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Published byAmbrose Gordon Modified over 8 years ago
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Jean-Philippe Tock (TE-MSC) On behalf of the SMACC project
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Activities since last LSC (14/03/2014) Arc splices installation By Activities By sectors SIT DFBA Dashboards Specials Update on overheated splices Cryomagnets removed during LS1 Activities for the next 2 weeks Conclusions
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JPh Tock 4/38 Sector 56 : Final leak test and reconnection of DFBAK Sector 67 : Reclose insulation vacuum and start final leak tests Sector 78 Work on NC Reconnection of DFBAO-SHM Sector 81 (Priority) Complete insulation vacuum leak test Sector 12 (Priority) Reclose last ICs Progress on insulation vacuum leak test Sector 23 Complete the installation of electrical insulation Complete M line rewelding (but NCs) Progress on M-lines leak testing Start reclosure of ICs Sector 34 Work on overheated splices Complete consolidation of Q diodes Sector 45 Progress on installation of shunts Progress on electrical insulation SMACC Main activities for the last 2 weeks Completed All M-lines reweded, > 90 % ICs are reclosed > 90% M lines leak tested ≈ 60% completed DFBAK/Q7 Insulation to be installed 12/14 vac subsectors leak tested > 97% is finally LT Completed From last LSC (14.03.2014) 17thCC/DFBA: Shunts resoldered, spool pieces busbars ready for reconnection // Last subsector to be leak tested >98% rewelded > 40% reclosed Started >98 % of the shunts are installed 3 ICs reopened to observe large realignement (> 3 mm) 3 out of 4 repaired, 4 th is started
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JPh Tock 5/38 SEQUENCE AND STATUS OK to open Open ICs Install DN200 Open M sleeves ElQC (old splices) Undo / Redo splicesElQC (new splices) Machine Cu ElQC after Cu mach. > 7.95 sectors Install shunts ≈ 7.95 sectors ElQC after shunt ≈ 7.95 sectors Insulate splices ≈ 7.5 sectors Weld M ≈ 6.5 sectors Leak test M ≈ 6 sectors Close IC > 5 sectors Final LT ≈ 4 sectors Consolidate Q diodes > 7 sectors Cancelled Completed Non-conformities (Before P Test) Non-conformities (After P Test) 1 completed ≈ 4.5 sec-eq Almost completed in 1 st sector (67) Completed
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JPh Tock 6/38 SMACC Progress report by activity Cu machining: Completed except NC and difficult cases (#5 remaining) Courtesy MDumas
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JPh Tock 7/38 SMACC Progress report by activity Shunts are installed in 1688/1695 ICs Saturation effect is seen Completed in 6 sectors Only 7 ICs remains in the whole LHC, mainly linked to overheated cables Courtesy H Prin
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JPh Tock 8/38 SMACC Progress report by activity Insulation box: Installed in ≈ 7.5 sectors equivalent Courtesy H Prin / G Maury On the baseline > 3 weeks buffer wrt welding Only 7 ICs left in 7 first sectors (<1 %) Issue with tooling solved (4 weeks sliding average) *Estimate for W13
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JPh Tock 9/38 SMACC Progress report by activity Consolidation of Q Diodes: in > 7 sectors equivalent Detailed schedule worked out Will not interfere with welding activities All components are at CERN and successfully tested Courtesy L Grand-Clement,
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JPh Tock 10/38 SMACC Progress report by activity M Welding : Done in ≈ 6.5 sec-eq: See next presentation by S Atieh (EN-MME)
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JPh Tock 11/38 SMACC Progress report by activity Excluding S45, all remaining activities up to M welding fit on ONE page
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JPh Tock 12/38 SMACC Progress report by activity M sleeves leak testing : Completed in ≈ 6 sec-eq Following the M lines rewelding, less regular by nature (sectorization) ≈ 3 weeks behind schedule, tendency to reduce Under recovery as for the M welding Started in 7 th sector Courtesy P Cruikshank / L Mourier
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JPh Tock 13/38 SMACC Progress report by activity Reclosure of interconnections : > 5 sec equivalent are reclosed Baseline rate achieved despite openings for special interventions (cfr S67) Courtesy A Chrul / A Musso
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JPh Tock 14/38 SMACC Progress report by activity Final leak test: > 800 ICs validated, ≈ 4 sec equivalent 3 weeks to have results after repumping S56: only DFBAK subsector remains S67: fully validated but subsectors to be revalidated after interventions on NC S78: 12 subsectors validated S81: Only 6 ICs to be validated S12: 1 subsector validated, 11 subsectors under test S23 :1 subsector under leak test About 2 weeks behind schedule Some issues (See later)
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JPh Tock 15/38 SMACC Progress report by activity W bellows closure: detected leaks (1/3) “Small” leaks in sector 8-1 (between 10E-5, 10E-6 mbar.l/s) Courtesy Andrea Musso – Anna Chrul – Paul Cruikshank Team / TE-VSC Sector Small leaks 5-60 leak 6-70 leak 7-81 leak 8-16 leaks During the leak test of sector 8-1, the detected small leaks at W-bellows level increased wrt previous sectors The analysis: Two leaking bellows (A7L1) were opened and inspected during a joint visit performed by TE-VSC (W. Maan) and TE-MSC (A. Musso). It was observed that: The joint was correctly in place The flange surfaces and all interfaces were clean The o-ring was correctly greased The clamps were correctly screwed In one case there was a deep scratch on the flange surface (QQBI.9L1) ……BUT….. The x-section of the O-ring was flattened around the circumference This was observed on both interconnections (2 x 3 o-rings) Dia 7 chord has deformed dimensions of ~6 mm x ~8 mm (Groove 5 mm)
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JPh Tock 16/38 SMACC Progress report by activity W bellows closure: detected leaks (2/3) “Small” leaks in sector 8-1 (between 10E-5, 10E-6 mbar.l/s) Courtesy Andrea Musso – Anna Chrul – Paul Cruikshank Team / TE-VSC The brainstorming: Further analysis performed by TE-VSC experts pointed out that: After opening of the interconnection during LS1, some W O-rings do not return to their original shape (permanent set). 3 W o-ring configurations – series > 5000, in-situ vulcanised ~ 20, glued ~ 10 For moment, no correlation bewteen small leaks and vulcanised or glued o-rings. Causes: Variations in o-ring material batches? Radiation? Other? The action: From now on, the team in charge of the closure will: Perform a deep inspection of the O-rings before to grease the joint. If flattening is observed, measure the deformed o-ring (VSC will define method). Open an NC to document the info – to discuss Use the spare O-ring(s) Call VSC expert if something unusual is detected.
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JPh Tock 17/38 SMACC Progress report by activity W bellows closure: detected leaks (3/3) “Big” leaks in sector 1-2 Courtesy Andrea Musso – Anna Chrul – Paul Cruikshank Team / TE-VSC The problem: During the leak test of sector 1-2 the VSC team pointed out O-rings squeezed by the W bellows and the vacuum vessel flange. The analysis: The closure team did not apply correctly the procedure, that indicates to perform a visual inspection of the entire circumference during positioning of W and ring, installation of clamps and nuts, and tightening. The solution: A meeting with the team leaders was held at the presence of the Project leader in order to point out the problem and to recall the procedure. The mistake was correctly identified and is closely followed (audits, check list…)
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JPh Tock 18/38 SMACC Progress report by activity Status of cryostat leaks (1/2) Courtesy V. Parma with inputs from VSC: P.Cruikshank, J.P.Espinos, A.Grimaud, L.Mourier, R.Wawrowski, W.Maan He leak (He to insulation vacuum): – SSS 653 (Sect.1-2). On Dipole Current Feed-through (DCF), Q8L2 (NC 1283585) 4 10-7 mbar/l/s. Leak was seen at installation 2007 & after 2 thermal cycles is stable. Actions underway (varnish + monitoring after pressure test). Prepare for replacement in-situ (if strictly necessary). Air leaks (air to insulation vacuum): – Dipole vacuum vessels. At internal supports interfaces (detected at reinforcement cradles locations). 4 units with leaks (1 known prior to LS1): 3 units: ~ 10-6mbar.l/s to 10-4 mbar.l/s (NC 1286359, 838450, 1346158) in sect.7-8, and 3-4. Action proposal VSC: “use-as-is”. 1 unit ~ 10-2 mbar/l/s (NC 1286355 ) in sect.5-6. Large leak. Action proposal VSC: repair, now under study by MSC – Leaks in SSS/QRL jumper envelope: Q7L2, Q29R2, Q21L3, Q21R3, Q33R7 5 cases, all existing before LS1. All cases treated, actions done or underway : Q7L2, NC 1286397 Q29R2, NC 1295369 Q21L3, NC 1295366 Q21R3, NC 1186284 Q33R7, NC 1286364 All leaks being treated by VSC (P.Cruikshank and his team) and MSC (V.Parma and SIT team)
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JPh Tock 19/38 SMACC Progress report by activity Status of cryostat leaks (2/2) Courtesy V. Parma with inputs from VSC: P.Cruikshank, J.P.Espinos, A.Grimaud, L.Mourier, R.Wawrowski, W.Maan Leak on dipole vessel B27L6, (NC 1286355) Leak on DCF in SSS 653, Q8L2 (NC 1283585) Leak detection zone Leak
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JPh Tock 20/38 SMACC Sector 67 Magnets realigned in DSR6 (> 3mm) On-going: Reclosure and final leak test of insulationvacuum Then: ElQA@warm before cooldown planned on 5.05.2014 SMACC Sector 81 On-line for a pressure test on 8.04.2014, known leaks to be treated after PT
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JPh Tock 21/38 SMACC Progress report by sector Main activities are : Leak test of M lines (14 ICs left) Closure of interconnections <20 ICs left Final leak test 12/14 subsectors released Main activities are : Leak test of M lines Reclosure of Ics
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JPh Tock 22/38 SMACC Progress report by sector Main activities are : Work on last overheated splices Rewelding of M lines Main activities are : Q diodes consolidation Installation of electrical insulation
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JPh Tock 23/38 SMACC Dashboards Shunting is nearing completion (7 ICs, < 0.5%) The installation of insulation boxes is ahead of the baseline Welding and M leak test rates are recovering the baseline schedule in parallel Reclosure: On baseline, nominal rate achieved Insulation vacuum leak test : RECOVERING Attention to put on facilitating the work of leak test teams
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Completed New
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JPh Tock 25/38 SMACC Progress report SIT SIT Team is reduced but can be remobilised very quickly Activities linked to NC, leaks and overheated splices Installation of the last RQF/D retrun started Courtesy N Bourcey, S Le Naour
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JPh Tock 26/38 SMACC DFBA Courtesy A Perin, E Vergara All 135 splices are consolidated Rewelding of cryogenics lines is on-going, followed by leak test and reclosure of insulation vacuum then final LT
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JPh Tock 27/38 SMACC Dashboards Baseline:87.3 % (82.7 %) Completed:87.1 % (84.2 %) Delay <1 (-3) days Baseline:78.6 % (76.9 %) Completed:79.5 % (74.9 %) Delay -3 (10) days On schedule Ahead of schedule Arc splices: Just on schedule SIT Final tests of some interventions completed succesfully DFBA: All splices consolidated Closure of cryogenics lines and corresponding validation Baseline:89.7 % (85.7 %) Completed:74.6 % (67.1 %) Delay 2.5 (3) months Recovering
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JPh Tock 28/38 SMACC Dashboards Progress: Baseline:86.6% (82.5 %) Completed:85.5% (82.1 %) Delay3 (2) days
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JPh Tock 29/38 SMACC Overheated splices From LSC of 07.02.2014 11 + 1 just started Courtesy C Scheuerlein, F Savary 2 1 6 Confirmed as is Within the present schedule, possible to repair 3 to 4 splices with new cables [Forecast is max 4]
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JPh Tock 30/38 Cryomagnets removed during LS1 (1/3) Courtesy A Musso, V Parma All magnets removed during LS1 are considered radioactive (until, and if, RP measurements can declassify them) Two type of magnets: SSS’ and dipoles => the approach is the same but the work to be performed is different 18 Cryomagnets removed : 3 SSSs 15 cryodipoles – 13 to be decryostated Completed so far : Q7 decryostated (Not installed during LS1) Beam screens removed from 10 cryodipoles (none radioactive) 2 cryodipoles decryostated (2353 – 2377) To do : 3 SSSs 11 cryodipoles Plan is to decryostat ≈ 2 cryomagnets per month (≈ end 2014 if no change in priority)
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JPh Tock 31/38 Cryomagnets removed during LS1 (2/3) Courtesy A Musso, V Parma Dipoles workflow for de-cryostating All the magnets are stored in a fenced RP supervised area (SMA18) Procedure settled to remove beam screens (TE-VSC / TE-MSC / DGS-RP) Beam screens were removed from the first two dipoles and measured: During removal Samples sent for spectrometer analysis Once the beam screens were declassified (i.e. considered no radioactive) the dipole was sent to SMI2 At SMI2, in a controlled area (settled up by RP), the magnet was de-cryostated, with RP measurements performed at every step of the workflow Once all measures performed are ok, the entire cryo-magnet can be declassified (up to now, two of them…) All the disassembly procedures were (and are still…) discussed with RP representatives in order to optimize RP safety aspects Standard RP procedures are applied during the activities (i.e. no destructive work without permission, RP vacuum cleaner, adapted waste boxes etc… Development / market survey on-going to equip workshops with orbital cutting machine (to avoid grinding of welds)
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JPh Tock 32/38 Cryomagnets removed during LS1 (3/3) Courtesy A Musso, V Parma Q7 disassembly The same work will be performed on Q5 (LS1)
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JPh Tock 33/38 SMACC Summary on progress Main 13 kA Splices: On schedule Q Diodes consolidation : All components are at CERN and tested Overheated splices : should be just OK within present schedule Leak test rate is according to forecast, slightly more needed Special Interventions: Back on schedule Almost all planned interventions are completed Focus on NC DFBA: Activities are back in the shadow of arc splices SMACC: About 3 days of delay, reducing wrt schedule defined > one year ago !!
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JPh Tock 34/38 Sector 56 : Final leak test and reconnection of DFBAK Sector 67 : Final leak testing Sector 78 Work on NC Reconnection of DFBAO-SHM Sector 81 Pressure test on 8.04.2014 Sector 12 (Priority) Reclose last ICs Progress on insulation vacuum leak test Sector 23 Complete all M lines rewelding Complete M-lines leak testing Progress on reclosure of ICs Sector 34 Complete work on overheated splices Progress on M lines rewelding Sector 45 Complete installation of shunts but overheated splices Progress on electrical insulation Progress on consolidation of Q diodes SMACC Main activities for the next 2 weeks
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JPh Tock 35/38 Conclusions Project is almost back on schedule (3 days delay) Mind the last X % effect W leaks are under control DFBA consolidation is nearing completion Overheated splices : On the critical path but under control S67 is almost ready for next step (ElQA before cooldown foreseen end of April) S81 should be ready on time for pressure test (8.04.2014) But known leaks to be treated after Work has started on cryomagnets removed during LS1 (SMI2 & 180)
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JPh Tock 36/38 Global wish status
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JPh Tock 37/38 Steps progress
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JPh Tock 38/38 Closure status
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