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a & w team

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

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a & w team

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  1. a & w team • Mandate • Activities • Procedures • Tooling • Resources • Planning • Conclusions Andrea Musso TE-MSC-CMI

  2. 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 Andrea Musso TE-MSC-CMI

  3. How to… W bellows opening Remove screws Open bellows Remove MLI blankets 1 Remove thermal shields Welds to cut Remove MLI blankets 2 Remove shield (screwed) Courtesy Thierry Renaglia Andrea Musso TE-MSC-CMI

  4. 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] Andrea Musso TE-MSC-CMI

  5. The new design… Clamp with silver-plated screws New design validated by analytical calculations and cold test at SM18 Approved by TE-TM – ECR fully approved Outer Inner Outer Courtesy G. Villiger Hinge Inner Snap fastener Braids Courtesy G. Villiger Clamp Outer side view Andrea Musso TE-MSC-CMI

  6. 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 Andrea Musso TE-MSC-CMI

  7. 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 Andrea Musso TE-MSC-CMI

  8. Installation of Safety Relief Devices (DN200) 2/2 Andrea Musso TE-MSC-CMI

  9. How to… M Bellows protections All M bellows protections need to be removed After removal, a threaded insert will be installed in order to avoid seizing [RP issue] Insert to be installed Screws to be removed Andrea Musso TE-MSC-CMI

  10. Procedures and ECR’s All procedures for these activities are written and were circulated for approvals Andrea Musso TE-MSC-CMI

  11. (Special) Tooling Safety 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 Andrea Musso TE-MSC-CMI

  12. Resources 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) Andrea Musso TE-MSC-CMI

  13. Resources 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 A video was realized in order to give information to personnel from Institutes before they arrive at CERN Click here to access video Andrea Musso TE-MSC-CMI

  14. 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. Andrea Musso TE-MSC-CMI

  15. 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 (+1700radiative shields); this includes 1700 hinges, 3400latchers, 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 Andrea Musso TE-MSC-CMI

  16. 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 Andrea Musso TE-MSC-CMI

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