CRYO TCS status

1
CRYO TCS status

• CRYO TCS Design and analysis status (complete)
• Manufacturing testing status
• Production status (VSB complete)

2

• CRYO TCS design complete
• Fourth LHP has been re-routed and
• design authorized for production

3
CRYO TCS BIMETALLIC JOINTS (BMJ) TESTING

• 4 CRYO LHP BMJ SAMPLES HAVE BEEN BUILT TO UNDERGO
  WELDING AUDIT
• 4 CRYO LHP BMJ SAMPLES HAVE BEEN BUILT TO UNDERGO
  WELDING AND EXPLOSION BOND QUALIFICATION
• 6 ADDITIONAL CRYO LHP BMJ SAMPLES HAVE BEEN BUILT
  TO UNDERGO QUALIFICATION FAILURE INVESTIGATION
  AND STRENGHT TESTING

4
CRYO TCS BIMETALLIC JOINTS (BMJ) AUDIT
TESTED SPECIMENS AND AUDIT TEST PLAN
5
CRYO TCS BIMETALLIC JOINTS (BMJ) AUDIT
WATER COOLING SETUP
6
CRYO TCS BIMETALLIC JOINTS (BMJ) AUDIT RESULTS

• FOR ALL AL-AL AND ST-ST WELDINGS THE
• VISUAL INSPECTIO
• DYE PENETRANT INSPECTON
• MACROGRAPHIC TEST
• MICROGRAPHIC TEST
• HAVE BEN SUCCESFULLY PASSED RESULTING IN POSITIVE
  AUDIT CONCLUSION

7
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON

• 4CRYO TCS BMJ SAMPLES HAVE BEEN WELDED TO
  ALUMINUM (AL) AND STEEL(ST) TUBES TO UNDERGO
  WELDING AND EXPLOSION BOND QUALIFICATION
• WELDING OF AL AND ST TUBES
• VISUAL INSPECTION
• LEAK-PROOF-LEAK TEST _at_ 25 BAR (1.5xMDP)
• LEAK-PROOF-LEAK TEST _at_ 66 BAR (4xMDP)

8
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON
RESULTS
LEAKAGE ON 1 OF 8 BMJ DETECTED RIGHT AFTER
WELDING IN THE EXPLOSION BOND AREA
9
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON
RESULTS (PART2)

• LEAKAGE ON BMJ, POSSIBLE CAUSES INVESTIGATED
• DEFECTIVE BMJ EXPLOSION BOND
• MACROGRAPHIC INSPECTION OF FAILING JOINT
  PERFORMED IN PARALLEL
• EXCESSIVE HEAT ON JOINT DURING WELDING
• ADDITIONAL 6 SAMPLES TESTED WITH IMPROVED COOLING
  (DRY ICE) AND TEMPERATURE MONITORING (ALSO BURST
  TESTED AND TENSILE TESTED

10
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON
RESULTS (PART2)

• LEAKAGE ON BMJ, INVESTIGATION
• THE FAILING JOINT (THAT WAS NOT PROOF SCREENED BY
  THE SUPPLIER) SHOWS BAD EXPLOSION BOND
  CARACTERISTICS AFTER METALLOGRAPHIC INSPECTION
  (METALLIC LAYERS AND WAVES UNIFORMIY)

ADEQUATE EXPLOSION BOND
INADEQUATE EXPLOSION BOND
11
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON
RESULTS (PART2)

• LEAKAGE ON BMJ, INVESTIGATION
• TEMPERATURES RECORDED BOTH WITH WATER (FIRST 4
  SAMPLES) AND DRY ICE (LAST 6 SAMPLES) ARE
  CONFIRMED TO BE WELL WITHIN THE RANGE OF THE BMJ
  APPLICABILITY. MOREOVER DRY ICE RESULTS IN HIGHER
  TEMPERATURE GRADIENTS DUE TO DRY ICE EFFICIENCY
  CREATING A WORST TEMPERATURE ENVIRONMEBT TO THE
  BMJ THAT IN ANY CASE SUCCEFULY PASSED LEACK,
  PROOF, BURST AND TENSILE TEST.
• POROSITY ONTHE AL-AL WELDING USING DRY ICE IS
  DETECTED BY RX AND THEN BY METALLOGRAPHIC
  INSPECTION (ST-ST WELDING IS OK)

AL-AL WELD
FAILED
FAILED
ST-ST WELD
PASSED
METALLOGRAPHIC INSPECTION
RX INSPECTION
12
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON
RESULTS (PART2)
2 OF THE LAST BMJ SAMPLES UNDERWENT TENSILE AN
BURST (DESTRUCTIVE) TESTING SUCCESFULLY, DESPITE
POROSITY SOWING APPROPRIATE BURTS PRESSURE AND
TENSILE RESITANCE
NOTE IN BOTH CASES THE AL TUBE FAILED IN ITS
NOMINAL SECTION BEING AS ESPECTED THE WEAKEST
PART OF THE JOINT
13
CRYO TCS BIMETALLIC JOINTS (BMJ) QUALIFICATON
RESULTS (PART2)

• CONCLUSIONS
• ROOT CAUSE IS IDENTIFIED IN THE BMJ EARLY
  DEFECTIVITIY ON THE EXPLOSION BOND AREA (NOT
  DETECTED JUST BY LEAK TEST AFTER PRODUCTON) THIS
  RISK IS AVOIDED ON THE FM SPECIMENS THAT ARE ALL
  LEAK AND PROOF TESTED BY THE SUPPLIER BEFORE
  DELIVERY
• FURTHER DISUSSION WITH MANUFACTURER CONFIRM THAT
  THE TEMPERATURE RANGES EXPERIENCED (lt300) ARE
  NOT AN ISSUE AND WATER COOLING IS PREFERRED TO
  DRY ICE FOR FM WELDING.

14
CRYO TCS RADIATORS MANUFACTURING STARTED
15
CRYO TCS manufacturing status

• Valves manufactured and assembled
• Evaporator saddles are maufactured

16
CRYO TCS jig manufacturing in progress
17
CRYO TCS radiator manufacturing

• SKIN AND AL TUBES PRE FITTED AND PROOF TESTED
  SUCCESFULLY
• BMJ WITH ST TUBE WELDED READY FOR BMJ WELDING ON
  ALUM. SIDE

18
CRYO TCS RADIATORS MANUFACTURING
FIRST PANEL WELDED
19
CRYO TCS RADIATORS MANUFACTURING
FIRST PANEL WELD TEST RESULTS

• PROF TEST SUCCESFULLY PASSED
• LEAK TEST SUCCESFULLY PASSED
• RX MINOR POROSITY IDENTIFIED

THE POROSITY CAUSE HAS BEEN IDENTIFIED IN A HIGH
COOLING INFLUENCE OF THE TUBING AND RADIATOR WITH
RESPECT TO THE SPECIMENS (SIMILAR TO THE ONE
IDENTIFIED ON THE SPECIMENS DRY ICE COOLED).
REDUCED COOLING SETUP IS CURRENTLY UNDER
EVALUATION USING BMJ FULL ALUMINUM SAMPLES
BEFORE TO PROCEED WITH THE OTHER FM PANELS
WELDING (5 SKINS AVAILALE AND 6 SPARE TUBE SETS
AVAILABLE) AND COMPETE SANDWICH PANEL
MANUFACTURING.
20
LHP system Assembly/Testing/Charging/Transportatio
n JIG
21
CRYO TCS schedule

• Deliveries at CERN
• of all 4 CRYO LHP Systems not later than
• December 19th 2008
• CRYO LHP Systems composed by LHP/Zenith
  Radiator/Start-up heaters/thermostats/PT1000/mecha
  nical miscellanea