1. ESS RFQ CEA CONTRIBUTION 19/03/2019
Chauveau Anne-Catherine /03/2019

2. Overview of CEA WP content
TABLE OF CONTENT
Overview of CEA WP content
WP content
Tenders status
RFQ status
Part list
Documentation
Non conformity
Review of installation
Plan changes
CEA installation planning
CEA installation team
CEA installation team planning
CEA tools requirements
CEA services requirements
CEA installation RAM
Transportation
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3. OVERview of WP content
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4. CEA WP CONTENT Partial RFDS system Conditioned RFQ on it’s support
5 RFQ sections
Partial RFDS system
Pick-ups (x22)
Tuners x60
Cooling system SKID and Control PLC
Power couplersx2
Cooling plates
x80
RFQ support
Conditioned RFQ on it’s support
MAIN Requirements:
Bunch the proton beam at the frequency of MHz
Accelerate the beam from the exit of the source from 75 keV up to 3.6 MeV
Pulsed operation at 4% duty cycle
Transmission > 90%
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5. CEA TENDERS STATUS Almost 30 tenders and numerous orders.
4 tenders still on-going
Part
Company
Copper
Carlier
5 RFQ sections
Mécachrome (MKA)
RFQ auxiliaries (brazed on the RFQ sections)
Atelier Mécanique de Deuil (AMD)
60 tuners
ACE
3 Power couplers
PMB
28 pick-ups
Solcera
IO plates
RFQ support
MGR, DKER, Court SA, Sermo Mécanique
Sections Transport chassis
RFDS support
Sominex
Bead-Pull instruments
COURT, SEL, Sominex
RFQ cooling system (SKID + soft hoses)
Technitub
Various assembly/tests tools
Various tenders
Miscellaneous (blank flanges, seals, screws…)
Various orders
Tender on-going
Tender closed
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6. At Saclay CEA RFQ STATUS TODAY 1/2
3 power couplers received – Leak tested – Conditioned.
At Saclay
RFDS support received – Assembly done
60 tuners received – Partial Leak & assembly test
RFQ support received – Assembly done.
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7. S1 assembled on RFQ support
CEA RFQ STATUS TODAY 2/2
S1 Brazing at Annecy
S1 after brazing
Section 1 delivered at CEA – tested – assembled.
Section 2 delivery due today.
Section 3 brazed – BP2 done – 1st Leak test done.
Section 4 on-going machining.
Section 5 on-going machining.
S1 assembled on RFQ support
At Saclay
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8. CEA WP Part list FBS with associated documents (on-going)
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9. 360 files sent already CEA DOCUMENTATION General documentation
General documentation
Design (Blue prints - 3D)
Manufacturing (FAT - Materials)
Assembly and integration
Test at Saclay
Materials and Conformity reports
RFQ_SUPPORT na
Need translation
RFQ
S1 (leak)
S2-S5 S1
POWER_COUPLERS
TUNERS
On-going
PICK-UPS
IO_PLATES
RFDS_SUPPORT
Delivered
Needed for installation
Not yet available at Saclay na
Not applicable
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10. NON CONFORMITIES Criticity L1, L2, L3 Author date Description
Component
Piece ID L2
ACE
déc-17
Tuner seizure UAC QB-1001
Tuner
UAC QB-1001 L1
CEA
juil-17
Power couplers seals – not adapted support on pick-up coupler
Coupler NA
nov-17
Drilling through for hydraulic channels
S1-S2-S3 work anticipated before mock-up delivery
RFQ
S1-S2-S3
MKA
juin-18
Section 1 right minor vane too short. => vane discarded D1
Section 1 left minor vane missing copper on vane => vane discarded G1
Section 1 low Major vane drilled through not reusable => vane discarded B1
janv-18
Section 1 low Major vane: drill broken in pick-up port repaired by electro erosion. => vane discarded H1
juil-18
Section 1 low Major vane: snached copper on vane because of programming error. => vane discarded
Section 2 right minor vane: increase of the diameters for tightening rods for brazing and pins. D2
avr-18
Section 2 high Major vane: Increase of the “big circle” diameter. H2
août-18
Section 1 left minor vane: shift of the cooling plates fixings + specific plates.
oct-18
Shift of the relaxing groove for the specific cooling plates on section 1 left minor vane +
Impact on the vane discovered during assembly. S1
PMB
Swagelock connector leaking repaired then replaced
Couplers
All
sept-17
Few dimensional deviations before assembly of power couplers.
L2?
New: Impact on the outside of section 2
New: Impact on the section vane end S2
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11. Review of INSTALLATION
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12. Installation changeS (1/2)
ESS RFQ Installation change:
Regarding RFQ sections manufacturing, ESS requested CEA to optimise the delay for delivery.
A new scenario was presented by CEA and chosen by ESS end of November 2018.
Main impacts of this change:
Less than 3 months for IRR preparation
Only 3 sections assembled at CEA (2 others sections will be delivered with no previous assembly tests.)
No tuning of the RFQ prior to delivery in the tunnel.
First delivery in Lund happens before the RFQ tender is closed, therefore main documentations from manufacturer is not yet available.
Installation scope is described in Installation Binder.
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13. Installation changeS 2/2
ESS RFQ Installation change 2:
An other change compared to what was initially planned is the fact that the drop hatch is not available for downloading the equipment. Therefore it was decided that ESS would handle the necessary tooling needed to download the RFQ girder in place.
ESS RFQ Installation change 3:
Last modification to the installation plan is the unavailability of the Tungalift. All the procedure was initially worked on with the assumption of Tungalift used for lifting. This has been replaced by use of forklift trucks handled by ESS operators.
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14. CEA Installation PLANNING
T0 depends on the arrival of section 3 at Saclay and on the readiness of ESS tunnel, tools, services and beam.
Actual Planning foresees transport end of April with arrival beginning of May.
Detailed planning in Installation Binder.
Detailed installation sequences follow in dedicated presentation from A. Dubois
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15. CEA Installation TEAM CEA contact Function Bruno POTTIN
RFQ WP project leader
Anne-Catherine CHAUVEAU
RFQ WP project leader deputy
Augustin DUBOIS
RFQ WP Installation responsible
Gabrielle PERREU
RFQ WP Installation responsible deputy
Olivier PIQUET
RFQ WP Instrument scientist and RF expert
Alain FRANCE
Bead-Pull measurement expert
Pierrick HAMEL
Yannick LE NOA
Bead-Pull control expert
Michel DESMONS
Conditioning and RF expert
Didier CHIRPAZ-CERBAT
Vacuum responsible
Maryam OUBLAID
Vacuum responsible deputy
Nicolas MISIARA
Coupler Mechanical engineer
Yannick SAUCE
Hydraulic technician
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16. CEA Installation TEAM PLANNING
Detailed team planning in installation binder.
Dark green mandatory.
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17. CEA TOOLS REQUIREMENTS LIST
Before arrival
Downloading
Girder installation
S1 installation
S1 alignment
S1 equipments
S1 leak tests
S2 Assembly
S2 leak tests
S3 Assembly
S3 leak tests
S4 iAssembly
S4 leak tests
S5 Assembly
S5 leak tests
BP tool and tuners ass
BP1 fingers
Coupler assembly
Coupler leak tests
BP2 cpl + tuners
Hard pipes assembly
RFDS assembly
ESS vacuum ass&test
BP3: Final BP
Final leak test
Soft hooses
After work
duration 1d
0.5d
1,5d
2,5d
2.5d 2d 3d 5d
2d 
10d
date
Support feet fixing rods
Plastic indicator strips
dumpsters
offices with an internet acces
changing rooms
lockers
strong table  
few chairs 
Electric sockets
RBS and alcoohol
1 forklift truck (fenwick type) or Tungalift crane
1 forklift truck operator or Tungalift crane operator
chain host (non electric)
3 wood Pallet  800*1200
Wood blocs
Slings
1 hand pallet truck
Mobilev
Mobilev operator
leak detection equipment with primary pump
Helium
Nitrogen
water
buckets
Compressed air
2 table for the laptops
Detailed tool list in installation binder.
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18. CEA SERVICES REQUIREMENTS LIST
Before arrival
Downloading
Girder installation
S1 installation
S1 alignment
S1 equipments
S1 leak tests
S2 Assembly
S2 leak tests
S3 Assembly
S3 leak tests
S4 iAssembly
S4 leak tests
S5 Assembly
S5 leak tests
BP tool and tuners ass
BP1 fingers
Coupler assembly
Coupler leak tests
BP2 cpl + tuners
Hard pipes assembly
RFDS assembly
ESS vacuum ass&test
BP3: Final BP
Final leak test
Soft hooses
After work
duration 1d
0.5d
1,5d
2,5d
2.5d 2d 3d 5d
2d 
10d
date
marking of the feet
dirty work finished
RFQ zone in the tunnel cleaned
instal. enveloppe: LEBT commissioning tank removed
Waves guides connected o the wall
ESS teams and equipment for downloading
No dust (area protected and over pressured)
no working in this part of the tunnel
site should be secured
Electric sockets
humidity level of up to 75%
ESS surveyor
alignment equipment
ESS vacuum system
ESS vacuum team
leak detection equipment with primary pump
Test envelope: LEBT solenoid and diag. removed
15˚C to 27˚C
temperature change of 5˚C per 24 hours
no vibrations
Workshop for tube cutting
Space and transport in RATS of remaining equipment
Detailed service list in installation
binder.
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19. CEA INSTALLATION RISK (RAM)
No.
Activity
Hazard
Who might be harmed and how?
Action to Mitigate Risk-
Controls 
Residual Risk Rating   S L
Risk 1.
Girder installation
Lifting of heavy objects - Falling objects
Manual handling
Everyone around
Mandatory PPE on site - Correct installation of tools
Min resources around - Fencing of work area 5 1 M 2.
TungaLyft installation
Rolling object
Lifting
Mandatory PPE on site - Min resources around
Signaling of work area 2 3.
Section X installation
Lifting - Manual handling - Moving
Mandatory PPE on site -Min resources around 4 4.
Section X equipment assembly
Manual handling - Hand crushing -
Back/muscle strains
Mandatory PPE on site
15.
Wave guide support installation
Rolling object - Hand crushing - Work at height
Mandatory PPE on site - Platform
16.
Couplers installation
Manual handling - Work at height- Back/muscle strains
Platform
17.
Helium leak tests
Inert gas, pressure
Everyone around work
Correct storage ?
18.
Cleaning of parts
Chemical hazard/Waste generation
Gloves - Waste management
20.
Box opening
Cut from utility knife/scissors
Falling objects
21.
Tripping on objects on the floor
Waste management
22.
Connection of utilities (power for gauges and pumps)
Electrical hazard - Tripping on cable
Cable management - Electrical management
Main risk is handling of heavy equipment
No Hot-work
No cutting
No Electrical work (except plugging laptops, BP and cooler)
Document Risk Assessment and Method Statement in installation binder.
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20. CEA TRANSPORTATION SPECIFICATION
One Dedicated standart truck with very extremely careful handling for RFQ sections and Power couplers (shock sensors, air suspension…)
A second standart truck for all other equipment.
Box dimensioning and weighting is still on-going.
Some boxes are still under manufacturing.
Document needs further working…..
Draft document in installation binder.
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21. CONCLUSION
In order to assemble the RFQ, all the tools and services listed in the document 05_RFQ_Lund_Installation_requirements.pdf in Binder 06 need to be ready and available.
Even though conditioning is not part of this review, the beam should be characterised before the RFQ is connected to the LEBT.
If the beam is not characterised, if any issues arises during commissioning it will be very difficult to know if the problem is on the BEAM or on the RFQ.
CEA will come for a pre-visit of the tunnel state about 10 days before the departure of the RFQ from CEA.
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22. Thank you for your attention
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