cabinet dismounting on the16 manifolds. Welding problems found, especially in the plant contaminated by the ‘Brine’. It has been decided to produce new manifolds. Design of the new manifold is ready and has been sent to companies for quotation. Production time will be ~4 weeks. Some examples of problems found:

F.Raffaelli11 New manifold We are going to receive the offer Monday 26 January Drain connection Air purging during filling

The manifold specification include a paragraph on the quality and qualification test F.Raffaelli 4 TECHNICAL REQUIREMENTS4 4.1General description4 4.2Manifold layout4 4.3Flanges5 4.4General requirements and procedures Materials Recommendations for machining Cleaning requirements Welding procedure Recommendations for storage, packing and transport8 5.INFORMATION AND DOCUMENTATION MANAGEMENT8 5.1Manufacturing drawings8 5.2Quality management8 5.3Contract follow up Inspections, test and quality control plan.9 6.TESTS9 6.1Pressure tests9 6.2Leak tests9 7.DELIVERY AND COMMISSIONING10 7.1Provisional delivery schedule10 7.2Acceptance and guarantee10 A fabrication and control plan is required and has to approved before the contract signature. A selection of adequate company has been addressed

Cabinets Pisa designer will work for the integration of the cabinets- Insulation & structural part can be separated, first the structural part Structural part design ready by the mid of January structural part implementation by the end of February

F.Raffaelli14 Air purging Air purging- Cern designer is working for the next 3 to 4 weeks for integration works Tank: the specification has been written by Andrea, the specification has been sent to VCS, DG technology, Cinel. To be sent to Deposito Coballes.- a frame for weight distribution has to be added Order out this week Production ~6 weeks The air purging implies a modification of manifolds of the return line. So we can revised also the inlet lines to the pump. All the plant is going to be re-designed to implement the new line, the air purge…

Air purge design F.Raffaelli15

Return manifold and pump inlet F.Raffaelli16 Traces of Lockite on joints

Additional monitoring sensors – As a significant part of the cooling system is located in the experimental cavern, unreachable during the operation, we would like to monitor the cooling plant components: pumps, motors, back pressure regulators etc. – The control and monitoring system should follow the ongoing modifications in the layout of SS1 and SS2. – We should have in mind a possibility to measure the cooling system’s performance. This is important since the current design of the system has diverted strongly from the initial phase.

Simplified scheme of the UXC cooling plant To the tracker Tank Pump Scales ΔPΔP P,T T T P Supply Return Brine Pump Level ΔPΔP P,T T T P Supply Brine LS1 LS2 ΔP,T T P SS1, as in 2008 SS1, with additional sensors

Time schedule a resources needed Time schedule Sensor purchasing: –Samples for test 26 Jan - 15 Feb –Final…. - 1 March Cabling – 26 Jan - 20 Feb Sensor installation and commissioning 15 Feb - 10 March Integration with PLC10 March – 23 March Additional Resources needed Cabling team – 4 cables x 4 days Electronics technician – 1 x 4weeks

Summary of the on going activities Leak search New line production and test Manifolds procurements Air purging procurements Drawing of the integration of the new distribution lines, manifolds, return line and connecting line to the air purge. Cleaning of the on/off valve improving the sealing. procurement and installation of additional monitoring sensors. Improving the filtering system E.Focardi20

General schedule overview

Resources Design phase (Engineers and Designers) by February –2 Eng. from Cern –2 Eng. Equivalent from INFN-Pisa –1 Eng. from USCB –1 Eng. from Fermilab –1 Physicist INFN –2 Designers from INFN Pisa and Cern. Implementation phase (field coordinators and technicians) from January through May. –External contractor (Cosmi or Zec). –3 Techs equivalent from Cern. –2 techs equivalent from Fermilab. –1 Tech from USCB –4 Techs equivalent from INFN –4 Eng/Phys equivalent as field coordinators Cost Current estimate is ~600 KCHF.

Financial impact (INFN) Agreement to contribute with manpower. INFN resources needed (ME ‘09 ?): 1 designer 1 mu 3 engineers 7 mu 1 physicist 5 mu 3 techniciens 15 mu ---> ~115 K€ Details on INFN sections sharing: Pisa 72 K€ Perugia 16 K€ Padova 16 K€ Firenze 4 K€ Torino 8 K €