quality control of the lhc main interconnection splices - Indico
Contents
1. ccccsceesecnusenes 20 OL DEROTO MICROCGAMMETER ad Sk 20 8 1 1 DELETE DLRO10X MEMORY AT LEAST TWICE A DAY cccccseceeeeeeeeeeeeeeeeueeesaneneneenenss 20 8 1 2 RECHARGE AND CHANGE DLRO10X BATTERY MODULE ccccceceeseeeeeeeeeeeeeaeeeeneeneass 20 813 DERO10X CALIBRATION TEST iii lcida 21 3 2 ALL ELECTRONIC EOUIPIEN Torrico 22 8 3 SAFE EXCEL SPREADSHEET REGULARLY IN DFS VIA 3G mcccccoccccnnnrrrrnron 22 9 REFERENCE DOCUMENTS ida 22 APPENDIX I TEST REPOR Toi a 23 APPENDIX II DRAWING U PIECE AND WEDGE sssaannssnnnnnnnsnnnnnnnnnnnnnnnnnnnnnnnn 25 APPENDIX III LOCAL GEOMETRICAL TEST GAUGES ssssasnnssuunnnnnnnunnnnnnnnnnnna 25 APPENDIX IV GLOBAL GEOMETRICAL TEST GAUGES sssssassnsnnnnsnnsnsnnnnnnnnnnn 25 LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 4 of 25 1 SAFETY All personnel working on the CERN site have to follow the safety rules as outlied in the TE Departemental Safety Plan http safety commission web cern ch safety commission SafetyPlan te f_index htm All personnel working in the LHC tunnel have to follow the following self training modules safety courses on SIR https sir cern ch Basic safety levels 1 et 2 Specific risks level 3 LHC machine level 4 Electrical Safety Awareness In addition all personnel working in the LHC tunnel have to follow specific training Self Rescue Mask Training Radiological Protection Inscription for the safety cou2. Figure 22 Positioning of the cursor in D6 cell next to the Current check cell of the Excel spreadsheet for automatic data acquisition Perform one resistance measurement on a splice with a voltage tap distance of about 8 cm The automatically selected test current is recorded If the recorded test current is 10 A continue with step 7 7 Otherwise the cell D6 appears in red and the step 7 6 needs to be repeated from the beginning When the test is done erase the cell content of D6 7 7 CARRY OUT R 8 R 16 MEASUREMENTS For each R 8 and R 16 test three resistance measurements are performed From these results an average value and the standard deviation are automatically calculated Mark the cell R 8 right 1 in the data acquisition Excel spreadsheet by a single mouse click see Figure 23 R 8 right R 8 left R 16 Threshold value 1 2 3 1 2 3 1 2 3 OR 8 right 12 3 95 94 94 94 96 9 7 18 2 179 18 9 4 12 3 7 6 Figure 23 Positioning of the cursor in the R 8 right 1 cell of the Excel spreadsheet for automatic data acquisition LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 18 of 25 Position the handspikes in the center of the U piece and on the right side of the splice to be tested see Figure 24 The voltage tap pins P not the current injector pins must be placed onto the position markers of the splice such that they are in a distance of 8 cm to each other
3. LHC splice review 28 11 2011 S Heck C Scheuerlein Statistical analysis of LHC main interconnection splices room temperature resistance R 8 results 2012 LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 23 of 25 APPENDIX I TEST REPORT Test report for quality control of LHC main busbar splices produced during LSI and before applying shunts Interconnection ID Comments Mit CA A MAYO poo OME po es ae ee CI a Comments OMAI OME Comments OMA Comments ee EAS E OME MAYO poo OME Pp MBI OME Comments CM o LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 24 of 25 _R 8 R 16 test passed Splice Ok Not OK Comments E E a E MIE MAH J OME OMT p S OMES Comments Figure 33 QC test report for LHC main interconnection splices produced during LS1 and before application of shunts LHC Project Document No Page 25 of 25 APPENDIX II DRAWING U PIECE AND WEDGE Profile en U Plat de fermeture EE 0 7 0 05 A 45 5 EE 2 25 da M18M2 m le 45 5 _ SS 3 6 t 0 2 re 2x R 0 2 max O 2 S m mi H al 4 un S mi 1 y 2 lt 20 04 0 4 M3 15 5 0 a 202s Bees i 2x R 0 2 max in Ss LO y Y Figure 34 Drawings of splice Cu profiles U pieces on the left and wedges on the right APPENDIX 111 LOCAL GEOMETRICAL TEST GAUGES R2 Front view Side view R2 Fron
4. R 8 cell background appears in red see Figure 27 and the R 8 and R 16 measurements need to be repeated Keep the old values repeat the measurements and record the values into the following row in the excel spreadsheet If after the second resistance measurement 2 R 8 is still not in agreement with the corresponding R 16 result save the results and comment in column AB measured two times 2 R 8 does not match with R 16 LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 20 of 25 R 8 right stdev R 8 left stdev R 16 stdev 2R 8 Figure 27 Example for R 16 2 uQ lt sum R 8 8 TEST EQUIPMENT MAINTENANCE AND CALIBRATION 8 1 DLRO10X MICROOHMMETER 8 1 1 DELETE DLRO10X MEMORY AT LEAST TWICE A DAY The DLRO10X can save up to 700 resistance values If the memory is full the data transfer to the Excel spreadsheet is not reliable anymore Therefore the memory of the DLRO10X needs to be erased regularly at least twice per working day To delete stored data from the DLRO10X memory push on the right side of the yellow coordination button in order to navigate to the OPTIONS menu see Figure 28 In OPTIONS submenu select DELETE DATA and push ENTER Select YES As a result all data is erased from the DLRO10X memory EN Figure 28 Display of OPTIONS submenu of the DLRO10X 8 1 2 RECHARGE AND CHANGE DLRO10X BATTERY MODULE Battery status can be checked anytime without seperating DLRO10X from the battery mod
5. The splice in the background is finished and in the foreground the two Rutherford type cables extending from the opposing busbar stabilizers are prepared for interconnection b Cross section through a LHC dipole busbar LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 8 of 25 4 EQUIPMENT The following equipment is needed to perform the QC tests on the LHC main splice interconnections Megger DLRO10X with one spare battery DH5 duplex handspikes with 2 5 m long cable RS 232 cable Notebook with one spare battery Digital Camera Gauges for local splice deformation test Figure 5 Gauges for local splice deformation test in the area where shunts will be applied Gauge for global splice alignment and deformation test Figure 6 Gauges for the global splice alignment and deformation test for dipole a and quadrupole b splices 2 Ruler Pen Black Stabilo OHPen universal permanent marker EAN 4006381118989 Mirror Torch SCEM 01 28 10 120 8 LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 9 of 25 The QC test station including the Megger and DH5 handspikes is presented in Figure 7 Figure 7 a Test station for resistance tests with automatic data acquisition and b RS 232 cable 5 TEST REPORT Before starting the splice QC enter all general test information in the test report Name of operators Date and time of test Interconnection ID During the QC en
6. droplets on the splice that could prevent mounting the splice insulation Figure 14 Appearance of properly cleaned splices An uncleaned and heavily oxidized busbar pair is shown in Figure 15 Figure 15 Appearance of unclean splices with remaining oxide scale 6 7 PHOTOS For all newly produced splices take a photo in the sequence M2 M1 and M3 Take photos of the splice pairs from the top as shown for instance in Figure 14 In case of non conform splices document the non conformity and add detailed photos of the defect 7 ELCTRICAL RESISTANCE TEST R 8 R 16 7 1 R 8 R 16 INTRODUCTION Room temperature RT splice resistance measurements can detect splices with an excessive resistance in the normal conducting state It has been shown that the low temperature stabiliser resistance can be estimated from the RT resistance results Four point resistance measurements are performed with a Digital Low Resistance Ohmmeter DLRO10X either with a voltage tap distance of 8 cm or 16 cm referred to as R 8 and R 16 respectively The R 16 result includes the resistance of both busbar to splice contacts while the R 8 result is influenced by one contact only R 16 values are measured as a cross check of the R 8 results The test current of 10 A is injected in a distance of 5 mm from the voltage taps The accuracy of the R 8 inhomogeneous current distribution due to the point like current injection close to the voltage taps causes a sy
7. follows 6 Mi M2 M3 see Figure 2 Figure 2 Sketch of LHC interconnection showing the location of M1 and M2 quadrupole and M3 dipole busbars External splice furthest to the ring center previously referred to as cryo QRL side see Figure 3 The abbreviation is E Internal splice closest to the LHC ring center previously referred to as corridor side The abbreviation is I Left side left splice side when looking from the center of the LHC ring previously referred to as lyra side The abbreviation is L Right side right splice side when looking from the center of the LHC ring previously referred to as connection or diode side The abbreviation is R an E ig s o s w 6 s PAS A e iG a Tam ye ne ne External QRL lt 4 EN gt Bey Riont Connection y aN 7 ZA a A E Internal Corridor gt y y a Figure 3 Location of internal external and left right side of an LHC main magnet interconnection LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 7 of 25 r a The LHC main splice components U piece tongue are shown in wedge busbar stabiliser and busbar meo TY roove ETA tongue CS vas a ae a Auperconductite cables busbar aeons eas e cables busbar stabiliser gt 4 Figure 4 a Main busbar interconnection splices in the LHC tunnel
8. in column AB of the excel spreadsheet and in the test report Before the second measurement make sure the DLRO10X battery is still at least 20 charged and check if splice components are moving while measuring R 8 right stdev R 8 left stdev R 16 stdev R 8 X e 96 0 1 178 O01 9 4 0 1 6 0 5 5 0 1 9 9 0 1 9 6 94 00 180 0 2 Figure 26 Example for a too high stdev of R 8 results on right splice side If after the second resistance measurement the stdev of the three resistance results still exceeds the standard deviation threshold value the splice is declared non conform In case splice components are loose the splice needs to be declared non conform and needs to be repaired Comment in column AB of the excel spreadsheet and in the test report splice components loose 7 9 2 SUM OF R 8 RIGHT R 8 LEFT 2 R 8 IS NOT COMPATIBLE WITH THE CORRESPONDING R 16 RESULT The R 16 measurement is performed as a cross check of the R 8 results The Excel program automatically compares the sum of R 8 right and R 8 left 2 R 8 results with the corresponding R 16 result always average values Due to the systematic error in the resistance measurements the R 16 value is typically 1 uQ lower than the sum of the corresponding R 8 values If the sum of R 8 right and R 8 left is in agreement with R 16 the cell background appears in green If the R 16 result is larger than 2 R 8 or 2 R 8 exceeds R 16 by more than 2 uQ the
9. 0004 ver 0 2 Page 15 of 25 The fitted R 8 data for 2009 production dipole and quadrupole splices is presented in Figure 16 and Figure 17 respectively together with the corresponding acceptance threshold values If the R 8 result exceeds these threshold values the splice is declared non conform Proceed with the R 8 R 16 test in the following sequence 7 2 LABEL R 8 R 16 MEASUREMENT POSITIONS ON SPLICES Label the R 8 R 16 measurement positions on the side of the splices in the splice center and in 8 cm distance of the splice center in either direction by using a ruler anda U profile edge a J U profile length 15 cm sks haay e A permanent marker Figure 18 Position of label on splice for R 8 R 16 measurements 7 3 CONNECT MEASUREMENT EQUIPMENT Connect the DLRO10X with the laptop via RS 232 interface see Figure 19 Figure 19 RS 232 interface of the laptop 7 4 LAUNCH SOFTWARE APPLICATIONS ON LAPTOP Open WinWedge application by double clicking on the icon DLRO10X data acquisition on the desktop of your laptop for automatic data acquisition of resistance results see Figure 20 Open the Excel workbook on the desktop of your laptop by double clicking on the icon R 8 R 16 new splices to save the resistance results LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 16 of 25 DLRO 10 X data acquisiti on R 8 R 16 new splices Figure 20 WinWedge and Excel app
10. 12 Q881 882 Mi 94 94 93196 96 951178 178 1739 9 4 0 1 9 6 0 1 178 0 1 15 10 2012 0881 82 M3 56 56154 55 S6 98 99 10 5 5 01 65 oi 9 9 gt 172012 He 2 M2 96 96 97194 94 94 179 179 182 9 6 01 94 00 18 0 17 10 2019 He 2 Mi 97 96 96 98 101 10 186 187 186 9 6 01 100 02 186 0 7 17 10 2012 Hee 8R2 56 57161 64 65 11 107 107 5 6 01 63 02 108 B 17 10 2012 Heck AAI BA n2 Ex 12 3 B 17 10 2012 Heck QBBI 8R2 M1 Ext 12 3 7 10 2012 Heck OBBI BR M3 Ext 7 6 A Figure 21 R 8 R 16 results Excel spreadsheet LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 17 of 25 7 6 SWITCH ON THE DLRO10X Always when the DLRO10X is switched on the first measurement is used to record the test current in the Excel spreadsheet After launching the DLRO10X position the cursor in the cell D6 next to Current check of the Excel spreadsheet see Figure 22 are e ree Puja ive roe a x sm ta nx mus F tras ee woe Fi z Nore eee Good Neutral Cakutstion we X E as nne y ezu gt A Bes ce 44 borai Pomat CoO egpare npa hed Ce et Dee Poma 2 3 acceptance threshold values 4 dipole 7 6 5 quadrupole 12 3 6 7 8 Date R 8 right R 8 left 9 DD MM YY Operator Interconnection Line Side Threshold value 1 2 3 1 2 3 65 17 10 2012 Heck QBBI 8R2 M2 Int 12 3 96 96 97 94 94 94 66 17 10 2012 Heck QBBI 8R2 M1 int 12 3 97 96 96 98 101 10 67 17 10 2012 Heck QBBI 8R2 M3 Int 7 6 56 56 5 7 61 64 65
11. AND PHOTOS wccsccscncnncennnes 10 6 CUP WEDGE POSITIONING ans A E 10 6 2 PRESENCE OF SOLDER AT THE CU PROFILE INTERFACES mccccconoccnnrnrnnrnnon 10 6 3 ABSENCE OF MACROSCOPIC VISIBLE GAPS o ooocicccccnccccccanncr rr rr 11 6 4 SPLICE WIDTH HEIGHT AND ABSENCE OF STEPS gt 1 5 MM AT THE SHUNT LOCATON Saas iscsi ace as rer A e id 11 6 5 GLOBAL SPLICE GEOMETRY AND ALIGNMENT TEST ccccceveusesesevaueusesavans 12 6 0 SPLICE CLEANLINESS wie at iinet sia 13 627 PROTOS wacom hutnadientenunc A A ARCADE 13 7 ELCTRICAL RESISTANCE TEST R 8 R 16 sssssusunnunnnnnnnunnnnnnnnnnnnnnnnnn 13 AE R 8 R 16 INTRODUCTION nd 13 7 2 LABEL R 8 R 16 MEASUREMENT POSITIONS ON SPLICES occoccccccnnn rn 15 7 3 CONNECT MEASUREMENT EQUIPMENT o occccccccccccccccccccr cnc 15 7 4 LAUNCH SOFTWARE APPLICATIONS ON LAPTOP cccecececeususeeeveueunenavaueune 15 7 5 SPECIFY SPLICE AND TEST INFORMATION IN EXCEL SPREADSHEET 16 728 SWITCHON THE DLROLOX A ata 17 7 7 CARRY OUT R 8 R 16 MEASUREMENTS cccccecescuceueueuveuseueesaueusuueeteuseneunes 17 Jo RESUETINTERPRERA TITO Nica taotide de wk eadadin E EO 18 7 9 INDICATIONS FOR POSSIBLE R 8 R 16 MEASUREMENT ERRORS 19 7 9 1 R 8 OR R 16 STANDARD DEVIATION TOO HIGH ccceccececceceeeeeeeeeeeueaeeeeeueneaneneenenes 19 7 9 2 SUM OF R 8 RIGHT R 8 LEFT 2 R 8 IS NOT COMPATIBLE WITH THE CORRESPONDING R 16 RESULT aimara 19 8 TEST EQUIPMENT MAINTENANCE AND CALIBRATION
12. C E RN LHC Project Document No CH 1211 Geneva 23 LHC QBBI TP 0004 ver 0 2 Sw j tze rl an d CERN Div Group or Supplier Contractor Document No TE MSC A MZ a a F e CA Hadron Collider project Date 2012 10 31 Test Procedure QUALITY CONTROL OF THE LHC MAIN INTERCONNECTION SPLICES PRODUCED DURING LS1 BEFORE APPLICATION OF SHUNTS Abstract This document defines the procedure and acceptance criteria that will be used to control the quality of the 13 kKA LHC main interconnection splices to be produced during the first long LHC shut down LS1 The splice QC will be performed on the splices before applying shunts Prepared by Checked by Approved by Simon Heck Christian Scheuerlein Jean Philippe Tock Amalia Ballarino Frederick Bordry Francesco Bertinelli Luca Bottura Nicolas Bourcey Ranko Ostojic Thomas Otto Jose Pereira Lopes Roberto Lopez Herve Prin Rosario Principe Frederic Savary Matteo Solfaroli Pierre Thonet LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 2 of 25 History of Changes Rev No Pages Description of Changes 0 1 2012 06 29 All First version submitted 0 2 2012 11 02 All Second version submitted for Approval LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 3 of 25 Table of Contents 1 SAFE Visca oa 4 2 ENTRODUCTTO Nicasio 5 3 NOMENCEATURE Goiania cada 6 A EQUIPMENT Sii ac 8 5 TEST RREPOR Toco 9 6 VISUAL INSPECTION GEOMETRICAL TEST
13. Figure 24 Positioning of the handspikes for a R 8 measurement on the left side of the splice and b for R 16 measurements The resistance measurement automatically starts when the spring loaded pins are in good contact with the splice One resistance measurement takes about three seconds During this time it is important not to move the handspikes in order to keep a good electrical contact to the splice The resistance result is automatically recorded in the Excel spreadsheet and the cursor jumps to the next cell for the 2 resistance measurement 2 The transfer via RS 232 interface of one value takes again about 2 seconds Perform the 2 and 3 resistance measurement by removing one of the two handspikes from the splice and reposition it afterwards at the same position When R 8 Right is completed the cursor in the Excel spreadsheet jumps automatically in the R 8 left 1 cell Perform three R 8 measurements on the Left side as described above When all three R 8 Left measurements are completed the cursor in the Excel Spreadsheet jumps automatically in the R 16 1 cell Position the handspike voltage taps on the busbar stabiliser in 5 mm distance from the U piece Perform three R 16 measurements 7 8 RESULT INTERPRETATION Average R 8 resistance R 8 average R 16 resistance R 16 and standard deviation stdev are automatically calculated by Excel and the results are compared with the correspon
14. cessary If needed use the corresponding user s manual to change batteries 8 3 SAFE EXCEL SPREADSHEET REGULARLY IN DFS VIA 36 9 REFERENCE DOCUMENTS 1 P Fessia Specification for the Consolidation of the LHC 13 kA Interconnections in the Continuous Cryostat CERN EDMS Nr 1171853 J M Demolis L Favier S Triquet R Principe Criteres de controle qualite interconnections 13 kA EDMS Nr 1171359 3 S Heck Test Procedure LHC QBBI TP 0006 Quality control of the LHC main interconnection splices produced before LS1 before application of shunts EDMS No 1240298 C Scheuerlein S Heck Test Procedure LHC QBBI TP 0005 Quality Control of the Stabilised LHC Main Busbar Cables before Splice Assembly EDMS No 1228962 gt S Heck Test Procedure LHC QBBI TP 0007 Quality Control of the LHC main interconnection splices after consolidation by application of shunts EDMS No 1240301 6 M Pojer H Prin Naming convention for the splice consolidation EDMS No 1234436 F Bertinelli L Bottura J M Dalin P Fessia R H Flora S Heck H Pfeffer H Prin C Scheuerlein P Thonet J P Tock L Williams Production and Quality Assurance of Main Busbar Interconnection Splices during the LHC 2008 2009 Shutdown IEEE Trans Appl Supercond 22 3 2011 1786 1790 oC Scheuerlein Quality control of the main interconnection splices before and after consolidation presentation at the 2nd
15. ding acceptance threshold values If the standard deviation of the three resistance results and the comparison of 2 R 8 and R 16 are within the specified limits see chapter 7 9 the R 8 result is compared with the acceptance threshold values for quadrupole and dipole splices If none of the R 8 exceeds the acceptance threshold values the corresponding cell is dyed green and a check appears This means that the R 8 splice test is passed If one R 8 result exceeds the acceptance threshold value the corresponding cell is dyed red and a black cross appears see Figure 25 This means the splice is declared non conform LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 19 of 25 R 8 right stdev R 8 left stdev R 16 stdev R 8 10 3 401 97 4200 189 01 11 9 0 1 9 6 0 1 20 4 0 1 5 8 0 0 1 0 1 12 3 0 1 8 2 0 1 63 0 1 13 6 0 1 Figure 25 Example for too high R 8 resistance on the right splice side 7 9 INDICATIONS FOR POSSIBLE R 8 R 16 MEASUREMENT ERRORS 7 9 1 R 8 OR R 16 STANDARD DEVIATION TOO HIGH If the standard deviation of the three measurement values is larger than 0 8 uQ this can indicate a measurement error In this case the stdev cell occurs in orange see Figure 26 and the resistance measurement needs to be repeated Keep the values and repeat the R 8 measurements by using the next row in the excel spreadsheet Make a comment to the second measured values splice measured twice stdev too high
16. guaranteed that shunts and the new insulation boxes can be installed on all 13 kA busbar splices The application of shunts requires that a flat and smooth surface can be machined on the busbars such that the solder can wet and spread the entire shunt to busbar interface by capilary action The acceptable tolerances for the assembly of the insulation box are outlined in 1 and 2 This QC procedure includes the description of the visual inspection of the splices the geometrical splice test with dedicated gauges the room temperature RT electrical resistance tests and the documentation of the QC results The regular maintenance of the test equipment is described as well The state of the QC either pending OK or not OK is communicated to the splice production teams via the WISH tool This procedure is to be distinguished from the QC procedure LHC QBBI TP 0006 for the already existing splices that were produced during LHC installation or during the 2008 2009 shutdown 3 The QC described in this procedure is preceded by the visual inspection of the stabilized cables before splice assembly which is described in the test procedure LHC QBBI TP 0005 4 The QC of the consolidated splices with shunts is described in the procedure LHC QBBI TP 0007 5 LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 6 of 25 3 NOMENCLATURE Throughout this note the splice location within the LHC interconnection is described as
17. lared non conform Document the defect by detailed photos and describe the defect in the test report 6 2 PRESENCE OF SOLDER AT THE CU PROFILE INTERFACES Verify that solder is present along the interfaces between U profile wedge and busbar stabiliser tongue as shown in Figure 8 Figure 8 Well aligned splices without macroscopic gaps Solder is present between U piece wedge and busbar tongues If there is no solder visible at the splice interfaces the splice is declared non conform In this case add detailed splice photos either from the top dipole or from the bottom quadrupole of the splice LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 11 of 25 6 3 ABSENCE OF MACROSCOPIC VISIBLE GAPS Verify that there are no visible gaps between U profile wedge and busbar stabiliser as Shown in Figure 9 and Figure 10 Figure 10 a Longitudinal gaps between busbar stabiliser tongue and U piece and b between U piece and wedge If there are visible gaps the splice is declared non conform Document the defect by detailed photos and describe the defect in the test report 6 4 SPLICE WIDTH HEIGHT AND ABSENCE OF STEPS gt 1 5 MM AT THE SHUNT LOCATIONS The splice geometry is tested at the splice region where shunts are applied later on using 60 mm long gauges Verify that the splice width does not exceed 21 5 mm and the height does not exceed 11 5 mm quadrupole or 17 5 mm dipole and or that there are no steps gt 1 5 m
18. lication icons as seen on the desktop of the laptop for automatic data acquisition 7 5 SPECIFY SPLICE AND TEST INFORMATION IN EXCEL SPREADSHEET Fill in the following QC information in the Excel spreadsheet as shown in Figure 21 to identify the splice use scroll down menu Date Operator Interconnection Line M1 M2 or M3 Side Internal or External Do so for all newly produced splices of the interconnection cell content can also be filled in by copy amp paste The corresponding threshold values are automatically selected a a 9 pes men Papa Layout Pomo Data FS ven asa ba H 5 ad ea u Aa T w gt F Vers teat saree al E H Nor me Bad Good Nital l Calculation e TA a Saen y sy A s Eoen B 7 y s gt A gt ses a r ue abres pr amp Center o a a format terperi Input I Line nent Delete Peral 2 Owr a ee dpto e d Fora d de gamer manna J yes meal ton ag cc Y A B C D f G H j K L M N O p Q R 5 uU Vv W x R 8 R 16 result spreadsheet for test splices before consolidation produced in 2012 acceptance threshold values dipole 7 6 quadrupole Current check 10 Date R 8 right R 8 left R 16 D0 MM YY Operator Interconnection Line Side Threshold value 1 2 3 1 2 3 1 2 83 OR Bright stdev R 8 left stdev R 16 stdev ER 3 lc _ _ _ _ _ _ a E 6 J gt gt J gt J aN 15 10 20
19. m between U profile wedge and busbar stabiliser see Figure 11 Figure 11 Step between U piece and busbar stabiliser For the geometrical test use the dedicated gauges as shown in Figure 12 gauge width is 21 5 mm gauge height is 11 5 mm for quadrupole and 17 5 mm for dipole splices LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 12 of 25 Figure 12 Geometrical test with dedicated gauges a height test and b width test If one gauge does not fit over the splice this is declared non conform Document the defect by detailed photos and describe the defect in the test report 6 5 GLOBAL SPLICE GEOMETRY AND ALIGNMENT TEST In order to make sure that the splice insulation can be mounted later on a 200 mm long gauge as shown in Figure 13 is used to check the splice alignment The gauge width is 23 mm and the gauge height is 21 mm and 15 mm for dipole and quadrupole splices respectively If the gauge is not mountable on both parallel aligned splices both splices are declared non conform A drawing of the gauge is shown in Figure 36 in the Appendix IV oy O Figure 13 Geometrical splice test a before application of the cover and b after application of the cover LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 13 of 25 6 6 SPLICE CLEANLINESS Verify that the splice has been cleaned after the soldering process and that there are no Sharp edges see Figure 14 Verify that there are no thick solder
20. rses in classes is via the CERN training catalogue https cta cern ch cta2 f p 110 9 4052417624575506 X_STATUS XS COURSE _NA ME XS_PROGRAMME XS_SUBCATEGORY X_COURSE_ID XS_LANGUAGE XS_SESSION R FA LO Lio Access requests for the LHC tunnel are made via EDH https edh cern ch Document General ACRO All personnel working in the LHC tunnel needs to be equipped with CERN access card Personal dosimeter Safety helmet with head lamp and safety shoes Biocell LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 5 of 25 2 INTRODUCTION This standard procedure describes the QC of the LHC main quadrupole M1 and M2 and dipole M3 interconnection splices that are newly assembled during LS1 and before application of shunts It is estimated that about 1500 existing LHC main splices have to be desoldered and reconnected during LS1 The sequence of local splice QC steps integrated in the splice production and consolidation work flow is shown in Figure 1 QC of 13 kA newly produced splices Redo splice QC of newly produced 13 kA splices gt AE Figure 1 Flow chart diagrams showing the sequence of local QC steps for LHC 13 kA main interconnection splices for a standard consolidation sequence b after magnet replacement b The QC shall assure that all splices produced during LS1 are made according the best praxis and are of comparable quality as those produced during 2009 It must be
21. stematic error in the R 8 and R 16 results of approximately 1 uQ LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 14 of 25 The precision of the R 8 measurements following the procedure applied in 2009 is about 0 30 uQ 0 The influence of the splice temperature on R 8 is neglected The estimated temperature variation in the LHC tunnel is between 14 C to 20 C This causes a maximum uncertainty in the R 8 results of 0 21 uQ and 0 12 uQ for quadrupole and dipole splices respectively The following R 8 acceptance threshold values for new splices that will be produced during LS1 have been defined for quadrupole and dipole splices R 8dipole 7 6 Q R 8quaa 12 3 pO 3P Burr fit of new dipole splices acceptance threshold value f x 4 4 4 8 5 2 5 6 6 0 6 4 6 8 7 2 7 6 8 0 R 8 uO Figure 16 Probability density function f x of dipole splices produced during 2009 R 8 fitted with 3P Burr function and acceptance threshold value for dipole splices produced during LS1 DM 3P Burr fit of new quadrupole splices acceptance threshold value x Y 84 87 90 93 96 9 9 10 2 10 5 10 8 11 1 11 4 11 7 120 12 3 12 6 R 8 10 Figure 17 3 Probability density function f x of quadrupole splices produced during 2009 R 8 fitted with 3P Burr function and acceptance threshold value for quadrupole splices produced during LS1 LHC Project Document No LHC QBBI TP
22. t A 1 2 3 value mA stdevicomments 3 pa NS AA al gt gt s 6 04 05 2012 Heck 1 10 032 10 032 10 032 10 0 00 7 04 05 2012 Heck 1 10 032 10 031 10 032 10 0 0 0 8 amp 8 10 05 2012 Heck 1 9 10 11 Figure 31 Excel spreadsheet for automatic data acquisition of the resistance of calibration standard The first measurement will check the automatically selected test current and record the value into the corresponding cell Subsequently the cursor jumps automatically into the next column labeled with Calibration resistance R 10 0 mQ 1 Perform three resistance measurements with the 10 0 mQ calibration resistance sample The three results are recorded and the average resistance value and the standard deviation are automatically calculated If the average resistance value is not within defined limits the corresponding cell in column G is dyed red If the resistance result is 10 0 MQ uQ proceed with the R 8 R 16 test LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 22 of 25 AXIMUM BOLT TORQUE INCH POUNDS Figure 32 Resistance measurements on DLRO10X calibration standard with a voltage tap distance P to P of 5 cm 8 2 ALL ELECTRONIC EQUIPMENT The batteries of all electronic equipment e DLRO10X digital camera and laptop need to be recharged at the end of a working day If spare batteries are available do check their batterie status in regular intervals e g 2 weeks and recharge them if ne
23. t view Side view Figure 35 Sketch of gauges for geometrical splice test for dipole a quadrupole b splices APPENDIX IV GLOBAL GEOMETRICAL TEST GAUGES Figure 36 Drawing of gauge for global splice alignment and deformation test for quadrupole left and dipole right splices
24. ter test results in the test report and give additional comments if needed Correct splice assembly Ok not Ok Presence of solder alloy at splice interfaces Ok not Ok Absence of macroscopic gaps Ok not Ok Local and global geometrical test passed Ok not Ok Is the splice clean and without sharp edges Ok not Ok R 8 R 16 test passed Ok not Ok The test report template is shown in the Appendix I of this procedure LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 10 of 25 6 VISUAL INSPECTION GEOMETRICAL TEST AND PHOTOS The goal of the visual splice inspection is to verify that all splice components are correctly assembled verify the presence of solder at the interfaces between the Cu profiles U piece wedge and busbar stabiliser verify the absence of macroscopic gaps between the splice Cu profiles verify the absence of steps gt 1 5 mm between the splice profiles verify that the splices are well alligned verify the splice cleanliness document the splice state by photos 6 1 CU WEDGE POSITIONING Verify that the groove see Figure 4 on the splice wedge is facing the internal side of the splice Verify that the correct wedge has been used 6 4 mm thick and 3 4 mm thick for dipole and quadrupole splices respectively In case that quadrupole and dipole profiles have been mixed up this is easily seen by a 3 mm step between U piece and wedge If the splice is not correctly assembled it is dec
25. ule either on the DLRO10X display or on the backside of the battery see Figure 29 Replace battery if the battery charge level is less than 20 LHC Project Document No LHC QBBI TP 0004 ver 0 2 Page 21 of 25 Figure 29 Check of the battery status 4 bars out of 10 indicate that the battery has still 40 of its maximum capacity At the end of each working day the DLRO10X batteries need to be recharged The battery module is attached to the bottom of the DLRO10X In order to charge the battery open the locks on the side of the DLRO10X see Figure 30 Afterwards lift the DLRO10X to access the battery plug The battery can be recharged now Connect DLRO10X with fully charged battery on the next day Fully recharging the battery takes between 2 4 hours UA EX 4 Y SS ES g Figure 30 a Removing and b charging the DLRO10X battery 8 1 3 DLRO10X CALIBRATION TEST At the beginning of each working day the well functioning of the DLRO10X test station is verified To do so switch on the DLRO10X and open the Excel workbook DLRO10X calibration test Position the cursor in the cell Current in column C see Figure 31 y y m eS imen en a Saw Fae coe E Bl Ju Good Nemai cacon em Ce e 17 NN Semana 120 ate ed SES Poon ifs tins sa ms E e ET JO hace ae EE ne z ie B c DA E F G H Spreadsheet for DLRO10X calibration test 2 3 Date Calibration resistance R 10 0 mQ 4 DD MM YY Operator Curren
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