Cold vacuum system recall Phase 1 2 amp 3 VSC activities Resources Infrastructure Still to do Paul Cruikshank on behalf of TEVSC Paul Cruikshank TEVSC Leak Testing in SMACC 3 ID: 488824
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Slide1
LEAK TESTING in SMACC
Cold vacuum system recallPhase 1, 2 & 3 VSC activitiesResources, InfrastructureStill to do......... Paul Cruikshank on behalf of TE-VSC
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide2
2
Paul Cruikshank TE/VSC Leak Testing in SMACC 3rd LHC Splice Review, 12-14 Nov ‘12Slide3
LHC arc cold vacuum systems - recall
3Paul Cruikshank TE/VSC Leak Testing in SMACC 3rd LHC Splice Review, 12-14 Nov ‘12Slide4
LHC arc cold vacuum systems - recall
4Paul Cruikshank TE/VSC Leak Testing in SMACC 3rd LHC Splice Review, 12-14 Nov ‘12Slide5
LHC arc cold vacuum systems - recall
5
LHC
magnetcryostat
QRL
cryostat
Jumpers
Vacuum
barriers
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide6
LHC arc cold vacuum systems - recall
6Paul Cruikshank TE/VSC Leak Testing in SMACC 3rd LHC Splice Review, 12-14 Nov ‘12Slide7
LHC arc cold vacuum systems - recall
7LHC cryostats were designed with DN100 ISO-K ‘pumping’ ports at vacuum subsector extremities. 300l/s turbos can be installed (and removed) without breaking vacuum
Tunnel equipment: 63 m
3
/
hr
mobile primaries – 20 units
300 l/s mobile primaries – 40 units
MS Leak detectors – 20 units
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide8
LS1 leak test
support & consolidation - cold vacuum8IC statusArc splice train
- LT supportLHC
cons- LT support
DFBA
- LT support
VSC
IV consolidation
VSC cold BV cons
Closed
(phase
1)
Degrade
IV,
Vent IV
,
LT
(80 K < T <300
K),
Localise
known He leaks,
He & RGA analysis
Vent BV, RF ball,
Open
(phase 2)
M clamshell,
Cryomagnets
,
CC, Y, Diodes
Splices
&
l
yra
,
DFBAK,
Flexibles,
Localise
He leaks (5 bar),
Vent QRL & SAM,
Flap valves,
DN200 springs &
pumpouts
,
Reclamping
of DN100 & 63,
Additional by-passes &
turbos
,
Turbo maintenance,
Pump & LT QRL
&
SAM,
PIM
temp
protection,
PIM exchange,
Rupture
discs,
RF
ball,
Pump & LT BV,
Protection shells,
Closed
(phase 3)
Pump
IV,LT envelope,LT internals,LT after PT,LT envelope,LT internals,LT after PT,LT envelope,LT internals,LT after PT,
b
efore train
t
ime window
-
typical activities in an arc
Paul Cruikshank TE/VSC Leak Testing in SMACC 3rd LHC Splice Review, 12-14 Nov ‘12Slide9
LS1 leak test
support & consolidation - cold vacuum9IC statusArc splice train
- LT supportLHC
cons- LT support
DFBA
- LT support
VSC
IV consolidation
VSC cold BV cons
Closed
(phase
1)
Degrade
IV,
Vent IV
,
LT
(80 K < T <300
K),
Localise
known He leaks,
He & RGA analysis
Vent BV, RF ball,
Open
(phase 2)
M clamshell,
Cryomagnets
,
CC, Y, Diodes
Splices
&
l
yra
,
DFBAK,
Flexibles,
Localise
He leaks (5 bar),
Vent QRL & SAM,
Flap valves,
DN200 springs &
pumpouts
,
Reclamping
of DN100 & 63,
Additional by-passes &
turbos
,
Turbo maintenance,
Pump & LT QRL
&
SAM,
PIM
temp
protection,
PIM exchange,
Rupture
discs,
RF
ball,
Pump & LT BV,
Protection shells,
Closed
(phase 3)
Pump
IV,LT envelope,LT internals,LT after PT,LT envelope,LT internals,LT after PT,LT envelope,LT internals,LT after PT,
b
efore train
t
ime window
50 %
10
%
10 %
20
%
10
%
IS Workload
-
t
ypical activities in an arc
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide10
Phase 1 leak testing
Cryostat still closed & under vacuumTightness status of arc IV and BV Under vacuum, > 80 K, He pressure constant, 3 days/arcLongitudinally localise known helium leaks (see later)
Insulation Vacuum degradation to assist warm-up
Insulation vacuum venting to tunnel air
RF ball test (see
C.Garion
presentation)
10
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide11
Phase 1 - activities
22 internal He leaks to solve 2 leaks > 10-4 mbarl/s , 12 leaks > 10-6 mbarl/s @ RTHighest priorities are: 3-4, A27L4, coldmass circuit – very large leak should be localised quickly 4-5 QRL SubS B, line C – will need dedicated intervention scenario with CRGNote: - the LHC operates with these leaks; - the 2 biggest leaks weren’t present at RT after welding and PTest; - for many of known leaks, search in 2006 & 2007 was not successful
, but they have not evolved.
- previously eliminated leaks a) at welds - incomplete, inclusions, porosity, LME, etc
b) others - shocks, inclusions, false arcs, ultrasonic vibrations,
etc
11
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide12
Longitudinal leak localisation
- which IC to open?12An under vacuum leak test in molecular flow conditions, using turbomolecular pump, mass spectrometer leak detector and helium as tracer gas.Assume linear conductance of cryostat, so C
1/L (with & without MLI)For S >> C1 or C2:
q1/q2
C1/C2
L2/L1
For
LHC cryostats, S ~ C so apply correction for effective pumping
speed
Experience shows method is not perfect to one interconnect! Additional adjacent interconnects were often opened to
localise
the leak.
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide13
Phase 1 - Leak testing
Known internal leaks:Re-measure the known internal helium leaks before venting:Cryostat under vac, temp > 80 K, He pressure constant, Two 8 hour days per known leak with above conditions.Need CRG support to pump and pressurise circuits.Leaks in the same arc can be treated in parallelAfter venting @ RT, MSC to open 5 priority interconnects/leak (1 day).VSC will need pressure ~ 6 bar in cold mass
& c’k circuit for
2 days.Co-activity with ‘special intervention team’ needs to be co-ordinated.
13
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide14
Clamshells
– recall~20 diameters and diameter combinations for LSS standalonesNBR, polyurethane, silicone rubber, metal+mastic
14
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide15
Clamshells
Support rings for asymmetrical modelsSealing on non-perfect tube surfaces:alcohol for small defects to allow a E-8 mbar.l/s residual signal to reduce to E-10 rangemastic for bridging gaps
vacuum grease for intermediate
defects (e.g. surface scratches)Same
space
as orbital
welding
machine
15
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide16
Phase 2 - Leak testing in train
Leak test all new welds before W closure:Validate beam vacuum – new PIMsValidate 100% M welds with clamshell – 60 IC/weekValidate 100% other new welds with clamshell (new magnets, etc. )Treat non-conformities with MSC special intervention team (& MME) 16
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide17
Phase 2 - Clamshells on M
Technical challenges: ~ 10’000 M welds to clamshell Want to develop & validate a ‘long clamshell’ to test both M welds How to supply He into 214 m cold mass volume (also pump out of air)?Baseline - via one unwelded M sleeveSpecial interface tool to develop – modified clamshell,Local pumping system and backfill (~ 6 m3) from He bottle, Option 1 - v
ia M2N hose – must be cut & rewelded – 13 positions/arc
Option 2 - via QRL – when available (R2E, cryo maintenance)
Any ‘holes’ in 214 m cold mass envelope will block clamshell test (& train)
eg
M lines, N connection box at SSS, jumper, diode, DFBA
Second pass required after final M sleeve is welded
Expect between 10 to 50 leaks on M welds (installation statistics).
17
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide18
Phase 2 - LT Support - SIT & DFBA
Special intervention teamCryomagnet exchange (MB & SSS) = V, X, E, N, C’, K linesY repairs = X, CCryostat, diodes, Q6 He level gauge, Q1 braids, Clamshells and special tools existDedicated VSC team DFBAMain splices, lyras, flexible hoses - 1.9 K volume of DS
Pigtails – 4.5 K bath – independent closed He volume DFBAK HCM removal – above plus jumper & LCM interconnect,
Clamshell geometries to develop, beam vacuum equipment to remove.
Dedicated VSC team(s) IV & BV
Other challenges:
Closed volumes can be pumped and backfilled (&
pressurised
)
with He
Open volumes must be injected with He just prior to welding then
clamshelled
on-line.
18
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide19
Phase 3 - Leak testing after W closure
Evacuate & global leak test all insulation vacuum subsectors after W closure:Evacuate with mobile groupsValidate cryostat envelope – W, DN200, new magnets, reclamping, etc Validate internal helium circuits at 1 bar – M, N, new magnets, Y, etc.Need helium via QRL, all headers of sectors closed A closure rate of 60 IC/week gives ~ 12 vacuum subsectors in parallelValidate internal circuits after P.Test at 50% of design pressureTreat any non-conformities with MSC special intervention team & CRG
Duration of 2-3 weeks/vacuum subsector – expect 0 - 3 internal leaks/arc.
19
Leak imported from phase 2:
Clamshell not possible,
Clamshell poor sensitivity,
Interconnection damage
Leak opened by
outgassing
or
Leak opened by
P.Test
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide20
Documentation
Procedures:Existing procedures for arc & LSS leak testingExisting maintenance procedures for pumping groupsExisting procedures for vacuum degradationExisting procedure for relief spring installationNeed to produce generic procedure for clamshell testsData storage: Use of WISH tool to define status of leak test tasks Create NCR in edms
in case of leak and attach to WISH step Maintain test/activity details in VSC Excel files – who, what, when,
Team leaders in the tunnel send daily reports
Maintain overview table of subsector status,
List of known He leaks – NCR in
edms
20
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide21
Resources summary
VSC Staff2 Engineers, 1 Fellow, 5 techniciansVacuum support contract S13314 industrial support staff required for ins vacuum system (& B.Vac) arc activities in 2013, then reduction will depend on agreed planning.FSU support (FSU-TE-09,S145)0.5 additional workshop mechanic for PIM activity (+0.5 for expts)Polish collaboration
6 eng/technical staff for cold beam vacuum interconnect QA
inspection at opening/closing, beam vac temporary protection,
endoscopy at PIM cutting positions
install protection shells
All will require safety training, access training, safety equipment..........
21
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide22
Infrastructure needs
Bungalows/office space:Office space at even points only (shared with VSC-LBV)CERN wireless intranet & telephoneQA, doc, tech meeting, storage of sensitive equipment Polish Collaboration – all equipment provided by VSCcars, bikes, trailers, safety equip, PC, camerasPEFRA;3 dedicated VSC
Pefra at each even point from tunnel access date.for mobile pumping groups, detectors, tooling – shared with LBV.
Dedicated VSC/EIV logistics zone on surface:
At each even point, 5m2 storage & 14 bicycles & 5 trailers.
22
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide23
Still to do in 2012
Optimise phase 1, 2 & 3 activities with SMACC & LS1 coordination Complete inventory of SIT & DFBA tasks Continue procurement of additional clamshells Develop tooling for helium injection at unwelded M sleeve. Expand, integrate, equip & train IS, FSU, & PL teams
Create ECRs
Complete QA procedures
Complete PPSPS, Safety Folder, DIMR,
Other?
23
Paul Cruikshank TE/VSC Leak Testing in SMACC 3
rd
LHC Splice Review, 12-14 Nov ‘12Slide24
Thanks for your attention.
24Paul Cruikshank TE/VSC Leak Testing in SMACC 3rd LHC Splice Review, 12-14 Nov ‘12Slide25
VSC Consolidation – Insulation Vacuum
25Paul Cruikshank LS1 Preparation - Insulation Vacuum 20th June 2012ActivityAreaMotivation(1/impact if not done)Other Groups Affected
Potential conflict with splice consolidation
Install Flap
Valves
arcs, LSS, QRL
Self closing over pressure valves
no
Install by-pass valves
arcs 2-3, 7-8, 8-1
Pumping
redundancy
no
Install additional
turbos
(& cables
)
QRL extremities
Pumping
redundancy
EL
no
Install long cable for
turbos
IR3R - LSS3
Eliminate
remote-restart
problem
EL
no
Localise and repair known leaks
all arcs
Eliminate helium leaks
MSC, CRG
yes
Leak test envelopes
–
cryostat & He
(before
& after
splice repairs)
arcs, LSS, QRL
Check tightness integrity
CRG
yes
Maintain turbo pumping groups
arcs, LSS
Maintenance - preventive and corrective
no
Inspect
beam screen capillary
arc 8-1
Understand
origin of
helium leak
no
Repair
gauge cabling in mid
arcs
all arcs
Eliminate faulty gauge reading
no
Add pump-out
ports
all
arcs
Increase pumping speed
in case of helium leaks
MSC
no
Finalise
‘auto-restart’
All arcs
Restart
turbos
after
p.cut
no
Minor taskSlide26
VSC Support – Insulation Vacuum
26Paul Cruikshank LS1 Preparation - Insulation Vacuum 20th June 2012ActivityAreaMotivationOther Groups Affected
Comments
Splice consolidation
All arcs
Busbar
non-conformities
Train activity
Cryomagnet replacement
All arcs
Except 5-6,6-7
Various non-conformities
MSC
s
pecial
intervention team
IR3 DS - bypass cryostat for collimators
Postponed
SMI2 proto
Connnection cryostat consolidation
TBC
Busbar
protection
MSC
s
pecial
intervention team
Y-Lines repair
All arcs?
Cryo
performance
MSC
s
pecial
intervention team
New
DN200,
Re-clamping
of
inst
flanges
2-3, 7-8, 8-1,
All
arcs
Safety
conformity
MSC
s
pecial
intervention team
SAM helium gauge consolidation
6R2,
6L8
Cryo
control
MSC
s
pecial
intervention team
Triplet braid
LSS1
& 5
Cryo
performance
MSC
s
pecial
intervention team
DFBA
consolidation
All arc ?
Busbars
& braids
?
These projects will require extensive VSC leak testing/technical support
Are they already in ‘PLAN’ ?Slide27
VSC Consolidation – Cold Beam Vacuum
27Paul Cruikshank LS1 Preparation - Insulation Vacuum 20th June 2012ActivityAreaMotivationOther Groups Affected
Potential conflict with splice consolidation
Exchange/repair PIMS
Arcs, LSS
Eliminate critical PIMs
MSC
yes
Install
beam vac.
protection
shells
Arcs, LSS
Protection against electrical arcs
MSC
yes
Exchange S3-4 beam screens with reversed saw teeth
Arc 3-4
Dynamic
vacuum effects
MSC,EL,SU
Yes
Install additional rupture
disc
Arcs
SSS, LSS
Protect
beam vac.
against overpressure
no
Leak test envelope- arc, LSS
Arcs, LSS
Check tightness integrity
yes
Install/remove mobile pumping groups
Arcs, LSS
Remove desorbed gas/recondition
no
Install additional gauges in arcs
Arcs
Consolidate instrumentation
EL
no
RF ball test
Arcs
Aperture check
no
Faster closing of some
sector valves
Pneumatics modification
Arcs
Reduce
debris propagation
no
Low priority
Due to synergies, some VSC resources are shared between insulation & beam vacuum arc activities Slide28
VSC Consolidation – Insulation Vacuum (not in tunnel)
28Paul Cruikshank LS1 Preparation - Insulation Vacuum 20th June 2012ActivityAreaMotivationOther sections Affected
Potential conflict with splice consolidation
Profibus interface on mobile
turbos
(41) & primaries (20)
Remote visibility/operation
of mobile groups
ICM
Rebuild 10
mobile pumping groups with offset electronics
Radiation
hard groups in case of helium leaks
ICM
Equip 14 MB + 5 SSS +
undulator
with beam screens
Replacement
cryomagnets
In advance of LS1
Activities outside tunnel are also added to ‘PLAN’ to have overview of all resource needs..........Slide29
Clamshells on M lines (1)
Why weren’t M line clamshells adopted during LHC installation ?Many ‘holes’ in 214 m cold mass chain (late magnets, NCR, ELQA, etc) – late clamshell tests would stop series W closure.Masked time was available to treat leak non-conformities after W closure.Was less leak testing parallelism per arc and per sector.Why adopt M line clamshells for splice consolidation?Early feedback on weld quality in advance of W closureLittle masked time available to treat leak non-conformities in global testWhole arc is closed in 4 weeks – twice rate of LHC installation peak
(Most) leak identification & repair is removed from critical path
In proposed LS1 planning, clamshells can be performed in masked time.If no M clamshell test – foresee several additional NC weeks in global test
29
Paul Cruikshank LS1 Preparation - Insulation Vacuum 20
th
June 2012