Download - Update of c ryogenic activities
L. Tavian, TE/CRG, LSC 13.09.2013 Page 2
Update of cryogenic activities
September 13th, 2013
LS1 Committee (LSC)
L. Tavian TE-CRG
L. Tavian, TE/CRG, LSC 13.09.2013 Page 3Page 3
Content• Update on:
• QRL compensator bellows• DFBA gimbal bellows• Major overhauling• Various consolidations
L. Tavian, TE/CRG, LSC 13.09.2013 Page 4
The faulty equipment (QRL Line C)
Witzenmann DN100 multi-ply bellows compensators (4 plies of 0.3 mm)
Internal ply damage (S45, 14R4) External ply damage (S78, 10R7)
L. Tavian, TE/CRG, LSC 13.09.2013 Page 5Page 5
QRL Line C compensator x-rays status
A B C D E F G H ILT
X-rayLT
X-rayLT
X-rayLT
LT
LTX-ray
LTX-ray
LTX-ray
Case 1: Damage compensateur identified by LT and confirmed by X-rays : Total (final) 7/560 (1.25 %)Case 2: Damage compensateur (still tight) identified by X-rays only: Total (provisional) 1/277 (~0.36 %)
Leak-tested sub-sector (VSC)
X-rayed sub-sector compensators on Line C (CRG, MME)
X-rayed sub-sector compensators on Line B, D, F (CRG, MME)
S67
S78
S81
QRL sub-sector
S12
S23
S34
S45
S56
X-ray
X-ray
E
E
E
E E
E
E
E: Extracted from the QRL(Nominal rate: 1 per week)
E
L. Tavian, TE/CRG, LSC 13.09.2013 Page 6Page 6
Repair plan for QRL compensators
CW 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10X-Ray S45 & S56 (CRG & MME)X-Ray of remaining QRL (~5 sectors) TBC (CRG & MME)CERN spare validation (12 units) (CRG & VSC)Delivery of new spares (5-10 units)New spare validation (5 units) (CRG & VSC)Sector 8-1 T1 T2 T1 T2 T3 PT 30.05.2014Sector 5-6 T1 T2 T1 T2 T3 PTSector 6-7 T1 T2 T1 T2 T3 PTSector 7-8 T1 T2 T1 T2 T3 PTSector 7-8 T1 T2 T1 T2 T3 PTSector 3-4 T1 T2 T1 T2 T3 PT 20.06.2014Sector 4-5 T1 T2 T1 T2 T3 PT 18.07.2014Sector 4-5 T1 T2 T1 T2 T3 PT 18.07.2014Sector 1-2 PT 23.04.2014Sector 2-3 PT 22.05.2014
T1 Mechanical preparation (CRG)
T2 Compensateur integration/welding and clamshell leak test (CRG & VSC)
T1 Screen and MLI interconnect integration (CRG)
T2 External envelop closure/welding (CRG)
Subsector pumping
T3 Individual and global leak test (VSC)
PT - preparation for pressure test (QRL to be closed)
T1 (Team 1): 2 persons (2 technicians)T2 (Team 2): 2 persons (1 welder + 1 mechnanics) (TE-VSC support to be added)T3 (Team 3): VSC support
20142013Aug Sep Oct Nov Dec Jan Feb
Welding of the fir
st
compensa
tor starte
d
in S81!
L. Tavian, TE/CRG, LSC 13.09.2013 Page 7
Line E and F compensator: FE model
Vacuum, Surfaces & Coatings GroupTechnology Department 14 August 2013 C. Garion 7
Line F: expected fatigue life
2nd cycle
1st cycle3rd cycle
If initiated, the deformation process with thermal cycles is very fast.
C. Gario
n
L. Tavian, TE/CRG, LSC 13.09.2013 Page 8
Conclusion of FE model
Vacuum, Surfaces & Coatings GroupTechnology Department
Conclusion
14 August 2013 C. Garion 18
A FE model is used to simulate the behaviour of a multiply bellows with interplypressurization.
The initial gap between the plies where pressure develops is the key parameter.
If plastification occurs during the warm-up, failure of the compensators is very fast (probably less than 10 cycles).
The line E compensator is critical. Failure of the compensators after few thermal cycles can not be excluded.The line D compensator seems less critical than the line E and should withstand such a interply leak scenario.
C. Gario
n
L. Tavian, TE/CRG, LSC 13.09.2013 Page 9
The faulty equipment (DFBA)
Calorstat DN120 multi-ply gimbal bellows (2 plies of 0.2 mm)
DFBAK shuffling module:Internal ply collapsing
L. Tavian, TE/CRG, LSC 13.09.2013 Page 10Page 10
DFBA IP Découpe M Inspection Lower Upper Découpe M Inspection Lower upper
DFBAB 1R 07-Aug 08-Aug ok ok 1-2 DFBAC 2L 20-Aug 20-Aug ok okDFBAD 2R 13-Aug 14-Aug ok ok 2-3 DFBAE 3L 04-Sep 04-Sep ok okDFBAF 3R 25-Aug 26-Aug damaged ok 3-4 DFBAG 4L 29-Aug 02-Sep ok okDFBAH 4R 29-Aug 02-Sep ok ok 4-5 DFBAI 5L 06-Sep 09-Sep damaged okDFBAJ 5R 20-Apr 18-Jul ok ok 5-6 DFBAK 6L 18-Jul ok collapsedDFBAL 6R 25-Apr 18-Jul ok ok 6-7 DFBAM 7L - 26-Jul ok okDFBAN 7R 15-Jun 02-Aug ok ok 7-8 DFBAO 8L - 02-Aug ok okDFBAP 8R - 25-Jul ok ok 8-1 DFBAA 1L 07-Aug 08-Aug ok ok
Dates Bellows status Bellows statusSecteur DFBA IP
Dates
DFBA gimbal bellows status for all DFBAs
Statistics (total 32 bellows all inspected): 3/32 (9.3 %)
Endoscopic inspection through line M interconnects
Thanks to MSC for early opening of M sleeves !
L. Tavian, TE/CRG, LSC 13.09.2013 Page 11
Pictures of the damaged bellows: DFBAF &DFBAI
DFBAF lower gimbal DFBAF lower gimbal
DFBAI lower gimbal DFBAI lower gimbal
L. Tavian, TE/CRG, LSC 13.09.2013 Page 12Page 12
In situ access by cutting the end door: possible solution
Questions/issues:
• Very limited space to cut/weld the door
• Cutting and welding of beam pipes to
be done in very difficult position
• Leak tests of beam pipes?
• Extreme very difficult work positions
• Safety to be assessed
Thanks for EN-MME contribution!
Gimbal patching(Rigid assembly)
L. Tavian, TE/CRG, LSC 13.09.2013 Page 13
Repair optionsIn situ repair Workshop repair
Gimbal positionLower
DFBAF & IUpper
DFBAKLower
DFBAF & IUpper
DFBAK
Gimbal patching ++ + +++ +++
Gimbal replacement +++ +++
Splice disconnection / reconnection N/A N/A - -
Safety for equipment ++ + +++ +++
Safety for personnel ++ + +++ +++
Probability of success (patching) > 80 % < 50 % 100 % * 100 % *
Probability of success (replacement) 0 0 100 % * 100 % *
Repair time (patching) [week] 6-10 6-10 15 15
Repair time (replacement) [week] N/A N/A 15 to 23** 15 to 23**
*: without 6 kA splice work uncertainty**: spare delivery time (13-14 week)
L. Tavian, TE/CRG, LSC 13.09.2013 Page 14Page 14
Repair strategy• 0/ Validate the patching scenario
• Done for the DFBAK (upper gimbal) acceptable force of +/- 500 N for +/- 4 mm of displacement
• Still to be done (in the coming days) for DFBAF & DFBAI (lower gimbal)
• 1/ Start with one lower gimbal in-situ repair (DFBAF or DFBAI) “easier” case
• 2/ Validate the disconnection & reconnection of 6kA splices
• 3/ depending of 1/ and 2/ experience return, decide on DFBAK repair (in-situ or in workshop)
L. Tavian, TE/CRG, LSC 13.09.2013 Page 15Page 15
Major overhaulingCompressors Motors
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LS 1 Major overhaul of LHC compressorsDASHBOARD for the major overhaul of the helium screw compressors
of the CERN helium refrigerators
Last up-date: 10/09/2013
Point 1 Point 1.8 Point 2 Point 4 Point 5 Point 6 Point 8
NEXT KEY DATES
LHCBATLAS SR LHCB LHCA LHCA LHCB CMS LHCA LHCB LHCA
Re-installation10/09/2013
Back10/02/2014
Back18/11/2013
De-installation14/10 – 28/10/13
Re-installation Back01/11/2013
Back01/11/2013
Re-installation23/09-10/10/2013
De-installation30/09 – 04/10/13
CP1 CP2 CP1
CP6
CP2
CP7
CP3
CP1
CP7
CP2
CP8
CP3
CP4
CP5
CP6
CP1 CP7
CP2 CP8
CP3
CP4
CP9
CPA
CP1
CP6
CP2
CP7
CP3
CP1 CP2 CP1 CP7
CP2 CP8
CP3
CP4
CP9
CPA
CP1
CP6
CP2
CP7
CP3
CP1
CP7
CP2
CP8
CP3
CP4
CP5
CP6
CP1
CP6
CP2
CP7
CP3
NEXT KEY DATES
De-installation21/09/2013
Transport Back08/11 – 11/11/13
LHCCBATLAS ANRS LHCCB LHCCA LHCCA LHCCB LHCCA LHCCB LHCCA
14/04 – 15/04/14
Back08/11/2013 (25/10
De-installation Back27/09/2013 (25/08)
Re-installation16/09-17/09/2013
CP1 CP1 CP2
ATLAS MR
CP1
CP5CP2
CP3
CP4
CP6
CP1 CP2 CP1-2 CP1 CP2
Legend
Not yet started
De-installation Transport Major
overhaulBack at CERN
Re-installation Conditioning Post
installationReady foroperation
CP1 CP2CP1-2 CP1-2 CP1-2
No majoroverhaul
Re-installation10/09/2013
Done : 26 % In progress : 42% To be done : 32 %
L. Tavian, TE/CRG, LSC 13.09.2013 Page 17Page 17
Major overhaulingScratches on rotors
Scratches on slide valve
Scratches on sleeve bearings
Recovery of new equipment!
Corrective maintenance
within expectation!
L. Tavian, TE/CRG, LSC 13.09.2013 Page 18Page 18
On site maintenance
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DFBX current lead controls
Flowmeter rack andPiping in UL14 (IP1 L)
Design
Dra
win
gs
Valv
es
Pipe
s an
d fitti
ngs
Flow
met
ers
Prep
arati
on
Inst
alla
tion
L: DFBXA
R: DFBXB
L: DFBXC
R:DFBXD
L: DFBXE
R: DFBXF
L: DFBXG
R: DFBXH
Procurement Field work
DFBXIP
1
2
5
8
L. Tavian, TE/CRG, LSC 13.09.2013 Page 20Page 20
Leak on refrigerator cold boxes
Cold box P2 : leak on MP circuit on HX collector
Cold box P6 : leak on LP circuit
on SS/ALU transition (DN400)
Cold box P8 : leak on LN2 circuit
on the precooler HX
Repairs foreseen by end of 2013 !
L. Tavian, TE/CRG, LSC 13.09.2013 Page 21Page 21
Conclusion• QRL compensator bellows:
• X-ray is progressing well (~4 sectors done) Statistics are presently encouraging (1 additional damaged bellows found)
• Repair of the first compensator (S81) has started.• If statistics remains low, the repair is compatible with the present sector pressure test
schedule.• What about Line E/F compensators? X-rays on a sub-sector (~8 compensators) are OK
but FE simulation shows a potential risk.
• DFBA gimbal bellows:• Endoscopic inspection completed 3 damaged bellows.• In-situ repair via patching could be envisaged for DFBAF and DFBAI (displacement forces
to be measured in the coming days)• In-situ repair of the DFBAK is not validated (technical and safety issues). Workshop repair
required a risk assessment of the splice disconnection/reconnection operation.• Resource and schedule still to be consolidated.
• Major overhauling of compressors and motors is on track. Ramp-up of the on-site maintenance must be carefully followed.
• DFBX current lead controls consolidation and cold-box leak repair are progressing well