a & w team

Andrea Musso TE-MSC-CMI

& a w team

• Mandate

• Activities

• Procedures

• Tooling

• Resources

• Planning

• Conclusions


Mandate

• To open all W bellows starting “The Train”

• To close all W bellows completing “The Train”

• To install all missing Pressure Relief Devices (DN200)

• To upgrade all thermal screens

• To remove, repair and reinstall all M bellows’ protections


How to… W bellows openingRemove screws

Open bellows Remove MLI blankets 1

Welds to cut

Remove thermal shields

Remove MLI blankets 2Remove shield (screwed)

Courtesy Thierry

Renaglia


Thermal screens upgrade

All the removed thermal screens have to be modified

The main reasons for modification are:

– To avoid welding in the tunnel [risk of fire]

– To avoid welds to be removed during (next) openings [RP issue]


The new design…

Cour

tesy

G. V

illig

erCo

urte

sy G

. Vill

iger

Hinge

Braids

Clamp with silver-plated screws

Snap fastener

Outer

Inner

Outer

Inner

Outer side view

Clamp

New design validated by analytical calculations and cold test at SM18

Approved by TE-TM – ECR fully approved


How to… Thermal screens upgrade

The main tasks to perform:

– RP clearance for transport

– Transport to surface (Building 183, dedicated workshop)

– Welds removal and re-shaping

– Installation of clamp, hinge, latches, aluminum braids

– ….. back to the tunnel, ready for installation


Installation of Safety Relief Devices (DN200) 1/2

This activity was partially performed during last shutdown (2008-2009)

There are 612 SRV left for installation in 4 sectors:

– Sector 2-3– Sector 4-5 (partially)– Sector 7-8– Sector 8-1

Nota: a partial opening of the interconnection (i.e. W opening and MLI removal) is requested to install the SRD’s


Installation of Safety Relief Devices (DN200) 2/2


How to… M Bellows protections

All M bellows protections need to be removedAfter removal, a threaded insert will be installed in order to avoid seizing[RP issue]

Screws to be removed

Insert to be installed


Procedures and ECR’s

All procedures for these activities are written and were circulated for approvals

Title Type Number EDMS Approved Released

Safety Relief Devices ECR LHC-QJ-EC-0001 1155385 Yes Yes

Safety Relief Devices Procedure LHC-QBBI-IP-0016 1236232 Yes In progress

Thermal screen modification ECR LHC-QBBI-EC-0002 1236451 Yes Yes

Opening of W bellows Procedure LHC-QBBI-IP-0017 1236329 Yes Yes

Closing of W bellows Procedure LHC-QBBI-IP0018 1236362 Yes In progress


(Special) ToolingSafety Relief Devices

• Cutting machine + saw blade => needed 125m, ordered• Electrical motor => needed 9x, OK• Gearbox => needed 6x, OK• Blade holder => needed 6x, in progress

• Swarf collector => needed 3x, OK

W Bellows (+ Thermal screens upgrade + M protections)

• Lifting rail => Needed 10x: 6x available, 4 in progress

• Swarf collector => prototype ready, 10x needed, order in progress

• Drilling template => prototype ready, 10x needed, order in progress

• All other tooling is standard from industry, being ordered


Resources

Andr

ea M

usso

(A

nna

Chru

l)

Jose Manuel Gomes De Faria SRD

Activity Leader

DUBNA Team leaderFeb 1st 2013

(March 1st 2013)

Team 1 (2x)March 15th 2013


Alain Bastard W Opening & Closure

Activity Leader

NTUA Dimitrios Damianoglou

(Kostantinos Razakias, Feb 1st)

Team 1 (3x)March 1st 2013



WUT InstituteNov 1st 2012

(Feb 1st 2013)



Team3 (3x)March 15th 2013

Graeme Barlow Thermal Shields Upgrade

Activity Leader

Team 1 (2x FSU)(Feb 2013)

Each team installs 3 SRD’s per day

(i.e. 30 per week total, 6 weeks / sector)

Each team opens or closes 3 or 4 interconnections per day(i.e. ~90 per week total, 3

weeks / sector)


Resources

A video was realized in order to give information to personnel from Institutes before they arrive at CERN

Click here to access video

Summary:– 4 CERN staff– 11 People from collaboration with Greece (NTUA)– 11 + 1 People from collaboration with Poland (WUT)– 6 (7) people from collaboration with Russia (DUBNA)– 2 FSU

Total: 32 persons

http://www.youtube.com/watch?v=KcRDMjNiBts&list=HL1352704232&feature=mh_lolz


Planning

Safety Relief Devices Considering the previous experience and the available personnel, there are no show-stoppers identified.The planning can be followed and the teams shall end before “the train” arrives.

W Bellows (+ Thermal screens upgrade + M protections) If openings could strictly follow “the train”, there would be an appropriate contingency.Considering other openings to be performed in parallel in several sectors (magnets exchange, leak detection, ball test…) , two teams will need to be detached from “the train”. Still feasible but needs good coordination.


Planning some numbers

During the Long Shutdown 1 our team will have to perform:

• 1695 Openings

• 1695 Closures

• Remove, transport twice, re-work and install 3400 shields (+1700 radiative

shields); this includes 1700 hinges, 3400 latchers, 3400 braids, 1700

clamps, 8500 holes to drill in-situ…

• Remove, repair and re-install 10200 M protections (~80.000 holes to drill)

• Install 612 SRD

• ………

+ needed due to NCR’s


Conclusions

• All documentation is ready and available

• Resources are adequate, training is foreseen for all members

• Planning can be respected but good coordination with parallel

openings is required to avoid stopping “the train”

• Tooling is (almost) ready

Documents

a & w team