th 2013 LS1 Committee LSC 25 th Meeting D Delikaris TECRG Cryogenics activities report Agenda Update on Cryogenic Activities Preventive Maintenance Major overhauling Helium Cold Boxes ID: 552154
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Slide1Slide2
October 18th , 2013LS1 Committee (LSC)- 25th Meeting
D. Delikaris, TE-CRG
Cryogenics activities reportSlide3
AgendaUpdate on Cryogenic Activities:
Preventive Maintenance - Major overhaulingHelium Cold Boxes repairs in LHC P2-P8-P6
cryoplants
QRL compensator bellows (Headers C & D)
DFBA
splice consolidation
DFBA gimbal bellowsSlide4
Preventive maintenance
C199 contract for Preventive & Corrective maintenance activities
Investigation launched to understand the “baseline
vs
work orders
vs
work progress” issue:
Work progress
on schedule
wrt
to LS1 planning; shifted with respect to the original CRG baseline (non-adapted to real work progress tracking)
Discrepancy between work progress & work orders (WO) completion
:
due to open WO that can only be closed at a later stage & dates
Remaining actions:
Work order line to be completed
wrt
expected milestones for closure
A new version of the
baseline
will be
definedSlide5
Major overhauling; Dashboards
Helium screw compressors
3.3 kV electrical motors
Everything on track
Delayed delivery of
Kaeser
compressors
caused by additional corrective maintenance
task (rotors replacement)Slide6Slide7
Major overhauling (compressors & 3.3 kV motors)
Reception from manufacturer and…
…installation, coupling
and alignment at LHC P6Slide8
P2 18 kW LHC cold box repairL
eak repaired on medium pressure He circuit to insulation vacuum (heat exchanger)First tightness testing: done
Reinstallation of MLI: underway
Closing of the vacuum jacket: w 44-45
Vacuum pumping: w 46
Final testing: w 47
1
2
3
Matter removal for two stage welding
Intermediate stage
Final stage
Excellent work from
Fives
Cryogenie
(FR)Slide9
P8 18 kW LHC cold box repairL
eak repaired on N2 circuit of to insulation vacuum (pre-cooling heat exchanger)First tightness testing: done
Reinstallation of MLI: underway
Closing of the vacuum jacket: w 44-45
Vacuum pumping: w 46
Final test: w 47
Leak observed
Matter removal
Final weldingSlide10
P6 18 kW LHC cold box repair
- Leak to be repaired on SS/AL transition, He to insulation vacuum
- Spare ordered (Japan), expected mid Nov.
- Order
done; repair to be done by
Linde
end of Nov.
Aluminium to Stainless Steel transition DN400
HP
LP
MPSlide11
QRL Headers C & D compensator x-rays statusSlide12
QRL Headers C & D compensator repair status
Header D in the LS1 planning
Additional information:
-
Header D in 14L2:
external envelope was open,
dedicated spare testing is underway
-
Header D:
4 additional spares available
-
Header E:
31/64 (LHC all sectors) compensators checked and OK (partially visible on line C x-ray)
-
Headers C & E new spares:
3 offers requested mid August, only one feedback from Witzenmann received, order will be sent next week with 12 weeks of delivery time for 30 DN100 and 15 DN80Slide13
DFBA 13 kA splices consolidation
Schedule shift caused by:
- Extra time for repair of non conformities (quality checks, geometrical) for DFBAN & DFBAO
- Discovery of damaged bellows in DFBAO
- Personnel illness (one)
Forecast:
- Disturbance due to disconnection (same team as splices) of DFBAK (for repairing the bellows) will add 1-2 weeks
- Training of additional personnel (existing) for recoverySlide14
DFBA gimbal bellowsFollowing the discovery of a damaged bellow in the DFBAO by using a
double endoscope inspection technique, a global inspection of the bellows is being carried out:t
o be completed by end of the w 43 on all DFBAs
Current status (4/32; 12.5 %):
2 DFBAs with upper bellows damaged (DFBAK collapsed &
probably leaking
,
DFBAO damaged but not leaking
)
2 DFBAs with lower gimbal damaged;
not leaking
(DFBAI & DFBAF)
First inspection of DFBAO
Double endoscope inspection of DFBAO
upper bellows
Lower bellowsSlide15
DFBA gimbal bellows: repair strategy
- Lower bellows:
in-situ repair
, 3 weeks each for DFBAI and DFBAF respectively (patching solution)
- Upper bellow DFBAK:
workshop repair
, bellows replacement, learning form opening
- Develop
local internal solution for DFBAO
by drilling the inner layer of the 2-layer bellow thus eliminating the helium accumulation issue and reinforce the mechanical resistance of the bellow by encapsulating it in an epoxy shell. Decision for DFBAO in 6 weeks.
DFBAK
closed 24/02/2014
DFBAO
closed,
if local
repair, 17/01/2014
DFBAO
closed,
if
workshop repair, 09/04/2014Slide16
ConclusionsPreventive Maintenance - Major overhauling
C199: Discrepancy on baseline/work progress/work orders clarified and to be closely followed; major overhauling of helium compressors and 3.3 kV electrical motors on schedule
Helium Cold Boxes repairs in LHC P2-P8-P6
cryoplants
Very good progress; P2-P8 completed; P6 on schedule
QRL compensator bellows
D
amaged bellow on header D in the repair planning compliant to LS1; Header C bellows repair work ahead of schedule; spares procurement for all bellow’s type on going
DFBA
splice
consolidation
Despite additional resources work progress remains constantly shifted from the baseline (originally expected to recover by end of 2013) due to geometrical non-conformities, personnel illness and the discovery of a 4
th damaged gimbal interfering with teams load. Training of additional personnel scheduled
DFBA gimbal bellows
On going cross-check by double endoscopy of all DFBAs bellows;
DFBAI, DFBAF: in-situ repair (patching)
DFBAK: workshop repair (bellows replacement)
DFBAO: development of dedicated local technical approach for in-situ repair prioritized; final decision in 6 weeks, if negative, workshop repair
(bellows replacement
)Slide17