Production and QA of Barrel / Endcap Heat Exchangers

1. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Heat Exchanger Production at QMUL

2. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Outline • Component Manufacture • Assembly • Cleaning • Testing & QA • Storage & Shipping • Schedules

3. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Production and QA of Barrel / Endcap Heat Exchangers Component Manufacture • Dedicated Machines: Dedicated machines have or will be set up for various in-house operations :   coil winding, turning and milling (end fittings etc) These will remain set up solely for the purpose and duration of production. • Parts Mass Production: Filters, connectors and some pre-formed pipework will be supplied by RAL. In the interest of efficiency and releasing machinery asap all parts will be made in a single production run for both Barrel and Endcap HEX.

4. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Production and QA of Barrel / Endcap Heat Exchangers Component Manufacture (contd) 90 complete sets to be made for the Barrel, initially 74 to be fully assembled. 60 complete sets to be made for the Endcap, initially 44 assembled. Remaining parts held as spares. • Timescales: Majority of bought-in components are on order and should arrive within next few weeks. In-House activities: estimated timescale 4 weeks to complete parts production for Endcap and 4 weeks for Barrel.

5. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Production and QA of Barrel / Endcap Heat Exchangers Component Manufacture (contd) • Pre-Clean: In an effort to reduce final cleaning times any component which fits inside our ultrasonic bath (500mm x 250mm x 250mm) will be cleaned in this manner. Larger parts will require hand cleaning with a final alcohol rinse. By this stage most of the large particles will have been removed. • Storage: Most components will be of manageable size.  Placed in bags and stored in plastic bins.  A simple pipe rack will be used to store longer pipe sections

6. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Assembly • Assembly: General assembly, soldering etc will be carried out in a dedicated area of the main workshop.  Area to be cleaned before production starts. • Prototype HEX Jigs: A great deal of time and effort has already gone into the making of various jigs, pipe benders and support blocks for the production of earlier prototypes. Some of these jigs are still useful and will be modified if necessary for future use, for example, creating the oval section of the Barrel HEX. However, these can only be finalised once all drawings have been received and signed off.

7. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Assembly (contd) • Final HEX Assembly Jigs The Endcap HEX jig design is well under way. Most of the forming of pipes is carried out in situ on a flat surface aided by support blocks at key points. The system is adaptable and can be easily altered to accept variations required in the overall design due to the use of dowelled alignment blocks. The Barrel HEX jigging will be of a similar design, however, this will require a frame support structure rather than just a flat surface due to its physical size (~2.5m long). Datum points are to be supplied by RAL in the near future and will use alignment blocks specifically built for each variant (currently 11). An electrical pipe heater has been purchased for soldering and modified to accept different pipe diameters. Power is controlled by a Variac to ensure precise heating of the joints.

8. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Assembly (contd) • Transport Jigs: Once assembled the HEX will be transferred onto a more simplified jig capable of holding 3-4 HEX at a time. They will remain on this frame throughout the cleaning, leak and pressure tests.  The intention is to have several jigs in order to keep production on going.

9. Production and QA of Barrel / Endcap Heat Exchangers Jerome Morin – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Cleaning • Overview Internal cleaning of the heat exchangers, Barrel and End Cap, will be done with a special solvent named Swansolv. This solvent was chosen at RAL for its efficiency and its compatibility with the ATLAS cooling system specifications. The internal cleaning procedure required the construction of a dedicated cleaning rig and the setting of a dedicated cleaning area within the QMUL physics dept to comply with the specific requirement associated with the use of Swansolv (Toxic Vapour). This cleaning rig is fully functional as of the 30th March and is described in detail in the following slide

10. Cleaning

11. Production and QA of Barrel / Endcap Heat Exchangers Jerome Morin – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Cleaning (contd) The external cleaning of the heat exchangers will be done with ethanol and did not require any specific investment. • Procedures The cleaning procedures are presented in the following slide. One can see that apart from the cleaning rig, the cleaning set-up is composed of 3 trays capable of holding up to 4 HEX each. These trays are used to transport in a safe manner the HEX between the different working stations used for soldering, cleaning and pressure testing them. Safe transport of the trays betweens the various stations will be done via a modified trolley.

12. Flush HEX with Swansolv Bring empty tray 2 hours Welding of HEX Remove Swansolv / flush with dry air or N2 Mounting on tray 10 min Tray full? (4) Reconnect filter Unconnect filter / check cleanliness (same room?) Move tray to cleaning area Is it clean (criteria to be defined) Connect HEX to cleaning rig Flush with dry air/N2 All night Unconnect hex/move tray to pressure/leak testing - area Pressure and leak tests Test OK Investigate with a external leak test, label fault and store bad HEX Cleaning (contd)

13. Production and QA of Barrel / Endcap Heat Exchangers Jerome Morin – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Cleaning (contd) It is expected that in a day, a maximum of 3 HEX will be assembled and soldered. The internal cleaning process takes also a day to be completed. The HEX are cleaned during the day and left to dry overnight. The HEX are then pressure and leak tested the following day. 3 trays are therefore used to ensure continuous operation. The trays are designed to contain any possible leakage and to facilitate the connection between the HEX and both the cleaning and the pressure testing rig. The trays are made of a structure constructed from 25mm aluminium square profile (‘speedframe’), and a thin sheet of aluminium supported by a 9mm plywood. The various jigging located on the trays and used to fix down the HEXs will accommodate the different ‘flavour’ of HEX .   The setting of the dedicated room is presented in the following slide.

14. Production and QA of Barrel / Endcap Heat Exchangers Jerome Morin – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Cleaning (contd)

15. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Testing & QA • Pressure Test: • The HEX will be pressure tested using O.F.N to 25bar. This allows for a 50% • safety margin beyond the 16bar working pressure. The test will be carried out in a • protective enclosure and should not take any longer than 10 mins per unit. Visual • inspection to follow.   • Only highlights catastrophic failure. • Helium Leak Test: • A global leak test will be carried out by placing the HEX inside a helium filled enclosure (pos as used for pressure test) and applying a vacuum to the HEX ports. • Leak rates less than 10-7 l/s will be considered within spec.  • Leak detector to be supplied by RAL within the next few days

16. Testing & QA (schematic1)

17. Testing & QA (schematic2)

18. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Testing & QA (contd) • Duration: • At present there is no real feel as to timescales for this operation. • Estimate 1 hour per unit, perhaps slightly less. • Depends on achievable pumping speeds and helium dispersion between testing each HEX. • Database: • Still need to resolve labelling of individual HEX • Some form of database / spreadsheet will be required to log QA. Not yet addressed.

19. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Storage & Shipping • Packaging: At this point the HEX will have all openings sealed with plugs or foil before removal from their transport frame.  There is a possibility of sealing HEX within a plastic bag for added protection.  HEX stored directly in transport crate. • Transport Crate: Size and construction of the crates have yet to be agreed and will vary between the two systems. Size of crate will also be determined by quantities required on site at any one time.  A suitable company needs to be found.

20. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Storage & Shipping (contd) • Costs: Custom built crate : currently no details. Transport : at the level of shipping one off it has been expensive.  Needs further investigation • Transit & Delivery: Transit time via shipping agent Calberson is 3-5 days and depends on meeting their collection day schedule. Transit time does not include customs release period.

21. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Schedules • Endcap HEX: Current effort suggests being able to produce 6 (possibly 9) completed HEX per week. This equates to 12 weeks in order to produce the required 72 HEX and does not include the 4-week machining period. • Barrel HEX: Figures for the Barrel HEX are similar at 5 per week, however only 44 are required initially and therefore should take 9 weeks to complete. Once again this does not take into account the 4-week machining time, which may take the same length of time due to the number of variants. 

22. Production and QA of Barrel / Endcap Heat Exchangers John Morris – Queen Mary, University London ATLAS SCT PRR April 13th & 14th 2005 Schedules (contd) • Contingency: • In addition a two-week contingency should be applied to both Barrel and Endcap schedules. • Timescales: • Schedules: Endcap HEX -16 weeks • Barrel HEX – 13 weeks • Contingency – 4 weeks • Total Production Time – 7 months • Still need to find some additional time for completing Barrel and Endcap • Finalised jigging.