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LHC Machine Advisory Committee Meeting no.19 QRL status

LHC Machine Advisory Committee Meeting no.19 QRL status. 16 June 2006 G. Riddone, AT-ACR On behalf of the QRL team. Content. Layout Fabrication status Installation status Schedule Conclusions. QRL layout. QRL is a continuous cryostat of ~3.2 km length

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LHC Machine Advisory Committee Meeting no.19 QRL status

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  1. LHC Machine Advisory Committee Meeting no.19QRL status 16 June 2006 G. Riddone, AT-ACR On behalf of the QRL team

  2. Content • Layout • Fabrication status • Installation status • Schedule • Conclusions GR, AT-ACR

  3. QRL layout • QRL is a continuous cryostat of ~3.2 km length • no header (4 or 5) sectorisation 9 vacuum sub-sectors •  vacuum insulation separate from machine • QRL elements in one sector • ~ 38 service modules • ~ 40 fixed point/vacuum barrier elements • ~ 235 straight pipe elements • ~ 10 steps/elbows • ~ 1-2 cryogenic extensions GR, AT-ACR

  4. QRL layout Sector 3-4 8 sectors:- 7 installed by Air Liquide- 1 re-installed by CERN Sector 5-6 • = 650 mm E-F= 50-75 B,C,D = 4-20 K GR, AT-ACR

  5. QRL fabrication status GR, AT-ACR

  6. QRL installation status • External supports (~ 700/sector) Progress: 97 % GR, AT-ACR

  7. QRL installation status • Positioning and alignment (~ 325 elements/sector) Progress: 86 % GR, AT-ACR

  8. QRL installation status • Welding and testing: ~ 325 interconnections/sectors  ~ 2000 inner welds made by orbital welding machine • ~ 180 “O” type interconnections (1 butt-weld per header) • ~ 75 “C” type interconnections (2 butt-welds per header) • ~ 70 “A” type Interconnections (3 welds per header) GR, AT-ACR

  9. QRL installation status “C” type interconnections “A” type interconnections Special interconnections • Inner weld progress: 85 % • Nominal rate: 20 int./w • Achieved rate: 30 int./w GR, AT-ACR

  10. QRL installation status Mounting of superinsulation Welding of external compensators and visual check External weld progress: 81 % - Nominal rate: 20 int./w - Achieved rate: 35 int./w GR, AT-ACR

  11. QRL installation status • NDT tests • Internal (video camera) and external visual control: 100% • Radiography tests: from 100% to 10% as a function of weld quality • Leak tightness tests: 100 % • Helium to insulation vacuum • each weld (header pressurization at 1 bar): < 10-9 mbar·l/s • each sub-sector (header pressurization at 3 bar): < 10-8 mbar·l/s • each sector (in parallel with pressure test): < 10-7 mbar·l/s • Air to insulation vacuum: 10-5 mbar·l/s GR, AT-ACR

  12. QRL installation status • Percentage of defects of inner welds (visual and radiographic inspections) for the 3 types of interconnections: • According to machine parameters two categories are defined (B and CDEF) Air Liquide target value: 3% Main defects: porosity, lack of fusion, metallic inclusions GR, AT-ACR

  13. QRL installation status • Number of internal leaks (helium to insulation vacuum) • on installation welds: 8/12000 • 7 detected with the clamp shells • 1 detected in sector 6-7 during the test of the sub-sector (reason: operator error during the test with clamp shells) • on internal compensators: 2 (sector 3-4) • on backing rings: 2 (sector 4-5) • on service modules (header F): 7 (6 in sector 8-1 and 1 in sector 4-5) • Number of external leaks (air to insulation vacuum) on installation welds: • Sector 8-1: 12/4250 • Sector 4-5: 10/4250 • Sector 3-4: 11/4250 • Sector 5-6: 3/4250 • Sector 6-7: 6/4250 GR, AT-ACR

  14. QRL installation status Sector 8-1: - installation completed - pressure, leak and cold tests successfully performed GR, AT-ACR

  15. QRL installation status • Sector 4-5: • installation completed • pressure and leak test without the JR successfully performed • JR and sub-sector A pressure tested in parallel with the magnets GR, AT-ACR

  16. QRL installation status • Sector 3-4: • installation completed • pressure and leak test successfully performed • - repair of an external leak in sub-sector I under way GR, AT-ACR

  17. QRL installation status • Sector 5-6: • installation completed • pressure and leak test successfully performed GR, AT-ACR

  18. QRL installation status • Sector 6-7: • installation completed • pressure and leak test successfully performed GR, AT-ACR

  19. QRL installation status • Sector 2-3: • 3 teams working in sub-sectors A to I • installation progress: 74.4 % • 3 sub-sectors under pumping GR, AT-ACR

  20. QRL installation status • Sector 1-2: • 3 teams working in sub-sectors E to H • installation progress: 11.7 % GR, AT-ACR

  21. QRL schedule GR, AT-ACR

  22. QRL dashboard Total to be installed contract GR, AT-ACR

  23. Conclusions • Fabrication • Production of pipe elements, fixed points and service modules under completion • Production of steps/elbows foreseen to be completed in CW30 (compatible with installation schedule) • Installation • Installation of the last two sectors under way • Thermo-mechanical validation • Sectors 8-1, 4-5, 3-4, 5-6 and 6-7 (and 7-8 sub-sectors A and B) successfully leak and pressure tested • Sector 8-1 (and 7-8 sub-sectors A and B) successfully cold tested • Schedule • At present installation is about 2.5 weeks in advance (schedule revised in November 2005) GR, AT-ACR

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