S. Evrard — EN/MEFIEFC Workshop, March 08, 2012

TCC2/TDC2 Shutdown Activities and Consolidation

Plans

http://cern.ch/tcc2tdc2WG

On behalf of the TDC2/TCC2 WG team

S.Evrard – IEFC Workshop, 08.03.2012

Agenda1. Planned works for TAX repair2. Other shutdown activities in the cavern: targets, magnets,

infrastructure improvements 3. List of activities for LS1 in view of operation in 2014

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S.Evrard – IEFC Workshop, 08.03.2012

Repair and review the North Area TAXs

‣TAX motor failure ‣The TAXs, installed downstream of the primary targets of the North Area, are made of massive blocks put on motorized tables that can move up/down.

‣High radiation environment‣The TAX blocks intercept about 1019 protons/year about 6 mSv/h outside the shielding and probably 30 to 40 mSv/h at the blocks and even higher near the beam impact point

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S.Evrard – IEFC Workshop, 08.03.2012 4

Repair of the North Area TAXs: Scope of work

‣XTAX Repair‣8 out of 12 TAX tables to be

repaired in the 2011/2012 shutdown

‣T2, T4 TAXs : avoid compromises to physics program as in 2011

‣T6 TAXs : present situation has no impact to physics of COMPASS

‣ T6 TAXs to be repaired in LS1‣Adopted solution

‣replace existing motors with spare ones

‣motors showed a rather long lifetime (10 years)

‣they are as RADHARD as we can presently get

‣search for new ones ongoing but longer delays

‣maintain existing location underneath the TAX blocks

‣investigated other options but rejected due to space limitations

‣optimize exchange procedure‣for motor itself but also for the area

in general‣fully remote exchange using robotic

manipulators under investigation

T2H2

H4

T4H6H8P0

T6 M2

TT20

S.Evrard – IEFC Workshop, 08.03.2012 5

Repair of the North Area TAXs: scenario

S. Girod EN-MEF

Telescopic spring

Access for greasing screw

S.Evrard – IEFC Workshop, 08.03.2012

Repair of the North Area TAXs: WDP & DIMR‣A detailed repair procedure and a risk analysis are prepared

‣Major remaining risk: PR537 reliabilityTechnical measures taken: extensive maintenance and spare parts

‣Optimization steps WDP and DIMR preparation DIMR link‣Design Review: reduce the dose in future interventions‣Handle TAX assembly (blocks + table) as a set: no access to most activated part

‣PR537 remote control: reduced presence in TCC2‣Increase PR537 lifting height: lateral shielding stays in place‣Bunker for mechanical work: operators well shielded‣Tailor made shielding (100 mm thick steel plate + lead 50mm): dose reduction /80

‣Optimize table repair sequence: # movements, start with least activated first

‣Extensive dry run tests in EHN1: train technicians‣Extensive dry run tests in TCC2 : train crane operators 6

S.Evrard – IEFC Workshop, 08.03.2012 7

Repair of the North Area TAXs: dry run tests

‣Check and validation of:

‣Work breakdown

‣Time estimate & allocated resources

‣Tooling‣Training sessions were organized for each stakeholder

S.Evrard – IEFC Workshop, 08.03.2012 8

Repair of the North Area TAXs: DIMR detail

Work breakdown & planning Dose estimate Risk analysis

Personnel involved, statistics

S.Evrard – IEFC Workshop, 08.03.2012

Repair of the North Area TAXs: Work Dose Planning

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Collective dose (uSv)

Individual dose (uSv)M1: mechanics (8)M2: mechanics expert (8)T: transport (6)RP: Radiation protection team (4)S: survey (2)

‣Collective dose: 8.4 mSv, ‣36 people involved, ‣max individual dose: 436 uSv

M1 M2 T RP S0

500

1000

1500

2000

2500

3000

3500

4000

2150

3491

1821

910

30

M1 M2 T RP S0

50

100

150

200

250

300

350

400

450

500

269

436

304

228

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S.Evrard – IEFC Workshop, 08.03.2012

Repair of the North Area TAXs: Work Dose Planning

10

Work near the hot elements Reminder TAX renewal in 2002: collective dose 23,9 mSv, Max individual dose 4.2 mSv

Surveys

Roofs handling

Roof block modification

TCC2 dry run

Downstream table repair

Worksite clean-up

Upstream table repair

Preparatory works

RP supervision

Reconnect services

Service disjunction

0 200 400 600 800 1000 1200 1400 1600

39.3333333333333

155

217.333333333334

258.333333333333

292.733333333333

475

556.733333333335

583.333333333334

763.823333333334

953.516666666667

1403.51666666667Dose breakdown by activity

Dose (uSv)

S.Evrard – IEFC Workshop, 08.03.2012

Repair of the North Area TAXs: Work Dose Planning

11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 240

1000

2000

3000

4000

5000

6000

7000

8000

9000

Dose breakdown by day

dose by day (uSv)cumulative dose (uSv)

Days

Dos

e (u

Sv)

S.Evrard – IEFC Workshop, 08.03.2012

‣ Overhead crane PR532 built in 1976‣ Logbook not frequently used (2001-2003: XTAX, 2006: Shielding, 2011: Lighting renewal)‣ Failure modes investigated (experiences from ECN3 crane, same generation) speed

variators are the weak link.‣ Thorough preventive maintenance and load tests including motor electrical isolation measurements

and cable connection check.‣ 3 speed variators were sent to and inspected by the supplier.‣ Auxiliary motors are available in case of motor failure‣ No embedded electronics (located in electrical cabinets in safe area TA801)

‣ A remote handling controller is now installed and new lifting jigs are available‣ Intensive crane training with dummy load in TCC2 is ongoing

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Other Shutdown activities: overhead crane upgrade

S.Evrard – IEFC Workshop, 08.03.2012 13

Other shutdown activities: TCC2 Targets

‣Review of failure modes and of the procedures to recover from each failure. ‣ Mobile shielding motor failure is the most important failure mode.

‣Identification of necessary urgent consolidation actions to be done during the 2011/2012 winter stop.

‣ Mobile shielding motor replacement test and annual target stations maintenance‣Review of the design and proposal of eventual modifications during LS1

‣ Redesign based on the same principles: no major change but replacement of existing and aged equipment with new generation items

‣Preparation of ALARA meetings for clearly identified procedures. ‣ Done for mobile shielding motor replacement‣ To be done for LS1 activities

S.Evrard – IEFC Workshop, 08.03.2012

Other shutdown activities: Vacuum repairs

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High radioactivity + high relative humidity + PVC (Cl)↓

Corrosions of stainless steel elements and deterioration of polymeric gaskets (valves’ mechanism)

↓Vacuum leaks and frequent interventions

‣General survey of the vacuum system‣Visual inspection of all vacuum chambers and bellows

‣Protect the existing vacuum chambers from falling acid droplets with Kapton foil

‣Removal of Al foils (not suited for acid protection)‣Chambers and splitters are covered by Kapton foils that are tighten by stainless steel wire

‣Detect and repair as soon as possible suspected leak

‣Leak found on the end window of sector 2020, new windows under construction, will be replaced in week 12

‣Replacement of two sector valves

S.Evrard – IEFC Workshop, 08.03.2012

Other shutdown activities: Beam line maintenance

‣Beam lines inspection & maintenance‣Collimator XCHV058 and XCHV070 exchange‣Vacuum leak search and fix (sector following TAX6 up to QWL080)‣Protective caps installation on 3 XCSV collimators (H2 and H4 lines)

beam

S.Evrard – IEFC Workshop, 08.03.2012

Other shutdown activities: Magnet, Cooling and ventilation, Survey

‣Magnets‣Magnet patrol carried out last Friday (02/03)‣3 Magnets to be shimmed‣1 magnet to be replaced (QNL)‣Will be completed in the coming weeks

‣Cooling and ventilation‣AHU’s maintenance completed‣Inspection of water circuit valves in view of replacement of faulty ones in LS1

‣Laser scanning TDC2 and TCC2‣Will allow integration and 3D modelling works in view of LS1‣Directly readable via TRUVIEW‣Reduce need of visit on site ALARA

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S.Evrard – IEFC Workshop, 08.03.2012

List of activities for LS1: TCC2 Targets

TBIU Monitor

Target Box BAC TBID Monitor

Mobile shielding motor

Patch Panel

Fan

Switchs

Equipment To be installed

Spare

To be manufacture

dTBIU T2-T4-T6-T10 (+ TBID T6)

5 3 8

TBID T2-T4 2 2 4BAC T2-T4 2 2 4BAC T6 1 1 2BAC T10 1 1 2Collimator T10

1 1 2

Total 12 10 22

Courtesy of D. Grenier (EN-STI)

Budget & resources O

K

for consolidation during

LS1

S.Evrard – IEFC Workshop, 08.03.2012

List of activities for LS1: Cabling campaign

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‣Replace irradiated cables, avoid unnecessary cable length if possible, eliminate cable with PVC if possible

‣Cable campaign foreseen end 2013 for 4 months‣Only signal and control cables (not DC cables) between patch RAL and Patch RX‣700 cables = 100 km in TCC2/TDC2 for the time being‣End user to fill a DIC if additionnal request

Cables trays from BA

Patchs RAL

Local patch

Patchs RX

Top Cable Tray (TCT)

Normal cable tray

TID TID TBS

Principe de câblage (2) – Example LSS1

1

Areas 1990 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05 06 07 08 09

TS1 All

TS2 ZS/MST/MSE All ZS/MST/V

acExc TCT Exc TCT

TCC2 All AA R

TDC2 All All

TS4 Part

TS6 ZS/MST/MSE

Exc TCT TCT Exc TCT Vac exc TCT TCT

TT60 All

TCC6 All

TNC All

TCT

Rem. ZS, Inst MKE

All

TCT: Top cable tray, AA: Almost All, R: Rest, Part: Partial.

Budget & resources O

K

for consolidation during

LS1

S.Evrard – IEFC Workshop, 08.03.2012

List of activities for LS1: Air handling unit and cooling circuit

19

‣Leaking valve replacement foreseen in LS1‣North Area AHU consolidation planned for 2017 and cooling station for 2021‣Should be re-considered in order to solve beam pipe stress corrosion issue (add

humidity control, make controls reliable)‣Increase efficiency of air ventilation: at present the TDC2 tunnel is a dead-end and

no clear air flow is set in the extremity toward TT20.

No budget nor resource

s

for consolidation during

LS1

S.Evrard – IEFC Workshop, 08.03.2012

List of activities for LS1: Magnet refurbishment

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‣New cooling connection for all magnets‣ Global replacement of EPDM/Kevlar water hoses and

gaskets in TDC2 / TCC2

‣Interlock: Thermometer and Manometer contacts get corroded, triggering inconsistent machine stops;

‣ Insulation of cables is cracked in the patch panels, the magnet safety system could malfunction

‣ Interlock systems will need consolidation in the future. A more modern system should be defined and implemented at the same time.

No budget nor resource

s

for consolidation during

LS1

S.Evrard – IEFC Workshop, 08.03.2012

List of activities for LS1: Other activities

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‣Vacuum beam pipe consolidation: Budget and resources TBC‣ Replace damaged vacuum chambers and bellows , add new ion pumps

‣T6 XTAX repair

‣Overhead crane PR537 revamping: only possible during LS2

‣General infrastructure consolidation‣ Maintain drain network‣ Lights upgrade (rad hard lights to be developed)