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Can we optimiseclean up process further ?
V. BaglinCERN TE-VSC,
Vincent Baglin LHC Performance Workshop 1
optimise the clean up process further ?
BaglinVSC, Geneva
Vincent Baglin LHC Performance Workshop - Chamonix 2010 - 25-29 January
Vincent Baglin LHC Performance Workshop Vincent Baglin LHC Performance Workshop - Chamonix 2010 - 25-29 January2
Back to sector 3-4
Inspections• 4.8 km of beam lines have been inspected by endoscope and documented• 212 interconnections have been inspected and documented
Inspections4.8 km of beam lines have been inspected by endoscope and documented212 interconnections have been inspected and documented
Results of inspections• Soot, MLI, metallic debris
LSS3
Ok
MLI
Soot
Total
Results of inspections
LSS4
V1 V2 V1 V2 Total
54 39 26 % 18 % 22 %
124 129 58 % 61 % 59 %
35 45 16 % 21 % 19 %
213 213 100 % 100 % 100 %
Development of tooling• In parallel to the inspections task, tools were • A vacuum cleaner was developped by the vacuum group !
Version 1
Development of toolingIn parallel to the inspections task, tools were developped to clean the sector
by the vacuum group !
Version 1
Development of tooling• Upgraded version with attached endoscope
Version 2
Development of toolingUpgraded version with attached endoscope
Version 2
Development of tooling• Harvest trials were done in the tunnel by end November 2008• Automatic pumping/venting based on RF ball technology
• Q8R4 till Q13R4 line V1 (~ 230 m)
3.2 g i.e 0.4 m2 1.2 g i.e
Development of toolingHarvest trials were done in the tunnel by end November 2008Automatic pumping/venting based on RF ball technology
i.e 0.1 m2 ~ 100 bits
Development of tooling• Chimney sweeping stick for beam screens polluted with soot• First successful tests before Xmas 2008
Development of toolingChimney sweeping stick for beam screens polluted with soot
Draft of cleaning procedure
• By mid December 2008
• A two step method :
- removal of gross contamination- fine cleaning
Draft of cleaning procedure
Validation of the vacuum cleaner• By January 2009• In the lab, use of a mock-up and real plug in modules extracted from sector 3
Results after 2 passages in a PIM (8 min total)
Validation of the vacuum cleaner
up and real plug in modules extracted from sector 3-4
Results after 2 passages in a PIM (8 min total)
Evaluation in the tunnel• Parameters to define :
- number of passages- time per PIM- time per beam screen- nozzle opening
Evaluation in the tunnel
Chamonix 2009
Definition of the required performance
• After discussion with AB-ABP and following Chamonix it was agreed with the management that :
- 1 fibre per half-cell (there are 82 half-cells to clean)- 2 debris (MLI or other less than 1 mm2) per magnet (there are 304 beam tube magnets to clean)
• Can be left in the beam tube after the cleaning process !
Definition of the required performance
ABP and following Chamonix it was agreed with
(there are 304 beam tube magnets to clean)
Can be left in the beam tube after the cleaning process !
Detailed cleaning procedure• Achieved by end-February
1st Step, automatic pumping/venting of the sector during at least one hour. At theend of this time, additional automatic pumping/venting of the so-called pumpinghoses (vacuum ports at each quadrupole) during at least 15 minutes.
2nd step, 10 passages along the vacuum sector with the nozzle-endoscope tooland the automatic pumping/venting. During passage 1, 2 and 3, the nozzleendoscope tool should be applied during 10 minutes at each PIM then 5 minutesare required. In the beam tube, the speed of the nozzle-endoscope tool is 3 tom/minute. In case of an event visible by the endoscope camera, the operatorshall insist with the tool to remove the event. The beam line is subjectedautomatic pumping/venting during passages 1,2,3,4,9 and 10. Additionalautomatic pumping/venting of the pumping hose is installed in parallel duringpassages 5,6,7,8. After each passage, the debris are collected in a plastic bag forfuture documentation.
3rd step, endoscopic control. Once a sector has been cleaned, quality controlensured by a systematic endoscopic inspection. Each beam position monitor,each PIM, each entrance, mid and end part of the beam screen and finally, eachunexpected event are recorded by video. A report is issued at the end of thecontrol.
4th step, validation of the cleaning of the sector and release of the sector for PIMwelding. In the absence of any quantitative information from the expert,maximum of one fibre per half-cell and two debris (from super insulation orother) per magnet is tolerated.
• Cleaning rate :~ 50 m / day / team
• Time for PIMs : 3h 15 min !
Detailed cleaning procedure
thepumping
toolnozzle-minutes
4operator
toAdditional
duringfor
ismonitor,
eachthe
PIMa
or
Follow up• Day by day reporting and analysis of the cleaning state
Follow upDay by day reporting and analysis of the cleaning state
Follow up• Final endoscopy report (both directions)
Follow upFinal endoscopy report (both directions)
Follow up• Weekly release of cleaned sector
Procedure set up phase
Follow up
Follow up• Documentation of non-conformities
Follow up
Examples of NCExamples of NC
Difficulties• CERN was not ready to such an incident :
§At the beginning, communication inside CERN was extremely reduced
§ Need to built a team of experts on a new task§ Need to identify, built, buy and qualify tooling
DifficultiesCERN was not ready to such an incident :
At the beginning, communication inside CERN was extremely reduced
Need to built a team of experts on a new taskNeed to identify, built, buy and qualify tooling
Difficulties• On the field :
§ Issue with resources : experts were called for other (urgent) activities§ Keep the motivation of the team members § Issue with coactivity (and performance) : Why should we clean a beam tube while somebody else doing a hole in a cryostat for a relief valve ?§ Issue with material : ageing or damaging when the nozzle is stuck in a PIM (required the cutting of it by TE§ Qualification of the cleaning process. How to distinguish with an endoscope a fibre or a MLI from a scratch or a stain ? Forget its estimation by vacuum performance ! Better stay quiet, away from planning’s stress and ask your team to clean a second time a sector in case of doubt : easy to say …
Difficulties
Issue with resources : experts were called for other (urgent) activitiesKeep the motivation of the team members Issue with coactivity (and performance) :
Why should we clean a beam tube while somebody else beside you is doing a hole in a cryostat for a relief valve ?
Issue with material : ageing or damaging when the nozzle is stuck in a PIM (required the cutting of it by TE-MSC)
Qualification of the cleaning process. How to distinguish with an endoscope a fibre or a MLI from a scratch or a stain ? Forget its estimation by vacuum performance ! Better stay quiet, away from planning’s stress and ask your team to clean a second time a sector in
Conclusions
• A new methodology was developed and applied for the cleanup process of sector 3-4
• ~ 3 months were required to set up the process
• ~ 3 months were required to cleanup the sector
• Final inspection was done by an endoscope
• We have 6 sets of tooling ready to intervene
• I hope they will stay on the shelves forever
Conclusions
A new methodology was developed and applied for the cleanup process of
~ 3 months were required to set up the process
~ 3 months were required to cleanup the sector
Final inspection was done by an endoscope
We have 6 sets of tooling ready to intervene
forever !
Acknowledgments
• FSU, AL43 and TS-MME teams for performing an excellent and difficult work in the tunnel
• HNINP collaboration for the qualification endoscopies
• B. Henrist, A Vidal, G. Schneider, E. Page, J. Finelle, B. Jenninger, A. Sinturel, E. Mahner, H. Kos for their developements, commitment and work performed in the tunnel
• J.M Jimenez, P. Cruikshank, R. Veness for their supports and expertises
Acknowledgments
MME teams for performing an excellent and difficult
HNINP collaboration for the qualification endoscopies
B. Henrist, A Vidal, G. Schneider, E. Page, J. Finelle, B. Jenninger, A. Sinturel, E. Mahner, H. Kos for their developements, commitment and work performed in
J.M Jimenez, P. Cruikshank, R. Veness for their supports and expertises
Vincent Baglin LHC Performance Workshop
Thank you for your attention !!!
Vincent Baglin LHC Performance Workshop - Chamonix 2010 - 25-29 January23
Thank you for your attention !!!