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Thermosiphon Project - Condenser repair CERN – Geneva January 8 th , 2014

Thermosiphon Project - Condenser repair CERN – Geneva January 8 th , 2014. M. Battistin & all TS team ATLAS + EN/CV. TS architecture. ATLAS Surface. Water circuit Low T chiller Brine circuit Condenser C 3 F 8 piping USA15 by-pass unit EL p ower supply Sonar systems Control system

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Thermosiphon Project - Condenser repair CERN – Geneva January 8 th , 2014

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  1. Thermosiphon Project-Condenser repairCERN – GenevaJanuary 8th, 2014 M. Battistin& all TS team ATLAS + EN/CV

  2. TS architecture ATLAS Surface • Water circuit • Low T chiller • Brine circuit • Condenser • C3F8 piping • USA15 by-pass unit • EL power supply • Sonar systems • Control system • Documentation • Planning PX15 UX15 USA15 M. Battistin - Thermosiphon Project

  3. C3F8 condenser on the roof of SH1 building Degassing Sonar System C6F14 expansion tank C3F8 condenser M. Battistin - Thermosiphon Project

  4. 1st November 2012 15th March 2013 M. Battistin - Thermosiphon Project

  5. Condenser installation SH1 roof C3F8 Condenser C6F14 expansion tank SH1 November 2013 M. Battistin - Thermosiphon Project

  6. Mechanical Design M. Battistin - Thermosiphon Project

  7. Inspected welds 3 5 4 1 2 M. Battistin - Thermosiphon Project

  8. Inspected welds 5 M. Battistin - Thermosiphon Project

  9. Milestone N1 – 15 Jan Before starting any grinding activity on any weld of the condenser, CERN will visit DATE to perform the following check: • Visual inspection of all the welds using an endoscope and all the holes previously prepared by DATE. • Review of the detailed reparation procedures, of the WPS that will be used and the “modes operatoires”. • DATE will present the result and the report of their not destructive inspection • 100% visual inspection • 100% of x-ray or ultra-sounds • Review of the cleaning procedure suggested for the end of the reparation process. As specified the leaning procedure shall be conform to the ASTM A380 (without any pickling and passivation). • Verification of the welding test executed on the sample described on the annexed drawing (see figure N1). This test welding shall be previously inspected visually and with ultra-sound by DATE. CERN will execute the same tests during the visit. It has been agreed that only the welder that has executed this test will be authorized by CERN to execute the reparation on the condenser. • Dimensional inspection of the condenser: • distance between the two pipe supporting plates • distance between the flanges of the compensator • These two distances shall be respected at the end of the reparation process with a precision of 1 mm to avoid (pre) stress on the piping inside the condenser. • During the meeting of the 15/1/14 DATE and CERN will validate this procedure and decide how many welds shall be treated. In principle the reparation will be done in two parts. M. Battistin - Thermosiphon Project

  10. Milestone N2 – 22 Jan Before this date, DATE will have executed the grinding of the welds and prepared the chamfer and the welding edges ready for the first weld. CERN will visit DATE to perform the following check: • Check the condition of the weld preparation. • Be present to the first weld (depending to the time needed to get good inert gas conditions inside the condenser). • No welding is allowed before. M. Battistin - Thermosiphon Project

  11. Milestone N3 – 29 Jan After the first welds. The strategy proposed by DATE is to grind ¼ of the circular welds and repair it. Two ¼ of every single weld could be prepared at the same time. Before CERN visits, all the repaired welds will be inspected and validated by APAVE-PRORAD. On 29/1/2014 the first half of the reparation will be inspected. It is agreed that DATE will complete the welds (four fillets) and not limit the activity to the first fillet welding. • Before this meeting DATE will have re-installed the branches too. They will be object of inspections of APAVE too (visual plus x-ray or ultra-sound) CERN will visit DATE to perform the following check: • Receive the APAVE not destructive inspection report done by APAVE-PRORAD. • Execute statistic ultra-sound inspection on the welds. M. Battistin - Thermosiphon Project

  12. Milestone N4 – 11 Feb Before this meeting DATE will have completed the second half of the repair on the condenser. All the repaired welds will be previously inspected and validated by APAVE-PRORAD. On 11/2/2014 the second half of the reparation will be inspected. CERN will visit DATE to perform the following check: • Receive the APAVE not destructive inspection report done by APAVE-PRORAD. • Execute statistical ultra-sound inspection on the welds. M. Battistin - Thermosiphon Project

  13. Milestone N5 – 21 Feb • Pressure test visit. DATE will prepare the vessel for the qualification pressure test at the presence of APAVE and the CERN inspector for the pressure test qualification. In case the Kenoll® equipment will not be available it has been understood that DATE will tailor dedicated flanges for the pressure test and the delivery at CERN. CERN will visit DATE to perform the following check: • Assist to the pressure test. • Execute the dimensional control of the condenser. In particular the distances between the pipes support plates and the distance of the flanges of the compensators will be verified and compared with the measures taken during the visit of the 15/1/2014. A precision of 1 mm is requested. M. Battistin - Thermosiphon Project

  14. Milestone N6 – 4 Mar Cleanlinessstatus check. Before the visit DATE will have executed the cleaning procedure agreed during the meeting of the 15/1/2014 and the helium test to guarantee the leak-tightness of the condenser. Qualified personnel shall execute these tests. APAVE will check the qualification of the personnel. It is agreed that after all the welding activities and before the reassembly of the condenser the two surfaces of the pipes support plates will be machined to guarantee their perfect planarity. CERN will visit DATE to perform the following check: • Verify the internal cleanliness of the condenser using an endoscope and the white rag. • Receive the helium test certificate. • Review all the new condenser certificates M. Battistin - Thermosiphon Project

  15. Milestone N7 – 19 Mar Laggingstatus check. Before the visit DATE will have executed the lagging of the condenser. The lagging material will be completely installed. The metallic shielding layer to protect the Armaflex® or Foamglass® material will not have been installed yet to allow the complete inspection of the lagging. CERN will visit DATE to perform the following check: • Quality inspection of the lagging. M. Battistin - Thermosiphon Project

  16. Milestone N8 – 24 Mar on that date the condenser will be ready for delivery. M. Battistin - Thermosiphon Project

  17. Financial situation Contract CA1524640 of 2/11/2012 https://edh.cern.ch/Info/Order/CA1524640 Value 138.850 kEuro Vessel delivered on March 2013 and installed on 15/3/2013. M. Battistin - Thermosiphon Project

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