CERN
LHC Project Document No.
CH-1211 Geneva 23
Switzerland
LHC-VBMB-IP-0001.00 rev. 2.0
CERN Div./Group or Supplier/Contractor Document No.
AT-VAC-EN/AV-01
the
EDMS Document No.
Large
Hadron
Collider
369533
project
Date: 2016-02-16
Installation Procedure
BEAM LINE ARC INTERCONNECTS
PLUG-IN MODULES
Abstract
The purpose of this Installation Procedure is to define the sequence of operations
required to install the Plug-in Modules on the beam lines V1 and V2.
These operations shall be performed in the tunnel during the interconnection of
cryomagnets and before the inductive soldering of the main superconducting bus bars
(ref. 1).
Prepared by :
Checked by :
Approved by :
Alexis Vidal
AT/VAC/EN1
Juan Knaster
AT/VAC/EN1
Raymond Veness
AT/VAC/EN1
Alexis.Vidal@cern.ch
Juan.Ramon.Knaster@cern.ch
Ramond.Veness@cern.ch
Didier Chauville
AT/VAC/EN1
Patrick Lepeule
AT/VAC/EN1
Didier.Chauville@cern.ch
Patrick.Lepeule@cern.ch
Distribution list:
LHC Interconnections: M. Bajko, P. Bonnal, D. Bozzini, J. Casas-Cubillos, I. Collins,
P. Cruikshank, K. Dahlerup-Petersen, L. Evans, G. Favre, C. Garion, N. Gilbert, C. Hauviller,
R. Herzog, A. Jacquemod, K. Kershaw, J. Knaster-Refolio, F. Laurent, Ph. Lebrun, P. Lepeule,
E. Manola, S. Marque, K-H. Mess D. Missiaen, L. Nielsen, R. Ostojic, V. Parma, G. Passardi,
A. Perin, J-L. Perinet-Marque, L. Perrollaz, A. Poncet, P. Proudlock, J-P. Quesnel, G. Riddone,
F. Rodriguez-Mateos, P. Rohmig, L. Rossi, E. Roy, S. Russenschuck, R. Saban, F. Savary,
W. Scandale, F. Schauf, G. Schneider, N. Siegel, A. Siemko, F. Simon, B. Skoczen, P. Strubin,
L. Tavian, J-Ph. Tock, D. Tommasini, Th. Tortschanoff, R. Trant, R. Veness, A. Vidal, J. Vlogaert,
L. Walckiers, R. van Weelderen, W. Weingarten, L.R. Williams.
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 2 of 15
History of Changes
Rev. No.
Date
Pages
0.1 – draft
2003-01-20
All
1st draft prepared by A. Vidal & D. Chauville.
0.2 – draft
2003-04-29
All
2nd draft checked by J. Knaster and P. Lépeule and sent for
approval to the above list. Deadline: 15th May 2003.
1.0
2003-05-23
All
Updated after circulation in accordance with comments given
by the members of the LHC Interconnections list. Version 1.0
released.
2.0
2005-01-25
5
8
9
10
Table 1 updated.
Information added in step 4.
Position measurement card suppressed in step 6.
Compression tooling identified in step 12 and step 13
updated.
Reference added in step 16 and 17.
Reference added in step 22.
Definition of RF bellows protection in step 35 and step 36
completed.
Paragraph 5.1 – Tooling list updated and new reference in
section 7.
Record card updated.
Version 2.0 released.
11
12
13
14
15
Description of Changes
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 3 of 15
Table of Contents
1. INTRODUCTION ..........................................................................................4
2. GLOSSARY OF ACRONYMS ...........................................................................4
3. SAFETY WARNINGS .....................................................................................4
4. SEQUENCE OF OPERATIONS ON A VACUUM LINE ........................................4
4.1 GENERAL COMMENTS ................................................................................... 4
4.2 LOCATION OF BEAM LINES IN THE TUNNEL ..................................................... 5
4.3 GLOBAL SECTION THROUGH A PLUG-IN MODULE (MB-MB)................................ 6
4.4 GLOBAL SECTION THROUGH DOWNSTREAM AND UPSTREAM SIDES (MB-MB) ..... 6
4.5 GLOBAL SECTION THROUGH DOWNSTREAM AND BPM SIDES (MB-SSS) ............. 7
4.6 GLOBAL SECTION THROUGH DOWNSTREAM AND UPSTREAM SIDES (SSS-MB) .... 7
4.7 DESCRIPTION OF OPERATIONS ...................................................................... 7
5. THE REQUIRED EQUIPMENT ......................................................................14
5.1 TOOLING ................................................................................................... 14
5.2 MATERIAL ................................................................................................. 14
6. RECORD CARD ...........................................................................................14
7. REFERENCES .............................................................................................14
8. ANNEXES...................................................................................................15
8.1 RECORD CARD ........................................................................................... 15
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 4 of 15
1. INTRODUCTION
The purpose of this Installation Procedure is to define the sequence of steps required to install
the Plug-in Modules in the beam line V1 and V2, in order to ensure the quality and the
reliability of this operation.
This activity shall be performed in the tunnel during the interconnection of cryomagnets and
before the inductive soldering of the main superconducting bus bars (ref. 1).
All positions, control and test results, observations and remarks will be recorded in the “Record
Card” (see section n 8).
2. GLOSSARY OF ACRONYMS
LHC:
Large Hadron Collider
V1:
Outer beam lines
V2:
Inner beam lines
SSS:
Short Straight Section
MB:
Cryodipole
AT/VAC:
Accelerator Technology Division – Vacuum Group
RF bellows:
Radio Frequency Bellows
QRL:
Cryogenic distribution line
BPM
Beam Position Monitor
3. SAFETY WARNINGS
Before starting the operations in the tunnel, a global authorisation should be obtained from
CERN safety division.
4. SEQUENCE OF OPERATIONS ON A VACUUM LINE
4.1 GENERAL COMMENTS
The line V1 (outer) should be installed before the line V2 (inner) in order to ensure the best
accessibility. This remark is applicable to all types of interconnects, see table 1.
The operations to perform the installation of the plug-in module are similar for the beam lines
V1 and V2 and applicable for all interconnects, MB-MB, MB-SSS and SSS-MB.
A visual inspection shall be performed on the 2 interconnects extremities (see step n5 in
section n4.7). A check of the relative position of the extremities of V1 and V2 lines is required
(see step n6 in section n4.7).
An inspection of plug-in modules installation (see step n37 and ref. 1) will be performed by a
final visual inspection (not under the present Contractor's responsibility).
Attention: the sequence of operations is similar but there are dedicated plug-in modules for
each type of interconnects, see table 1.
All welds shall be performed by an automatic orbital welding machine. The tacking operations
should be done manually with the compression tooling in place (prototype supplied by
AT/VAC).
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 5 of 15
Table 1 – References of plug-in module
Interconnect
Dipole-Dipole (MB-MB)
LHCLVIBB0008
Dipole-SSS (MB-SSS)
LHCLVIBB0009
SSS-Dipole (SSS-MB)
LHCLVIBB0010
Plug-in module
MB-MB Plug in module - series
LHCVBMB_0001
Identification boxes: MMxxxx
(x=serial numbers)
MB-SSS Plug in module - series
LHCVBMB_0003
Identification boxes: MSxxxx
(x=serial numbers)
SSS-MB Plug in module - series
LHCVBMB_0002
Identification boxes: SMxxxx
(x=serial numbers)
Extremities definition
Downstream – Upstream
Downstream – BPM
SSS – Upstream
The following points must be respected during the operations:

All manipulations with the beam line extremities and plug-in modules must be performed
with clean gloves.

All manipulations of plug-in modules must be performed with care and any damage of RF
bellows, contact strips, insert parts and pollution shall be avoided.

All tooling must be kept clean during each operating phases.

The nested bellows protection (Aluminium shields) must be kept always in place.
4.2 LOCATION OF BEAM LINES IN THE TUNNEL
Beam lines
V1 and V2
Magnet
Space
reserved
for
transport
QRL
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 6 of 15
4.3 GLOBAL SECTION THROUGH A PLUG-IN MODULE (MB-MB)
Downstream
side
RF Bellows
Contact Strips
Copper Transition Tube
Upstream
side
RF fingers
Contact Strips
RF-Contact
4.4 GLOBAL SECTION THROUGH DOWNSTREAM AND UPSTREAM SIDES (MBMB)
Beam Screen
Pin
MB Downstream side
MB Upstream side
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 7 of 15
4.5 GLOBAL SECTION THROUGH DOWNSTREAM AND BPM SIDES (MB-SSS)
Pin
MB Downstream side
Remark: No pin
SSS side
4.6 GLOBAL SECTION THROUGH DOWNSTREAM AND UPSTREAM SIDES (SSSMB)
Pin
SSS Downstream side
MB Upstream side
4.7 DESCRIPTION OF OPERATIONS
The operation sequence described in this section corresponds to the line V1 (outer) of DipoleDipole interconnects.
However, this procedure is applicable for both lines (V1 and V2) and for each type of
interconnects (see Table 1).
The operations of tacking (step 15-21) and welding (step 26-32) can be performed in series by
the Contractor.
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 8 of 15
Beam line V1 (outer)
Step
1
Description
Picture
Unpack the Plug-in module with care
from cardboard tube and polyethylene
bag (clean gloves shall be used).
Check the type of Plug-in module on
the Traveller sheet.
Tooling 2
2
Remove the tooling n1 (ref. 2).
Tooling 1
3
Visual inspection of Plug-in module
in order to check eventual damage on:
- RF bellows
- Flange extremities
- Contact strips
- External and internal envelope
The reference must be recorded in the
installation Traveller.
4
Remove the extremities protection of
the line V1 (metallic flanges).
Keep the nested bellow protection
(Aluminium shields).
The extremities protection of V1 shall
be returned to a surface building (to
be defined).
5
Visual
inspection
of
the
2
interconnects extremities.
Check the presence of the pin in each
extremity (Not applicable for SSS
side).
Look inside the beam lines, in both
directions and survey carefully (with a
torch and mirror) the absence of
objects in the beam lines.
If any damage is detected, the defect
must be reported to Traveller sheet and
another plug-in module must be installed.
Downstream
side
Nested bellow
Upstream side
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
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6
Check the relative position of the
extremities of the V1/V2 lines and
record the result on the “Record card”.
REMARK:
Measurement tooling (to be defined)
and “Record card” supplied by AT/VAC.
If the position of the extremities is out
of tolerances, the installation process
has to be stopped temporally until the
decision of CERN responsible.
7
Introduce
manually
the
plug-in
module between both beam line
extremities.
8
Insert the downstream flange of the
Plug-in module into the downstream
extremity.
WARNING:
This operation must be performed
smoothly so as not to damage the RF
contact strips. The pin inserted will
address the orientation.
Part of operation #LI-1-02 (ref. 1).
Downstream
side
Knurled nuts
9
10
Extend the RF bellows progressively
with the knurled nuts (ref. 2).
Turn smoothly the Plug-in module
until the pin is housed in the copper
component on the upstream side.
WARNING:
This operation must be performed
smoothly so as not to damage the RF
contact strips.
Upstraem side
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
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11
12
Install the RF bellows protection
(Kapton foil).
WARNING:
This protection must be not electrically
conductive in order to preserve the RF
bellows during the tack weld phases.
Insert the compression tooling n3
(ref. 4) on the downstream flanges.
Tooling n3
Downstream side
13
Apply a torque (to be defined) on
screw in order to obtain a force of
60 kg with the compression tooling.
Check the distance between flanges
(this distance must be 1 mm on whole
circumference within a tolerance to be
determined
after
the
pre-series
assembly).
14
Install the ground cables of the
welding machine on both sides
(downstream and upstream side).
WARNING:
If this procedure is not followed, the
plug-in module may be destroyed
during the tack welding.
15
Tack welds manually the downstream
flanges (between 4-8 points at
equally distance).
NOTE:
The oxidation from the weld must be
removed with a stainless steel brush.
1 mm
Downstream side
Ground cable
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
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16
17
Remove the compression tooling n3
(ref. 4).
Insert the compression tooling n3
(ref. 4) on the upstream flanges.
WARNING:
The knurled nuts should be unscrewed
during the insertion of the compression
tooling on the upstream side.
Upstream side
18
Apply a torque (to be defined) on
screw in order to obtain a force of
60 kg with the compression tooling.
Check the distance between flanges
(this distance must be 1 mm on whole
circumference within a tolerance to be
determined
after
the
pre-series
assemblies).
19
Remove tooling n2 of the Plug-in
module (ref. 3).
20
Check if the ground cables of the
welding machine are installed on both
sides (downstream and upstream
side).
WARNING:
If this procedure is not followed, the
plug-in module may be destroyed
during the tack welding.
1 mm
Upstream side
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 12 of 15
21
22
Tack welds manually the downstream
flanges (between 4-8 points at
equally distance).
NOTE:
The oxidation from the weld must be
removed with a stainless steel brush.
Remove the compression tooling n3
(ref. 4).
WARNING:
Keep the RF bellows protection in place
(Kapton foil).
RF bellow protection
23
Install rolling shells on the RF bellows
for welding of downstream side.
24
Install orbital welding machine on
rolling shells.
25
26
27
Install the ground cables of welding
machine on both sides.
WARNING:
If this procedure is not followed, the
plug-in module may be destroyed
during the welding.
Make the welding.
NOTE:
The oxidation from the weld must be
removed with a stainless steel brush.
Visual inspection of the welding.
Category B
See ISO 5817
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
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28
Remove orbital welding machine and
keep in place the ground cables in both
sides.
29
Install rolling shells on the RF bellows
for welding of upstream side.
30
Install the orbital welding machine on
rolling shells.
31
32
Check if the ground cables of welding
machine are installed in both sides.
WARNING:
If this procedure is not followed, the
plug-in module may be destroyed
during the welding.
Make the welding.
NOTE:
The oxidation from the weld must be
removed with a stainless steel brush.
33
Visual inspection of the welding.
Category B
See ISO 5817
34
Remove orbital welding machine,
ground cables and rolling shells.
35
36
37
Install the RF bellows
(Aluminium shields).
protection
The plug-in module assembly is
finished for the line V1 (outer).
Repeat steps from 1 to 36 for the
second line V2.
Inspection of the plug-in module
assembly (not under the present
Contractor's responsibility).
Operation #LI-1-04 (ref. 1).
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 14 of 15
5. THE REQUIRED EQUIPMENT
5.1 TOOLING
The tooling required for performing the plug-in module assembly is given in the following list:

Orbital TIG welding machine with double ground cables (this welding machine must be
equipped with a system to archive the welding parameters after each operation).

Manual TIG welding machine with double ground cables or equivalent.

Torch and mirror.

Rolling shells.

RF bellows protection (one prototype supplied by AT/VAC).

Compression tooling n3, see ref. 4 (one prototype supplied by AT/VAC).

Torque wrench.

Measurement tooling (one prototype, supplied by AT/VAC).

Empty “Record Card” sheet provided by AT/VAC.
5.2 MATERIAL
The material required for performing the plug-in module assembly is given in the following list:

Clean gloves (scem number: 50.43.20.750.8 or 50.43.20.760.6).

Alcohol ethylic (scem: 58.04.38.220.0).

Clean waste (scem: 30.41.20.200.3).

Scotch tape (scem: 04.95.45.263.4).

Aluminium foil (scem: 44.01.35.900.4).

Protection gas (Argon).

Stainless steel brushes (scem: 34.90.08.010.4).

Kapton foil (scem: 44.88.80.010.6).
6. RECORD CARD
The “Record Card” ensures the traceability of the installation parameters, records remarks
pertaining
to
the
installation
phases
and
the
location
of
each
plug-in module.
The operator responsible shall fill in this Card after each operation as part of the Quality
Assurance Programme. The Card will be transmitted to the Quality Officer who is in charge of
the follow-up of the installation."
An example of this “Record Card” is presented in Annex 1.
7. REFERENCES
1
LHC-LI-ES-0009
Interconnection Work Package 1 (IWP 1)
Interconnections: Interconnection of the inner lines
2
LHCVSS_H0074
Plug-in Module Assembly Tooling 1
3
LHCVSS_H0075
Plug-in Module Assembly Tooling 2
4
LHCVSS_H0184
Compression Tooling 3
–
Cryomagnets
LHC Project Document No.
LHC-VBMB-IP-0001.00 rev. 2.0
Page 15 of 15
8. ANNEXES
8.1 RECORD CARD
Plug-in module – Record Card
Interconnection: ……………………………………………
Line number:………………………
Contractor responsible:………………………………….
Date: .. / .. / ..
Plug-in module number
Starting time: …. H ….
……………………………………………………………………………………………………..
Visual inspection result(step n°3)*
OK
NO
Remarks
Interconnects extremities
Visual inspection result
(step n°5)*
Pin installed*
Downstream side
Upstream Side
OK
NO
OK
NO
YES
NO
YES
NO
Measurement result of extremities offset for the line V1 (step n°6)
……………………
………….
……………………
Extremities offset
of of
line
V1
Measurement
result
extremities
offset for the line V2
………….
……………………
………….
……………………
Measurement result of the distance between extremities for the line V1
Measurement result of the distance between extremities for the line V2
………….
Remarks
Tacking phases
Differences with procedure
(step n°15-21)*
Name of welder:………………………………………………………………………....
Downstream side
NO
Upstream Side
YES
NO
YES
If yes, details
Welding phases
Differences with procedure
(step n°26-32)*
Name of welder:………………………………………………………………………....
Downstream side
NO
Upstream Side
YES
NO
YES
If yes, details
Final control (Attached the “welding parameters”)
Differences with procedure*
Downstream side
NO
Upstream Side
YES
NO
YES
If yes, details
Visual inspection result*
In conformity with ISO 5817, category B
YES
* Make a cross to give result (for example:  √  No  or  √  YES )
NO