activities on the triplets at cern

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Activities on the triplets at CERN

• Reception and Acceptance• Triplet String Assembly in Building 181• Handling and Transport• Preparation for Installation• Tests carried out in the tunnel• Repairs• Present Status

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Reception and Acceptance

• Acceptance tests to be performed following shipment: Q1: Acceptance Plan for LQXA LHC-LQX-TP-0002

Q2: Acceptance Plan for LQXB LHC-LQX-TP-0001

Q3: Acceptance Plan for LQXC LHC-LQX-TP-0003

DFBX: Acceptance Plan for Inner Triplet Distribution Feedboxes LHC-DFBX-ES-0001

D1: Acceptance Plan for Beam Separation Dipoles LBX LHC-MBX-ES-0003

• Tests to be perform at CERN according to these documents Physical inspection Mechanical measurements Electrical measurements

• Coil resistance

• Quench protection heater resistance

• Coil inductance

• Insulation resistance

• Leakage current measurements

• Thermometer resistance

• Warm-up heater resistance

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Physical inspection in Building 181 Visual inspection of containers and shockwatches fasten on it

Removal of the container and inspection of the transport restraints

Transport data recorder return to sender for analysis

Removal of transport restraints and “spider” inspection

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Electrical measurements in Building 181

Electrical checks and measurements• Coil resistance• Quench protection heater resistance• Coil inductance• Insulation resistance• Leakage current measurements• Thermometer resistance• Warm-up heater resistance• Continuity of leads, busses and instrumentation for the DFBX

Polarity checks using a rotating mole

Leak checks on the internal pipes of the DFBX

8 K A

8 K A

E

E

H 1+

V1+

C /SS/C

Q1C orrec tion

Co il

S

S

S

C

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H 1-

V1-

IHi

I Lo

VHi

VLo

4 Wire Measuring Device

1.234

Fermi ‘Break Out’ Box

J4

'13 F’Q1-Q2Connector

‘B’

‘A’

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Geometrical measurements in Building 181

Alignment stability• Cold mass length• Cryostat length• Cartography of the tubes at the cold mass ends• Cold mass horizontal and vertical shapes• Position of the cold mass within the cryostat• Comparison with FNAL data

OR

Fiducialisation• Same as above with different measurement methods• Geo Mole + AC Mole measurements to increase the accuracy on the magnetic

axis determination

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Triplet String in Building 181

String assembled in April 2005 with the collaboration of FNAL, AT/CRI, AT/MEL, AT/VAC, TS/IC, TS/SU

Check availability of components and tooling

Assemble interconnects, check tooling and procedures

Perform instrumentation and continuity checks for the string from DFBX

Mount and check alignment equipment

Check string behaviour under insulation vacuum

Check handling equipment

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Triplet String in Building 181

What was learned:

Validation of most components and tooling for the interconnections Demonstration of interconnect procedures in conditions close to the ones in the tunnel Polarity of magnets confirmed in the string Instrumentation and continuity from DFBX confirmed Alignment of magnets under vacuum confirmed Limited rigidity of the jacks and their supports

Actions: Some tools and components had to be improved Procedures were refined BPMS signal cables redesign due to interference with Q2 thermal shield Thermal shield of DFBX/D1 interconnection had to be modified A software bug corrected in survey applications

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Handling and Transport

Mean(s) Container Restraints Data Recorder

US to CERN Truck / Boat / (Plane)

Q1/Q3 Fixation on transport Frame inside a metallic container 1 per side

ShockwatchAcceleration Recorders

Q2 Fixation on transport Frame inside a wooden box 1 per side

D1 Fixation on transport Frame inside a metallic container 1 per side

DFBX Fixation on transport Frame inside a wooden box Springs

181 ↔ storage

↔ Smi2Truck

Q1/Q3

1 per side

SchocklogsQ2 1 per side

D1 1 per side

DFBX covered truck

Smi2 ↔ 181 ↔ storage

Truck

Q1/Q3

1 per side

SchocklogsQ2 1 per side

D1 1 per side

DFBX covered truck

Installation Truck

Q1/Q3

1 on the non IP side

SchocklogsQ2

1 on the non IP side

D11 on the non IP side

DFBX covered truck

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Handling and Transport

radial direction (R)

longitudinal direction

(S)

vertical direction (T)

HCLQXA_001-FL000001 0.16 -0.87 0.48

HCLQXA_001-FL000002 -0.30 -4.17 1.20

HCLQXA_001-FL000004 0.03 0.79 0.95

HCLQXA_001-FL000005 0.02 0.45 1.09

HCLQXA_001-FL000006 0.21 0.40 -0.27

HCLQXA_001-FL000007 -0.23 -0.25 0.95

HCLQXA_001-FL000008 -0.06 1.04 0.81

HCLQXA_001-FL000009 -0.08 2.45 0.53

HCLQXB_001-FL000001 0.03 0.63

HCLQXB_001-FL000002 -1.03 -0.78 0.72

HCLQXB_001-FL000003 -1.03 0.72

HCLQXB_001-FL000004 -0.11 0.15 -0.37

HCLQXB_001-FL000005 0.08 3.72 0.55

HCLQXB_001-FL000006 0.36 -1.10 0.52

HCLQXB_001-FL000008 -0.05 -0.85 0.54

HCLQXB_001-FL000009 -0.27 -0.20 0.60

HCLQXB_001-FL000010 -0.31 0.69 0.58

HCLQXB_001-FL000011 -0.03 -0.66 0.26

HCLQXC_001-FL000003 0.11 -0.99 0.60

HCLQXC_001-FL000004 -0.12 1.34 0.60

HCLQXC_001-FL000005 -0.04 0.47 0.65

HCLQXC_001-FL000006 -0.02 -2.99 0.88

HCLQXC_001-FL000007 0.16 -4.20 0.58

HCLQXC_001-FL000008 -0.30 1.26 0.18

HCLQXC_001-FL000009 0.14 -2.57 0.59

RMS 0.32 1.90 0.35

HCLQXA_001-FL000003 -0.46 -26.79 -2.01

HCLQXC_001-FL000001 0.08 -9.14 0.05

HCLQXC_001-FL000002

Cold mass displacements within the cryostat during transport from the US To CERN

3 assemblies were broken during transport probably due shocks between wagons as they were shipped by train :

Q3R8 cold mass has moved by ~3mm during transport to the tunnel without any shocklog alarm

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Preparation for Installation

• Mechanical preparation to put the different interfaces in conformity Thermal shield modification of the D1 Flange replacement to remove NCs (D1 and DFBX)

• Preparation in Smi2 Cold bore cleaning Beam screen insertion Pick up connection Cold warm transition assembly Thermal shield closing MLI insulation O-Ring seals installation Vacuum vessel closing Bearing pieces fixation

• Preparation of the DFBX in 181 Electrical instrumentation preparation Frames assembly and instrumentation box Warm gas recovery line assembly and vacuum test Control valves installation on each line Differential pressure valves installation

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Tests carried out in the tunnel

• Vacuum tests in L8 (22 Sept. 06) and R8 (17 Nov. 06) Monitoring the various displacement of the assemblies and supporting

system under insulation vacuum

Result: OK

Go ahead with the pressure test

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• Pressure test in L8

Guarantee the inner triplet piping mechanical stability under He pressure at warm

Result: Test interrupted at 12 bars by X line bucklingCause of rupture : brazed joints anneals the extremities of the tubes

All the exchanger tubes in Q1, Q2, Q3 have to be replacedPressure test L5 after repair to qualify X line replacement and the complete design

Design Pressure

Test Pressure

LD1/LD2 21 bars 26bars

CY/XB 5bars 6bars

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• Pressure test in L5 (27 march 2007) Guarantee the inner triplet piping mechanical stability under pressureValidate the new X line along the triplet (copper corrugated tube + interconnections)Monitor the H pieces displacement under pressure

Result: Test interrupted at 20 bars when the support system broke and M1 bellows rupturedCause of rupture: axial movement of Q1 cold mass towards the IP

The heat exchanger circuit remained leak tight even after the cold masses displacementX line replacement on the other triplets continue as planedThe cold mass support system of all Q1 and Q3 has to be reinforced

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Repairs

“Spiders” replacement on the 3 assemblies that were broken during shipment to CERN

• Removal from the vacuum vessel• MLI and thermal shield removal• “Spider” exchange (3/4) or repair (1/4)• Cold mass recryostating• Leak test of pipes that were cut to remove the spiders

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RepairsX tube removal and installation of new tubes

• Removal of the heat exchanger tube Removing the vacuum vessel dome in front of Q1 Cutting fix point between L and X lines on Q1 and Q3 L line extremities cutting Extracting the copper corrugated tube

• Installation of the new heat exchanger tube Replacement of L line flanges and M4 line bellow Insertion of the new copper corrugated tube Welding fix points at the extremities

• Interconnection of the X, L and M4 circuits (see C. Garion’s presentation) Installation of the “H” pieces Welding X line Leak test of the exchanger circuit from the Q1 to Q3 Welding M4 and L lines Leak test on the cold mass circuit

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Present Status

R1 L2 R2 L5 R5 L8 R8

6(/8) triplets were installed in the tunnel

21(/28) cryomagnets and 6 (/8) DFBX were installed

5(/8) triplets were interconnected (at least the bus bars connections)

2(/8)triplets were pressure tested in the tunnel

15(/24) new exchanger tubes were produced

10(/24) exchanger tubes were exchanged

3 cryomagnets and one DFBX have to come out of the tunnel

1 cryomagnet have to be replaced by its spare and has to be de-cryostated to exchange the supports

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Standard actions summary and information

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Additional tests on the spiders

i max sample 1 = 309.6 MPa

i max sample 2 = 322.3 MPa

The tests were initially intended to merely assess a possible prematurate breakdown occurring at limited flexural strain at break. For this reason and due to the limited size of the available material, two non normalised specimens have been machined radially for flexural testing. Three-point loading test, load applied at midspan, direction of force normal to the plane of the running of the fibers.Results (values are qualitative due to non-standard sample geometry and set-up):Average flexural stress at break = 316 MPaAverage flexural strain at break = 3.3 %Average modulus of elasticity in flexure = 12.7 GPa

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Additional tests on the spiders

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Cold mass displacement

Fix point displacement

F

Q3 supporting system rigidity = 0.49mm/ton

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Additional tests on the spidersQ2 supporting system rigidity = 0.43mm/ton

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Additional tests on the spidersQ1 supporting system rigidity = 0.66mm/ton

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activities on the triplets at cern

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