2. Update of cryogenic activities
September 13th, 2013
LS1 Committee (LSC)
Update of cryogenic activities
L. Tavian TE-CRG

3. Content Update on: QRL compensator bellows DFBA gimbal bellows
Major overhauling
Various consolidations

4. The faulty equipment (QRL Line C)
Internal ply damage (S45, 14R4)
External ply damage (S78, 10R7)
Witzenmann DN100 multi-ply bellows compensators (4 plies of 0.3 mm)

5. QRL Line C compensator x-rays status

6. Repair plan for QRL compensators
Welding of the first compensator started in S81!

7. Line E and F compensator: FE model
C. Garion

8. Conclusion of FE model
C. Garion

9. The faulty equipment (DFBA)
Calorstat DN120 multi-ply gimbal bellows
(2 plies of 0.2 mm)
DFBAK shuffling module:
Internal ply collapsing

10. DFBA gimbal bellows status for all DFBAs
Endoscopic inspection through line M interconnects
Thanks to MSC for early opening of M sleeves !
Statistics (total 32 bellows all inspected): 3/32 (9.3 %)

11. Pictures of the damaged bellows: DFBAF &DFBAI
DFBAF lower gimbal
DFBAF lower gimbal
DFBAI lower gimbal
DFBAI lower gimbal

12. In situ access by cutting the end door: possible solution
Gimbal patching
(Rigid assembly)
Questions/issues:
Very limited space to cut/weld the door
Cutting and welding of beam pipes to be done in very difficult position
Leak tests of beam pipes?
Extreme very difficult work positions
Safety to be assessed
Thanks for EN-MME contribution!

13. Repair options In situ repair Workshop repair Gimbal position Lower
DFBAF & I
Upper
DFBAK
Gimbal patching ++ +
+++
Gimbal replacement
Splice disconnection / reconnection
N/A -
Safety for equipment
Safety for personnel
Probability of success (patching)
> 80 %
< 50 %
100 % *
Probability of success (replacement)
Repair time (patching) [week]
6-10 15
Repair time (replacement) [week]
15 to 23**
*: without 6 kA splice work uncertainty
**: spare delivery time (13-14 week)

14. Repair strategy 0/ Validate the patching scenario
Done for the DFBAK (upper gimbal)  acceptable force of +/- 500 N for +/- 4 mm of displacement
Still to be done (in the coming days) for DFBAF & DFBAI (lower gimbal)
1/ Start with one lower gimbal in-situ repair (DFBAF or DFBAI)  “easier” case
2/ Validate the disconnection & reconnection of 6kA splices
3/ depending of 1/ and 2/ experience return, decide on DFBAK repair (in-situ or in workshop)

15. Major overhauling
Compressors Motors

16. LS 1 Major overhaul of LHC compressors
Done : 26 % In progress : 42% To be done : 32 %

17. Major overhauling Corrective maintenance within expectation! Scratches
on rotors
Scratches
on sleeve bearings
Corrective maintenance within expectation!
Scratches on slide valve
Recovery of new equipment!

18. On site maintenance

19. DFBX current lead controls
Flowmeter rack and Piping in UL14 (IP1 L)

20. Leak on refrigerator cold boxes
Cold box P8 :
leak on LN2 circuit on the precooler HX
Cold box P6 :
leak on LP circuit on SS/ALU transition (DN400)
Cold box P2 :
leak on MP circuit on HX collector
Repairs foreseen by end of 2013 !

21. Conclusion QRL compensator bellows: DFBA gimbal bellows:
X-ray is progressing well (~4 sectors done)  Statistics are presently encouraging (1 additional damaged bellows found)
Repair of the first compensator (S81) has started.
If statistics remains low, the repair is compatible with the present sector pressure test schedule.
What about Line E/F compensators? X-rays on a sub-sector (~8 compensators) are OK but FE simulation shows a potential risk.
DFBA gimbal bellows:
Endoscopic inspection completed  3 damaged bellows.
In-situ repair via patching could be envisaged for DFBAF and DFBAI (displacement forces to be measured in the coming days)
In-situ repair of the DFBAK is not validated (technical and safety issues). Workshop repair required a risk assessment of the splice disconnection/reconnection operation.
Resource and schedule still to be consolidated.
Major overhauling of compressors and motors is on track. Ramp-up of the on-site maintenance must be carefully followed.
DFBX current lead controls consolidation and cold-box leak repair are progressing well