Special interventions Status of production and QC

Transcription

1 Fourth LHC Splice Review November 2013 Special interventions Status of production and QC Nicolas Bourcey TE-MSC-MDT

2 Outline I. Work organisation II. III. Sector 5-6: lessons and improvements Status of special activities IV. Status of magnets replacement V. QC VI. Traceability VII. Still to do and conclusion

3 Work Organisation Interventions prior to the train: PIM consolidations Special opening (ELQA, leaks, RQ busbars segment shortening, early opening for splice analysis, Q7-DFBA M sleeves opening ) Magnets exchange Interventions in parallel of the train: Fixed urgent NCR raised during train consolidations

4 Team (16 persons) 3 month of training in surface before LS1 on mock-ups in building 180.

5 Sector interventions planned before start of LS1 (PIM consolidations, 3 leaks, ELQA). More than 40 interventions done! Flange replacements for too short lip (12) Corrective action: partial cutting Cut of flanges for busbars machining (18) Corrective action: tooling re-design Cutting mark on flange weld Corrective action: modify tooling PIM damaged (5) Corrective action: add protections Q7-DFBA M sleeves opening (train machine doesn t fit) SIT intervene in 23% of the IC of the sector.

6 Sector 5-6: lessons and improvements PIM damaged Mark during cutting M flange cutting Q9 M-N pipes cutting Only 7 interventions in sector 6-7 up to now! Corrective actions applied in sector 5-6 improve the quality.

7 Status of special interventions PIM Sector Total Magnets 0/0 0/0 8/8 0/0 24/24 8/12 0/16 0/8 40/68 NCR + preventive 10/10 2/2 6/12 5/7 2/2 0/4 0/2 6/6 31/45 Only 2 PIM found broken during ball test (1-2 and 8-1) instead of 14 expected. 5 PIM damaged during SMACC (5-6). Leaks 3 old leaks repaired in 5-6 (2 M flange and 1 M2N flexible) 1 old leak repaired in 7-8 (M2N flexible)

8 Status of special interventions Early opening of M line sleeves and removal of insulation Sector Total ELQA tests 3/3 3/3 3/3 3/3 3/3 3/3 3/3 3/3 24/24 Splice analysis Electrical NC Opening for ELQA instrumentation 0/0 0/0 5/5 4/4 8/8 22/22 0/11 5/5 44/55 0/0 0/0 4/4 4/4 1/1 0/0 0/0 0/0 9/9 77/88 M sleeves opened prior to the train

9 Courtesy of S. Le Naour Status of special interventions RQ busbars segment shortening at point 1 and 5 4 IC s opened, desoldering and cutting of busbars done. QEQI.11R5: soldering of the shortcircuit. M1 ok but NCR on M2 (cable initially too long and external copper wedge too soft). (D.Etiembre / G.Bachmann) Before repairing After repairing

10 Secteur Slot Disconnection Transport old magnet (night) Refurbishment Transoprt new magnet (night) Alignment Welding activity Spools US welding ELQA Line N US welding ELQA Final welding (line N) Status of magnet exchange 14/18 magnets removed (last transport foreseen 09/08) 12 installed (last transport foreseen 15/08) Reconnection of all magnets foreseen before end of the year Q5L8 B30R7 31/05 07/06 B21L8 03/06 06/06 C15R1 17/06 19/06 A22R1 20/06 25/06 C30R1 24/06 01/07 C33R1 28/06 03/07 B33L2 02/07 08/07 A29L2 04/07 10/07 A23R2 05/07 11/07 B25R2 09/07 15/07 C15L3 11/07 18/07 Q23R3 17/07 23/07 A26R3 22/07 01/08 Q27R3 26/07 12/08 B32R3 01/08 13/08 C17R4 06/08 14/08 B31R4 09/08 15/08

11 Some pictures of cryomagnets transport Thanks to EN-HE colleagues

12 QC: Welding Welders qualification (automatic and manual welding) Internal QC Visual inspection Endoscopy Parameters recording for automatic welding External QC Visual inspection 100% (WQC) Radio on butt weld 100% (WQC) Leak tests (VSC) Systematic change of M line flanges 1 NCR detected by radio: crack due to copper particles (leak test ok). Corrective action: modification of the shielding tooling from copper to stainless steel (see EDMS report of A.Gerardin). Courtesy of A.Gerardin

13 QC: Desoldering and stabilisation Internal QC Same procedure than train Visual inspection Gauges Process data recording Traceability of data in MTF External QC Visual inspection (ELQC) SIT never do soldering of 13KA busbars.

14 QC: US welding US welding of line N US welding of spools

15 QC: US welding Qualification of welding machines before LS1 and after each transport. Production of standard samples for cold Rc measurements (cryolab) and tensile test (EN-MME). Same welding program than 2009 production. Same criteria than during the installation.

16 QC: US welding Example of reports for machine qualification

17 QC: US welding Internal QC production of samples just before soldering to warm-up the machine Visual inspection, gauges External QC Visual inspection by ELQC team N line EDMS # M line EDMS # Electrical tests by ELQA team after completion of a sector > 0.5 mm non-conform Alignment Excess length 1 mm ± 0.5 Gauge

18 Traceability New step created in MTF to register process data. REMPLACEMENT DIPOLE 2438 (A26R3) 2438 / 1242 QBQI.24R3 QQBI.25R3 QBBI.A25R3 QBBI.B25R3 QBQI.25R3 QQBI.25R3 QBBI.A26R3 QBBI.B26R3 QBQI.26R3 QQBI.26R3 QBBI.A27R3 QBBI.B27R3 QBQI.27R3 Ouverture manchettes W et écrans thermiques Retrait instrumentation cryogénique QC (ouverture) Découpe manchettes M1, M2, M3 Découpe manchettes N Découpe PIM Découpe soufflet E Découpe C' Découpe X, Y Découpe K Ouverture boitier ligne N Deconnection boitier ligne N Retrait cable ligne N Dépose isolation Déconnection spools QC (elect) Débrasage busbars 13KA QBQI.24R3 QBQI.25R3 QQBI.25R3 QBBI.A25R3 QBBI.B26R3 QBQI.26R3 QBQI.27R3 Date Operateurs Date Operateurs Date Operateurs Date Operateurs Date Operateurs Date Operateurs Date Operateurs TRANSPORT Stabilisation busbars 13KA QC (elect) Découpe brides lignes M Soudures brides lignes M QC (soudures) QC (soudures) / radio Tests de fuites TRANSPORT QC (SIT) Alignement Installation PIM Soudure PIM QC (soudures) Soudure manchette C' Test de fuite manchette C' Soudure soufflet E Test de fuite soufflet E Brasage ligne Y Soudure manchette X Test de fuite manchette X Soudure flexible K Test de fuite soudure flexible K QC (soudures) Soudure US spools QC (elect) Insertion ligne N Montage boitier ligne N QC (elect) MPAQ AIV1 Soudure US ligne N QC (elect) AIV2 Fermeture boitier ligne N Soudure manchettes ligne N Test de fuites manchettes N Cablage instrumentation cryogénique QC (SIT) All activities done by SIT are registered in excel files

19 Still to do and conclusion Still to do: Magnets replacement will finish before end of weeks of delay on the planning. Connection cryostat: 6/16 inspected ok. Still 2 to repair. Line Y repair Triplets copper braid SAM level gauges Follow train NCR SIT is able to follow the needs and we expect to free resources for major NCR last quarter of 2013.

20 Thank you for your attention.