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Can we optimise the clean up process further ?

Can we optimise the clean up process further ?. V. Baglin. CERN TE-VSC, Geneva. 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. Results of inspections.

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Can we optimise the clean up process further ?

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  1. Can we optimise the clean up process further ? V. Baglin CERN TE-VSC, Geneva Vincent Baglin LHC Performance Workshop - Chamonix 2010 - 25-29 January

  2. Back to sector 3-4 Vincent Baglin LHC Performance Workshop - Chamonix 2010 - 25-29 January

  3. Inspections • 4.8 km of beam lines have been inspected by endoscope and documented • 212 interconnections have been inspected and documented

  4. Results of inspections • Soot, MLI, metallic debris LSS4 LSS3

  5. Development of tooling • In parallel to the inspections task, tools were developped to clean the sector • A vacuum cleaner was developped by the vacuum group ! Version 1

  6. Development of tooling • Upgraded version with attached endoscope Version 2

  7. 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) ~ 100 bits 3.2 g i.e 0.4 m2 1.2 g i.e 0.1 m2

  8. Development of tooling • Chimney sweeping stick for beam screens polluted with soot • First successful tests before Xmas 2008

  9. Draft of cleaning procedure • By mid December 2008 • A two step method : • - removal of gross contamination • - fine cleaning

  10. Validation of the vacuum cleaner • By January 2009 • In the lab, use of a mock-up and real plug in modules extracted from sector 3-4 Results after 2 passages in a PIM (8 min total)

  11. Evaluation in the tunnel • Parameters to define : • - number of passages • - time per PIM • - time per beam screen • - nozzle opening Chamonix 2009

  12. 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 !

  13. Detailed cleaning procedure • Achieved by end-February • 1st Step, automatic pumping/venting of the sector during at least one hour. At the end of this time, additional automatic pumping/venting of the so-called pumping hoses (vacuum ports at each quadrupole) during at least 15 minutes. • 2nd step, 10 passages along the vacuum sector with the nozzle-endoscope tool and the automatic pumping/venting. During passage 1, 2 and 3, the nozzle-endoscope tool should be applied during 10 minutes at each PIM then 5 minutes are required. In the beam tube, the speed of the nozzle-endoscope tool is 3 to 4 m/minute. In case of an event visible by the endoscope camera, the operator shall insist with the tool to remove the event. The beam line is subjected to automatic pumping/venting during passages 1,2,3,4,9 and 10. Additional automatic pumping/venting of the pumping hose is installed in parallel during passages 5,6,7,8. After each passage, the debris are collected in a plastic bag for future documentation. • 3rd step, endoscopic control. Once a sector has been cleaned, quality control is ensured by a systematic endoscopic inspection. Each beam position monitor, each PIM, each entrance, mid and end part of the beam screen and finally, each unexpected event are recorded by video. A report is issued at the end of the control. • 4th step, validation of the cleaning of the sector and release of the sector for PIM welding. In the absence of any quantitative information from the expert, a maximum of one fibre per half-cell and two debris (from super insulation or other) per magnet is tolerated. • Cleaning rate : • ~ 50 m / day / team • Time for PIMs : 3h 15 min !

  14. Follow up • Day by day reporting and analysis of the cleaning state

  15. Follow up • Final endoscopy report (both directions)

  16. Follow up • Weekly release of cleaned sector Procedure set up phase

  17. Follow up • Documentation of non-conformities

  18. Examples of NC

  19. 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

  20. 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 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 case of doubt : easy to say …

  21. 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 !

  22. 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

  23. Thank you for your attention !!! Vincent Baglin LHC Performance Workshop - Chamonix 2010 - 25-29 January

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