CERN experience: Vacuum design, interventions and ...

Vacuum design, interventions and

operation in radioactive

environmentJose A. Ferreira on behalf of TE-VSC

CERN experience:

Vide en milieux ionisants, 22-24

noviembre 2017, GANIL1

Contributions from Pawel Krakowski, Robin Nelen, Jaime Perez Espinos and Lukasz Piotr Krzempek

Outline



• Material validation

• Reduce exposure

• Tooling

• Remote handling

Vacuum design of radioactive areas

• Preparation

• Dose planning

• Tooling and training

• Execution

Interventions in radioactive areas

• RIBs operation: ISOLDE

• New RIBs facility: MEDICIS

Operation of radioactively contaminated areas

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Design: Material Validation

Why?

Consequences of equipment

radiation damage :

• Machine unavailability

• Unforeseen replacement

costs

Equipment qualification allows :

• Meeting equipment lifetime

and specs

• Anticipate failures



Vacuum bake out jacket irradiation with

gamma up to 10 MGy is heavily damaged

Design: Material ValidationCERN has a tested and extensive compilation of radiation test data: “Yellow books”

Late 70’s - early 2000’s :

Yellow books: Compilation of radiation damage test data

Current situation

Increasing demand for high dose irradiation tests

Equipment owner fully responsible for their equipment

R2E and R2M



Yellow book report CERN-98-01

Compilation of radiation damage test data

http://cds.cern.ch/record/357576




Preparation

Material(s):

Representative radiation (Gamma, Particles)

Installation area(s) and

expected lifetime:Total dose /

fluency

Pre- and Post-Irradiation

characterization test(s):

Samples size / shape / number

RequirementsChoice of an

irradiation facility

The sub-WP1 (R2E):

• Task 1: Active gauges in the arcs;

• Task 1.2: Active piezo gauges in the arcs & dump lines;

• Task 2: Active gauges in the LSS;

• Task 3: 24 VDC local power supply for fixed pumping groups.

• Radiation Hardness Guideline for VSC electronics developments for 500 Gy




LOG#1LOG#2 4-20 mA

Vac sim 11TΩ

The sub-WP2 (R2M):

• Task 1: O-ring seals;

• Task 1.2: F6 and F14 O-ring seals under compression; (Awaiting

for irradiation)

• Task 2: Permanent bake-out components;

• Task 2.2: New bake-out jackets for LHC bellows close to

collimators;

(Awaiting for irradiation)

• Task 3: NiTiNb SMA (Shape Memory Alloy) connectors;

• Task 3.2: SMA (Shape Memory Alloy) connectors set-up in

TDC2;

• Task 3.3: 4 SMA set-ups in TDC2 with pumping and online

monitoring (Just approved!)

• Task 4: Primary and turbo pumps;

• Task 5: Micro switches and distributors for sector valves;

• Task 6: Passive penning gauge and its HV cable under high

HEH;

• Task 6.2: Induced current in HV cables under radiation;

• Task 6.3: Radiation induced cables aging impact on their

electrical performance

(all samples irradiated, awaiting for post studies);

• Task 7: Silicon rubbers and polyurethanes clamps, vacseal &

epoxies;

• Task 8: Piezoelectric venting valve;

• Task 9: Passive piezo resistive gauge in the LSS & dump lines.




Immediate pressure change when

beam ONImmediate pressure change when

beam ON or OFF

When no beam pressure values

come back to previous states !

No memory effect…

BEAM OFF

BEAM ONBEAM ON

BEAM OFF BEAM OFF

BEAM ON

4E-10 mbar

6E-11 mbar

~E-12 mbar

RUN_2 and 3 have confirmed that the TFA3 Triaxial cable is the source of “spikes”

RUN_2 and 3 only 3 penning gauges and 1 simulator

Gaugea2

disconnected

and replaced by

passive simulator

(11 TΩ)

RUN_1 only penning gauges

4 passive penning

connected to small

vacuum chambers

pumped down in

ranges from 10-10

up to 10-12 mbar

The same behaviour

was observed with

gauge and passive

vacuum simulator !

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Design: Reduce exposure



1970 quick connect clamp

developed for PSB:

Low cost seal

Quick installation and

removal

Low activation (aluminium)

Extreme reliability for UHV

Space allowed along beam

axis for joint including

clearance <40 mm

Small radial space occupied

by the quick connect

Option to be electrically

insulated

Mild bake-out 130°C

PS195 clamp (quick connect up to 150 mm)

Low Cost Vacuum Hardware Developed for the CERN PS Booster

C.E. Rufer and W. Unterlerchner

IEEE Transactions on Nuclear Science Vol 18-3, June 1971

Design: Reduce exposure


noviembre 2017, GANIL

11

PS195 clamp was extremely successful Other designs followed during 70’s

PS250 (up to 200 mm tube)

SPS collars:

Tube up to 70, 159, 219,

273 mm

Bakeable up to 150°C for

D70 and DN159, 80°C for

bigger sizes

Design: Reduce exposureShape Memory Alloys

No seal

Open/close by heating/cooling



Proof of concept of SMA connectors for

Ultra High Vacuum (UHV) chambers.

T<As (40 °C) T>Af (>100 °C)

pmax

SMA ring

Tube

1. Mounting at room temperature

2. Tightening by heating above 100 °C

3. Leak Rate < 10-10 mbar·l·s-1 at room temperature

4. Dismounting by cooling down to -40°C

Mounting Clamping

T = RT

pop

Operation

T<Mf (-40 °C)

Dismounting

As: Austenite start temperature Af: Austenite finish temperature Ms: Martensite start temperature Mf: Martensite finish temperature

Material properties:

NiTi based alloys

Magnetic permeability < 1.002

Thermal outgassing: < 10-13 mbar∙l∙s-1∙cm-2

Radiation hard ?? (tests ongoing)

Design: Reduce exposureShape Memory Alloys

No seal

Open/close by heating/cooling



Proof of concept of SMA connectors for

Ultra High Vacuum (UHV) chambers.

T<As (40 °C) T>Af (>100 °C)

pmax

SMA ring

Tube

1. Mounting at room temperature

2. Tightening by heating above 100 °C

3. Leak Rate < 10-10 mbar·l·s-1 at room temperature

4. Dismounting by cooling down to -40°C

Mounting Clamping

T = RT

pop

Operation

T<Mf (-40 °C)

Dismounting

As: Austenite start temperature Af: Austenite finish temperature Ms: Martensite start temperature Mf: Martensite finish temperature

Material properties:

NiTi based alloys

Magnetic permeability < 1.002

Thermal outgassing: < 10-13 mbar∙l∙s-1∙cm-2

Radiation hard ?? (tests ongoing)

A compact, leak tight and easily mountable/dismountable connection system

Possibility of remote controlling

Possibility to use in high demanding areas (e.g. collimator areas,

machine/detector interface)

Possibility to use in limited access spaces

Possibility to connect dissimilar materials

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Design: Tooling



1979 SPS clamp for remote handling: Two sizes DN159

and DN350 in double and single configuration

NAHIF plugin magnet

Design: Tooling



https://cds.cern.ch/record/1054083




Design: Tooling







Design: Tooling



Combination of automatic clamps and bellows

compression tools operated by robot. VAX ATLAS for HL-

LHC

Design: Tooling



Compression tool for replacement of LHC collimators

Design: Tooling



The replacement of the seal is one of the most difficult steps

Male + Female flange and

seal adapted to robot

Last developments require the

use of remote controlled robots

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Design: Remote handling



70’s and 80’ MANTIS and MANTIS2

Two extremely versatile tele-manipulators

Force reflecting servo Master-Slave

manipulators. Force feedback




MANTIS:Able to

perform very

complex

actions

Very fast

learning curve

Difficult to

deploy




3 robots in RIBs facilities (ISOLDE &

MEDICIS) to move irradiated targets

tEODor ,Telemax (bomb disposal

robots) and new multipurpose platform

with different arms under development

Robots currently used at CERN




Impact wrench

Telemax

Robot capabilities can be extended


11/27/2017 Document reference 31

Leak detection with remote

operated robots


Robots vs Human

Cost

Difficult operation (trained personnel)

Time consuming

No dose

Example: remove 1 clamp at 5 mSv/h

Torque wrench: 3 minutes (250 μSv)

Cordless impact wrench: <20 seconds (<30 μSv)

Robot: 15-30 minutes (0 μSv)


Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Interventions in radiation areas

11/27/2017 34

Lessons learned

ActionTooling

and training

Define steps

Gather information

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Sources of information

1. Drawings and pictures (2D, 3D)

2. Immersive 3D

1. High-Definition Surveying (Laser

scans)

2. 360º cameras

3. Robot inspections

Interventions: Preparation

11/27/2017 36

11/27/2017 37

Preparation: Drawings

2D

Portable (paper)

11/27/2017 38

Preparation: Drawings

Easy manipulation of

virtual world

3D

Preparation: Pictures

11/27/2017 39

Preparation: Immersive 3D (High

Definition Survey)

11/27/2017 40

Preparation: Immersive 3D (High

Definition Survey)

11/27/2017 41

Real 3D model

Exportable to CAD

Measure

Preparation: Immersive 3D (360º

video)

11/27/2017 42

Preparation: Immersive 3D (360º

video)



Preparation: Robot Inspections


Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Interventions: Dose planning

11/27/2017 46

Define steps

Gather information

Allows to determine the level of the intervention

Define the number of participants

Evaluate the need of compensatory

measurements (longer cooldown, tooling, etc.)

Work and dose planning (WDP)

Working timeEffective

avg. dose rateCollective dose Collective dose

Working time

real

Collective

real dose

Collective

real dose

[man.hours] [µSv/h] [man.µSv] [man.µSv] [man.hours] [man.µSv] [man.µSv]

Totals: 60,8 236 14334 14334 0 0 0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

No. Work description (Task) Responsible personDep/Grp

(executing)WorkTeam

Location

(check table 'DoseRates')Persons [No.]

Exposure time

[min]

Dose rate

[µSv/h]

Estimated dose

[µSv]

Estimated total

dose

[µSv]

Real time

[min]Real dose [µSv]

Real

total dose

[µSv]

Remarks

1 Vacuum sector 143 3780 0

1,00 Install VVSB 11960 Jose A. Ferreira TE/VSC/IVM 11960 3 45 41 92

1,01 Install pumps MKPA 11931 Jose A. Ferreira TE/VSC/IVM 11931 4 120 80 640

1,02 Install pumps MKPA 11936 Jose A. Ferreira TE/VSC/IVM 11936 4 120 80 640 0

1,03 Install pumps MKPC 11952 Jose A. Ferreira TE/VSC/IVM 11952 4 40 60 160

1,04 Install pumps MKP 11955 Jose A. Ferreira TE/VSC/IVM 11955 4 60 42 168

1,05 Connect 4xbellows Jose A. Ferreira TE/VSC/IVM 11931-11955 2 40 57 76

1,06 Install VVSB 11903 Jose A. Ferreira TE/VSC/IVM 11903 2 45 800 1200

1,07 Connect VVSB 11903 to MDVA 11904 (NEWmagnet) and BPCE 11906 (new monitor) Jose A. Ferreira TE/VSC/IVM 11904 2 15 800 400

1,08 Connect QDA 11910 Jose A. Ferreira TE/VSC/IVM 11910 2 10 1000 333

1,09 Pump down Jose A. Ferreira TE/VSC/IVM 11903-11960 2 15 140 70

1,10 Leak detection 11903-11960 0 ???? 140 robot (time)

1,10 Leak detection Jose A. Ferreira TE/VSC/IVM 11903-11960 0 ???? 10 robot (time)


2,01 Connect vacuum 8 xchambers Jose A. Ferreira TE/VSC/IVM 11971-11990 2 40 50 67 Without TBSJ

2,02 Install pump 11993 Jose A. Ferreira TE/VSC/IVM 11993 2 15 120 60 0 To be done in BA5 or A6 -

2,03 Connect TBSJ (entrée 1m) 2 5 200 33

2,04 Connect TBSJ (sortie - de 40cm) Jose A. Ferreira TE/VSC/IVM 11995 2 5 150 25 0

2,05 Pump down Jose A. Ferreira TE/VSC/IVM 11971-11995 2 15 176 88

2,06 Leak detection 11971-11995 1 15 176 44 Perche pour sprayer

2,07 Leak detection Jose A. Ferreira TE/VSC/IVM 11971-11995 1 15 176 44

3 Vacuum sectors 131-132-133 49 0

3,01 Remove old group and install new chamber Jose A. Ferreira TE/VSC/IVM 11653 2 45 8 12

3,01 Connect MKQH 11653 Jose A. Ferreira TE/VSC/IVM 11653 2 20 8 5 0

3,01 Connect 2xpumps Jose A. Ferreira TE/VSC/IVM 11653 2 30 8 8 0

3,01 Pump down Jose A. Ferreira TE/VSC/IVM 11653 2 15 8 4 0

3,01 Leak detection Jose A. Ferreira TE/VSC/IVM 11653 2 10 8 3 0

3,01

3,01 Vacuum sector 132 0

3,01 Pump down Jose A. Ferreira TE/VSC/IVM 11672 2 15 6 3 0


3,01

3,01 Vacuum sector 133 0

3,01 Remove old group and install new chamber Jose A. Ferreira TE/VSC/IVM 11679 2 45 3 4,5 0

3,01 Connect MKQV 11679 Jose A. Ferreira TE/VSC/IVM 11679 2 20 3 2 0

3,01 Connect 2xpumps Jose A. Ferreira TE/VSC/IVM 11679 2 30 3 3 0

3,01 Pump down Jose A. Ferreira TE/VSC/IVM 11679 2 15 3 1,5 0


6 Vacuum sector 142 (TT10) 660 0

6,01 Connect chambers and equipment from 102871 to 103000 Jose A. Ferreira TE/VSC/IVM 102871-103000 2 120 165 660 0

0


7,01 Install valve VVSB 11740 Jose A. Ferreira TE/VSC/IVM 11740 2 30 5 5 0

Reinstallation vacuum equipments LSS1

Work and dose planning - LSS1 reinstallation: vacuum

Prior intervention

To be completed and checked by work coordinator(s) and experts

Prior intervention

To be checked and completed by RP

Posterior intervention

To be completed by work coordinator or/and RP


Detailed step by step description

of the different tasks

Number of participants

Depending on the dose levels

justification/optimization could

be required

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Tooling and Training



Window replacement in North Area

next to target T6

Mockups help to train participants no necessarily

familiarized with the activity

Mockups help to check assumptions done to prepare

WDP

Use the information collected to prepare the WDP

during the debriefing

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





Execution



Any discussion in the field must be

avoided!

Follow up the intervention with cameras

if available

Picture taken from overhead crane

Execution



During leak detection: Was everything tested? Repeat?

Cameras help to avoid repeating the work

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





RIBs



http://www.scholarpedia.org/wiki/images/3/3b/ISOLDETarget.jpg

RIBs: Operation



The On-Line Isotope Mass Separator

ISOLDE production of radioactive ion

beams (RIBs)

FrontEnd area, highly activated,

contaminated and corrosion (air ionization)

Pumping with turbomolecular pumps (no

maintenance) and oil rotary vane pumps

Radioactive isotopes from the target:

Stick to the surface (vacuum chambers

and turbopumps)

Volatile pumped out by the vacuum

system

Rotary vane pumps retain part of the

contamination Highly contaminated

RIBs: Operation



Oil replacement

Reduce risk of contamination:

Fast connection and portable pump to extract the oil

RIBs: OperationExhaust system has two pressure levels:

Buffer volume (receives gas from primary pumps). Always below atmospheric.

Storage tanks (receive gas from buffer). From vacuum to 2500 mbar

Operational pressure of buffer volume has a huge impact on gas loads

Original operation From 400 to 700 mbar

Operation from 625 to 825 mbar > factor of 5 reduction of gas load

Gas loads dominated by He injection from ISCOOL (RFQ) when operating

Outline




• Reduce exposure

• Tooling

• Remote handling


• Preparation

• Dose planning


• Execution





RIBs: New facility



RIBs: New facility

Only 10% of the beam taken

by ISOLDE target Irradiation

of MEDICIS target

Off-line irradiation and transfer

tor isotope collection

High levels of radioactive

contamination inside vacuum

system are expected

Gas storage system for

radioactive decay before

release



RIBs: New facility



Sector 2: MSEP10Sector 1: MFE10

MCOL110.VVS.01

MFE10.VVS.01

MFE10.VVH.01 MFE10.VVR.01

MFE10.VVV01

MSEP10.VVH.01

MSEP10.VVR.01

MSEP10.VVV.01

MSEP11.VPT.01

MFE11.VPT.01 MSEP11.VVB.01

MSEP11.VVD.01

MFE11.VVB.01

MFE11.VVD.01

MR10.VVI.02

MB10.VVI.01

MR10.VPV.01 MB10.VPV.01

Exhaust

VGPVGR

VGP VGR

VGR

VGR VGR

VGR

Venting Ar

VGM

Chamber 1: MCOL110Chamber 2:MCOL210

MCOL210.VVV.01

VGP

VGR

VGR

MFE11.VGR.01

MFE10.VGP.01

MFE10.VGR.01

MFE10.VGM.01

MSEP10.VGP.01MSEP10.VGR.01

MSEP11.VGR.01

MR10.VGR.01

MRAB10.VGR.01

MCOL110.VGP.01

MCOL110.VGR.01

MCOL210.VVM.01

MCOL210.VGR.01

MAR10.VGM.01

MCOL110.VVH.01

MCOL110.VVR.01

MCOL110.VVV.01

MCOL210.VVR.01

MCOL210.VVH.01

VGP

MSEP11.VGP.01

MRAB10.VVY.01

MB10.VGR.01

MAR10.VVV.01

Ar line

RIBs: New facility



RIBs: New facility



From machine

MEXH10.VPV.01

VGM

Tank 1 (1000L)

Tank 2 (1000L)

MEXH20.VVI.01

MEXH20.VVI.02

MEXH30.VVI.01

MEXH30.VVI.02

MEXH30VPD.01

MEXH30.VVI.03

VGM

VGM

MEXH10.VGM.01

P

MEXH20.VSA.01

MEXH20.VGM.01

MEXH20.VGM.02

P

MEXH30.VSA.01

Buffer volume (100 L)

MEXH01.VVI.02

MEXH01.VVI.01


MEXH02.VVI.02

MEXH02.VVI.01


MEXH03.VVI.02

MEXH03.VVI.01

P

MEXH00.VSA.01

VGR

VGR

P

MEXH10.VSA.01

MEXH10.VGR.01

MEXH00.VGR.01

VGR

MEXH01.VGR.01

VGR VGR

MEXH02.VGR.01 MEXH03.VGR.01

VGR

MEXH20.VGR.01

VGRMEXH20.VGR.02

P

MEXH00.VSA.02

Gas recovery system:

Two buffer volumes inside bunker with adjusted minimum

decay of 7 days

One bypass volume to pump from atmospheric pressure

Buffer volume (600-800)

Two storage tanks to accumulate gas (150-2000 mbar)

Summary



Material validation is extremely important to reduce the failure rate and

define lifetime of vacuum components exposed to radiation damage

Important for future collective dose

Evaluate dosing interventions during design phase design to

consider human or/and possible remote intervention

Remote handling can have a strong impact on collective dose (but not

for free, time consuming and expensive)

Preparation and follow up of interventions in radioactive areas

(training, tooling, etc.) can have a big impact reducing collective dose

The vacuum operation RIBs facilities require specific exhaust storage

system to reduce the activity released to the environment

CERN experience: Vacuum design, interventions and ...

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