Bilan du contrat Renco Piping contract F467 TS workshop Archamps Mai 25 th 2005 R. Principe TSCV

II TS Workshop ArchampsR. Principe2 Contract F467 Supply and installation of stainless steel pipelines for LHC, A wide variety of pipelines installed AISI 304L, DN200 to DN65 1. Cooling Water circuits 2. Compressed Air circuits 3. Demineralised Water ditribution 4. Helium Recovery line 5. Helium Quench line 6. Ring line

II TS Workshop ArchampsR. Principe3 F467 scope Engineering: installation dwgs based on the CERN basic engineering Supply and installation of all new stainless steel pipes for a total length of about 200 Km, including PA5 and 7 Ancillary equipment including supports, joints, valves, drains, air vents …

II TS Workshop ArchampsR. Principe4 Piping installation The welding of pipes is mainly performed by using a automatic orbital TIG welding system However manual welding is also used in the numerous chambers along the tunnel

II TS Workshop ArchampsR. Principe5 Welding class Construction category (Ex, A, B, C) B Welding coefficient (1, 0.85) 0.85 Welding quality criteria B ref. CODETI Company requests for a class reduction Welding time vs welding quality New chamfrain profile Calibration of the machines (surface and underground)

II TS Workshop ArchampsR. Principe6 TIG orbital welding FRONIUS PC – FPP 2004, Generator TIG 2600, Kit KD 4001 – Austria POLYSOUDE – welding head 6" MU 195 – France Orbital welding is a particularly interesting option where high replicability of the welding results is required. This system is essential to obtain exactly reproducible quality and the lowest possible error rates. Production times are subject to very tight limits. This technique allows consistent productivity improvements and a high degree of flexibility and modularity for this particular task. TIG orbital welding is based on the tungsten inert gas process (TIG)

II TS Workshop ArchampsR. Principe7 Complexity of the process The following factors have a decisive influence on the welding results and reproducibility Careful joint preparation by chamfering pipes Inert gas shielding (Argon) to avoid oxidation Correct coupling of the pipes to be welded Development of specific welding programs for every type of pipe (and material) to be welded

II TS Workshop ArchampsR. Principe8 Human factor It is not a completely automatic process Operator intervention is essential to obtain perfect welds: Quality of the resulting weld depends widely on the preparation of the joints (coupling, welding head clamping, etc.) Pipes are not calibrated due to their sizes: the operator adjusts parameters during the welding process So the operators are highly qualified personnel Follow up ”ad personam”

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II TS Workshop ArchampsR. Principe12 Quality control – before installation In order to fulfill the requirements, many iterations for welding procedures/programs Close collaboration with the sub-contractors - Fronius, Polysoude – several weeks at CERN Destructive tests have been carried out on several samples to evaluate the quality achieved of the welding process – macrographies based tests

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II TS Workshop ArchampsR. Principe16 Quality control – production phase During installation phases, the Quality Control on the welds is carried out using Non Destructive tests - NDT Visual inspections Radiographies X-Rays 100% “inspectable” welds Some 10% checked by CERN Helium leak test for He Pipes

II TS Workshop ArchampsR. Principe17 QAP follow up “in situ”

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II TS Workshop ArchampsR. Principe22 Welding defects Ref. to ISO handbook 19 Defect category 515 Root porosity (Rochage) Defect category 500 to 513 Cavities: undercuts and incomplete fills (during the qualification phase, weld dimensional criteria)

II TS Workshop ArchampsR. Principe23 Installed ss-pipes per sector

II TS Workshop ArchampsR. Principe24 Welds per sector

II TS Workshop ArchampsR. Principe25 Repairs per sectors

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II TS Workshop ArchampsR. Principe27 Conclusion Contract closed in April 2004 All sectors accepted Non-conformities solved Requests for modification require a contractual frame Difficult start-up CERN 3D models vs. Renco detailed engineering Welders to be certified Discussion around the welding class Storage of the pipes Welding procedure High pressure Installed 170 km 304L pipes in this contract Welding process: 26’000 done, 82 repaired First sector 0.98% repairs Average 0.31% repairs Last two sectors no repairs