update of c ryogenic activities

L. Tavian, TE/CRG, LSC 13.09.2013

Update of cryogenic activities

September 13th, 2013

LS1 Committee (LSC)

L. Tavian TE-CRG

L. Tavian, TE/CRG, LSC 13.09.2013 Page 3

Content• Update on:

• QRL compensator bellows• DFBA gimbal bellows• Major overhauling• Various consolidations


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)


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


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!


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


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


The faulty equipment (DFBA)

Calorstat DN120 multi-ply gimbal bellows (2 plies of 0.2 mm)

DFBAK shuffling module:Internal ply collapsing


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 !


Pictures of the damaged bellows: DFBAF &DFBAI

DFBAF lower gimbal DFBAF lower gimbal

DFBAI lower gimbal DFBAI lower gimbal


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)


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)


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)


Major overhaulingCompressors Motors


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 %


Major overhaulingScratches on rotors

Scratches on slide valve

Scratches on sleeve bearings

Recovery of new equipment!

Corrective maintenance

within expectation!


On site maintenance


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


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 !


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

update of c ryogenic activities

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