Crab cavity installation in SPS Feedback from installation

Crab cavity installation in SPS - Feedback from installation and lessons learnt G. Vandoni TCC 24 th May 2018

http: //elogbook. cern. ch/e. Logbook. jsp? shift. Id=1098085 G. Vandoni @ HL-LHC 50 th TCC 2

Test stand architecture – tunnel Cryogenic distribution line RF power transmission lines Crab-cavity cryomodule Y-chamber RF power waveguides CM gate valve SPS vacuum sector valve Moving Transfer table G. Vandoni @ HL-LHC 50 th TCC 3

System architecture – Crab-cavity test stand Helium pumps Vacuum sectorization valve Valvebox 2 Service module RF power, loads & circulators Vacuum sectorization valve Y-chamber Transfer table Cryomodule Trans port l ane Y-chamber G. Vandoni @ HL-LHC 50 th TCC 4

Installation in YETS - activities IOT amplifiers commissioning Cryogenic compressor skid Oil removal skid Faraday cage and LLRF commissioning 10 large transport items Helium pump zone Cryogenic ancillaries and pipework On crab-zone, at least 9 teams relay each other BA 6 – surface area BA 1 BA 5 Crab zone Valve. Box#2 connection to cryogenic line Transfer Table SB + CRYOMODULE RF equipment and waveguides Vacuum beamline ODH and Alarms From TS 6 - to TS 6+ >15 teams involved at 4 main locations (+distributed cabling and ODH) TA 6 - alcove Cryogenic Cold-Box Valve. Box#1 connection to cryogenic line LN 2 flex line & phase separator Connecting flexibles and pipework G. Vandoni @ HL-LHC 50 th TCC 5

Statistics 64 IMPACTS 367 Max Participants 200 Estimated participants ~20 Teams involved G. Vandoni @ HL-LHC 50 th TCC 6

Installation story All margin exploited by anticipation G. Vandoni @ HL-LHC 50 th TCC 7

EN/EL Staging of deadlines CABLING Cabling TA 6 Tunnel BA 6 and ext CRYOGENICS BA 6 Tunnel TEST STAND Powering Transfer Table RF equipment CRYOMODULE Vacuum Workload on EN/EL distributed along YETS G. Vandoni @ HL-LHC 50 th TCC 8

List of non conformities Item Team Deadline Cryo danger zone not marked SMB LS 2 Cryo-lines versus insulation vacuum status, procedure not indicated on items TE-CRG TS Water pressure on circulator & load too high EN-CV LS 2 Cable’s hard protection missing BE-RF LS 2 Mechanical instrumentation cables missing EN-EL LS 2 Brakes on motors? EN-MME LS 2 Vacuum interlocks to cryo are not hard cabled EN-EL, TE-VSC LS 2 VVS interlock to table position is not hard cabled EN-EL, BE-RF LS 2 VB 2 and SB mutual distance not according to integration TE-CRG, EN-MME LS 2 Helium leak on line between CB and VB 1 TE-CRG LS 2 ODH signals impacted by occasional noise, reach pre-alarm BE-ICSG. Vandoni @ HL-LHC ? 50 th TCC 9

Safety file completion status Safety inspections & documents (electrical, …) Carry out and complete EIS issue intervention procedure and update layout database Cryogenics safety Implement LN 2 feed stop versus ODH signal Update Cryogenic Risk analysis 1730771 Provide final PID plan on CDD (SPSQAIL) Issue procedure for cryoworks on cold CM Mechanical safety Issue procedure for heavy transport at cold CM Issue procedure for use of table local mode Ergonomics Evaluate noise in local BA 6 CRG control room Safety file Draft and submit to the SPS CSAP G. Vandoni @ HL-LHC 50 th TCC 10

Seen with Christelle Gaignant Worksite safety Large number of involved teams Small space No contingency schedule Coactivity Stress, Hazards Field treatment of unexpected changes in planning and technique GSI-WS-1 “Safety Coordination for Works and Services” applied first time after approval 2016. Defines roles : Safety Coordination, Technical Coordination, Work Supervisors cat 1: one objective, >4000 hrs, single cordoned worksite, several entities cat 2: all the others Technical Stop: scheduled shutdown, […] maintenance or performance upgrades of machines Crab test-stand installation corresponds to TS, plus cat 2 at surface when outside (E)YETS. G. Vandoni @ HL-LHC 50 th TCC 11

Worksite safety Large number of involved teams Small space No contingency schedule Coactivity Stress, Hazards Field treatment of unexpected changes in planning and technique Not outspoken situation: • Zone and activity circumscribed, exhaustive in BA 6 • Large number of entities → WP 4 deliverable responsible was both Tech Coordinator (planning) and Safety coordinator (safety). • Work supervisors not formed, not defined correctly on all activities. • Complex contractual situation, communication issues Seen with Christelle Gaignant G. Vandoni @ HL-LHC 50 th TCC 12

Worksite safety Issues and incidents during the installation were reported. In the framework of the LS 2, the process of « work package analysis » has been introduced, to prepare, identify and address complex worksite situations. New work supervisor training implemented. G. Vandoni @ HL-LHC 50 th TCC 13

Evacuation Test 26 th January at 11 h 30, the evacuation alarm rings in LSS 6 47 persons exit the tunnel in 3 minutes (most of them by taking the lift) Evacuation test not scheduled with the worksite coordination, it introduced a schedule risk as no check was done that the field situation was compatible with the test (welding!) G. Vandoni @ HL-LHC 50 th TCC 14

Interlocks full test ACCESS G. Vandoni @ SPS & LHC Machine Protection Panel 15

Interlock non-conformity Table position to Vacuum valves opening is now via software Cable to be pulled for hardware interlock Vacuum to cryogenics is now via software Cable to be pulled for hardware interlock Interlocks Engineering Specification defines Modify the Interlocks Engineering only Safety and Machine Protection Specification to include all equipment interlocks, not the equipment mutual protection interlocks protection G. Vandoni @ HL-LHC 50 th TCC 16