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H. Felice and all 1
Collar Pack #2 Disassembly IncidentSummary and Plan
Helene FeliceHeng Pan, Dan Cheng, Xiaorong Wang, Soren Prestemon, Maxim Martchevsky,
Ahmet Pekedis, Matt Reynolds, Daryl Horler, Jason Duponte, Tom Lipton, Jordan Taylor
07/13/2015
H. Felice and all 2
• On 07/07/2015• During the collar pack #2 disassembly an incident happened:
• The upper coils shifted and collapsed
• Preliminary assessment immediately after incident • No one was injured• No assembly tooling were damaged• All collar stacks are intact.
07/13/2015
H. Felice and all 3
• Normal setup
• During the incident• The center coil support spud was not in place;• The technicians were removing the side collar pack, the steel angle block
was released
Context of the incident
Steel Angle block
Coil support spud
Assembly Table Assembly Table
Return End Return End
1- Disassemble the top collar stack 2 -Disassemble the collar stack #2
07/13/2015
H. Felice and all 4
Incident sequence
Return end view• Coil 104 fell onto the assembly table, • Coil 3 fell into coil 5• Red circles indicate the edge of the coil impacting
other coil or assembly table.
03 104
103 05
03 104
103 05
03
104
103 05
Return end view
Ready to disassemble Removed the collars Coils fell off
03 104
103 05 103
104
104
07/13/2015
H. Felice and all 5
Preliminary Assessment summarydetails in back-up slides
03
05103
104
Coil 103• No visual damage• Electrical tests ongoing –
delayed due to high humidity
Coil 3• Some local scratches (red
circle area) • All electrical tests ok
Coil 104• OL splice: epoxy delamination• Damaged wiring of the SG bridges
(temp comp), SG are intact• Indents on the coil OD• Bump on the midplane• All electrical tests ok
Coil 5• Sectioned wiring from bridges to
connector• Kapton GPI damage observed with
epoxy amange underneath where coil 104 SG impacted coil 5
• Electrical tests ongoing – delayed due to high humidity
07/13/2015
H. Felice and all 6
1st assessment following the incident
• Visual inspection presented at a dedicated meeting the day after the incident on 7/8/2015
• Electrical tests started on 07/07/2015 and ongoing• Continuity checks with hand-held meter:
o between PH and coilo between coil and end shoeso between IL and OL ends at both ends
• Take sequential R measurements for all coils. • Inductance measurements for all coils.• Impulse tests and compare with pre-assembly measurements.• Full set Hi-pot test (e.g., coil vs. PH, endshoe vs. endshoe and etc).
07/13/2015
H. Felice and all 7
Plan agreed on 07/08/2015
• Assessment of the coils continues this week (07/13/17) by LBNL to provide a more detailed description of the observations. Complete electrical tests.
• LARP management visit to LBNL for the MQXFA review: will take a look at the coils• CERN/LARP skype call on Friday : possible decision to move forward if coils are assessed
ok
• Early following week (07/20-22): report finalized
• Readiness review (if coils not ok) or decision meeting (if coils ok) week of 07/27
Possible spare coils• Coil 6: being impregnated• Coil 102: possible problematic splice• Coil 2: already tested in the mirror
Updated schedule will be presented soon
07/13/2015
H. Felice and all 9
Incident pictures
Coil 104
Epoxy delaminated on the lead end splice area
Before incident
Before incident
07/13/2015
H. Felice and all 10
Incident pictures
Coil 104
Strain gauge wires broken Before incident
• The temperature compensator strain gauges were inspected, no damage.
• Need to be rewired.
Temperature compensator pad separated
07/13/2015
H. Felice and all 11
Incident pictures
Coil 104
• Dent observed in the GPI Kapton layer. No visible damage to the coil itself
07/13/2015
H. Felice and all 12
Incident pictures
Coil 104
• Bump on the midplane, dent observed in the Kapton GPI. Evidence of epoxy damage on the coil.
07/13/2015
H. Felice and all 13
Incident pictures
Coil 104
• Dent on the RE end shoe observed. It looks like the coil dropped on an object on the assembly table (not sure what).
07/13/2015
H. Felice and all 14
Incident pictures
Coil 05
• All strain gauge wires were cut.
Coil 03
Coil 05
03
05103
07/13/2015
H. Felice and all 15
Incident pictures
Coil 05
• Kapton GPI damage observed, likely due to catching the SG temperature compensator pad of Coil 104. Evidence of epoxy damage underneath.
Coils fell off
03
05103
104
07/13/2015
H. Felice and all 16
Incident pictures
Coil 03
• RE endshoe: Dents and scratches observed.
07/13/2015
H. Felice and all 18
Incident pictures
Coil 03
• Dents and scratches observed on the lead end.
Before incident
07/13/2015
H. Felice and all 19
Coil inspections
• Visual inspections• Electrical checks (priorities on 104, 3, 5):
• Continuity checks with hand-held meter:o between PH and coilo between coil and end shoeso between IL and OL ends at both ends
• Take sequential R measurements for all coils. • Inductance measurements for all coils.• Impulse tests and compare with pre-assembly measurements.• Full set Hi-pot test (e.g., coil vs. PH, endshoe vs. endshoe and etc).
Coil 104 Coil 03 Coil 05 Coil 103
Visual inspection √ √ √ √
Continuity check √ √ planned planned
Sequential R √ √ planned planned
Impulse test √ √ planned planned
Inductance measurement planed planed planed planned
Hi pot √ ongoing planned planned
07/13/2015
H. Felice and all 20
Coil inspections
0.00E+00 1.00E-05 2.00E-05 3.00E-05 4.00E-05 5.00E-05 6.00E-05
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
MQXFS 104 Pre/Post Event Impulse Test
2000 V Pre Event 2000 V Post Event
0.00E+00 1.00E-05 2.00E-05 3.00E-05 4.00E-05 5.00E-05 6.00E-05
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
SQXF 03 Pre/Post Event Impulse Test
2000 V Pre Event 2000 V Post Event
07/13/2015
H. Felice and all 21
Coil inspections
Coil
PHA01 2500/2500 PHA01
PHA02 2500/2500
PHB01 2500/2500
PHA02
PHB02 2500/2500 PHB01
PHB03 2500/2500 PHB02 PHB03 PHB04
PHB04 2500/2500 LE IL
Endshoe
LE IL Endshoe 1000/1000 2500/2500 2500/2500
LE OL Endshoe 1000/1000
2500/2500 2500/2500 2500/2500 2500/2500 600/600RE IL
Endshoe
RE IL Endshoe 1000/1000 2500/2500 2500/2500
RE OL Endshoe 1000/1000
2500/2500 2500/2500 2500/2500 2500/2500
600/600
Pole 500/500
Coil104 – pre/post incident
07/13/2015
H. Felice and all 22
Summary and next steps
Electrical assessment• Coil 104 passed all the electrical tests listed in the slide 15.• Coil 03 passed the continuity test, sequential R test and impulse test, hi
pot test is ongoing.• Coils 05 and 103 will be electrically checked as well.
Repair plan:• GPI layers replacement• Repair/dress epoxy as necessary• Strain gauge repairs to 104 and 005• Schedule TBD
07/13/2015