Risk analysis : - Splitters replacement - TCSC replacement WG TDC2/TCC2 18 th June 2013 E. HARROUCH...

E. HARROUCH EN/MEF

Risk analysis :- Splitters replacement

- TCSC replacement

WG TDC2/TCC2 18th June 2013

http://en-dep.web.cern.ch/en-dep/index.html

http://cern.ch/

General risks

• Common risk related to handling operation– Breakdown of a handling equipment : Renewed

and spares pieces available for repairs• External exposure: Reduced to the minimum.– Number of contact operation very limited– Time of exposure limited– Add of shielding and training of the operators to

optimize their position during the operation

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Risk analysis for North Area splitters replacement

• Procedure• Hazard inventory, risk analysis and proposed

measures step by step

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Where are they installed?

BA 80

One groups of 3 magnets

They are designed with V supporting and automatic plug ins

Installation rails are on place, and prealigned with the magnet

TDC2

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Replacement procedure for North Area splitters

• Slides from Jean-Louis : https://espace.cern.ch/sba-workspace/tcc2wg/21st%20Meeting/default.aspx?InstanceID=1

https://edms.cern.ch/document/1155859/1 Installation has as well been tested

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https://espace.cern.ch/sba-workspace/tcc2wg/21st%20Meeting/default.aspx?InstanceID=1

https://espace.cern.ch/sba-workspace/tcc2wg/21st%20Meeting/default.aspx?InstanceID=1

https://edms.cern.ch/document/1155859/1

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3

E. HARROUCH EN/MEF

JL GRENARD EN/HE

Operation Risk Measures already taken

Probability of

occurenceMeasures to be

takenFinal

probability

Failing scenario

1Damaged rails providing the trailer to translate

2011 inspection already performed and did not revealed significant damages to the rails

LowCleaning and visual inspection before operation

Very low Remove the trailer from the rails and fix the rails

2

The gravity centre of the plugin table is not located in the geometric centre of the table

A spring keep the plug in table balanced. The same mounting is used on the surface mock-up. Nothing wrong with the balance has been noticed

Low

-

LowIn case of problem the

spring can be re-adjusted manually.

2Bad positioning of the trailer before the lifting of the splitter.

Mechanical stops with switch to make sure that the positioning is correct

LowVisual marking for human check before lifting Very low

The splitter is lowered on the table and the

trailer is re-positioned

2

Breakdown of the lifting system

-

Medium

All the mechanical and electrical component will be renewed before intervention and tested

Very Low

The motion can be finish manually or hydraulic jacks can support the charge

during the repairs of the trailer.

Mechanical repair : In Situ

Electrical repair : in TA801.

The system is mechanically

irreversible, the charge cannot be released.

1ere étape : Retrait des splitters


Probability of


takenFinal

probability

Failing scenario

2Damage the splitter because it is not high enough during the translation

A doubled switch indicate the right positioning of the splitter

LowQuick visual check during the motion

Very low Damages to the splitter or the table

1-2-3A switch is wrongly activated and provide the system to finish a motion

-Low

-Low The operator can switch

to a “mode degradé”

1-3During the translation of the trailer. The trailer move out of the rails

Mechanical and electrical stop make sure that the trailer cannot leave the rails

LowQuick visual check during the motion

Very Low

Damage to the surrounding equipment

2-3

The splitter hits the elements located upstream/downstream during its manipulation

There is 100mm on each side of each splitters Low

Quick visual check during the motion

Very Low

Damage to the surrounding equipment

1-2-3

The grounds surface shape changed and give to the rail a light slope

The brake of the trailers are normally closed so the trailer will not move if the motors do not work.

Low

Test on the mock up will performed at the surface

-Damage to the

surrounding equipment

1ere étape : Retrait des splitters

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Probability of


takenFinal

probability

Failing scenario

1-2-3 Same as the first step

1-2-3

The splitter is wrongly in installed on the temporary support

The same operation is repeated on the mock-up and use of simple support.

Low

Precise positioning with rails and use of an installation template.

Very lowDamage to the

surrounding equipment and splitters

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2ere étape : Dépose du splitter dans le fond du TDC2

3eme étape : Réinstallation du splitter sur les tables plugins


Probability of occurence Measures to be taken

Final probabil

ityFailing scenario

1-2-3 Same as the second step

2

Losing the alignment of the splitters

Re-install the splitter at its original location Medium

Take the reference of the plug-in tables before removing the splitters to make sure they are aligned before installing the splitters (If possible)

Very lowIntervention of the

geometers to realign the splitters after the

operation

2Bad connection of the hydraulic plugins

-Medium

Visual check and water tightness test (with the trailer in position)

Very low Intervention of the transport.

2Bad connection of the electrical plugins

-Medium

Visual check and electrical tests (with the trailer in position)

Very low Intervention of the transport.

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Risk analysis for the TCSC replacement

• Procedure• Hazard inventory, risk analysis and proposed

measures step by step

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JL GRENARD EN/HE

Procedure

BA 80954• Removal of the TCSC for storage in the 954

• Transport of the TCSC with the PRATT to the entrance of TCC2

• TCSC moved into TA801 with the trailer• The TCSC is lifted into the PA80 and

transported to the 954 for storage

• Installation of the new TCSC in TDC2 -> Inverted procedure

TCSC


Probability of


takenFinal

probability

Failing scenario

LevageMauvaise accroche des hanses de levage entrainant une chute du TCSC

Entrainement en surface Low

Une vérification visuelle est réalisée avant le levage du collimateur pour assurer une bonne accroche

Very low

Endommagement du TCSC, table plugin et élément environnant

LevageEndommagement des plugins lors du levage

guidage vertical sur 400mm, les joints des plugins sont sur le TCSC

LowVérification visuelle Very

lowEndommagement des plugins

Levage/Translation

Une panne du PRATT (les différentes pannes possibles sont identifiées par la suite) cause une descente de la charge non voulu pendant le levage. Le TCSC va redescendre sur la table plug-in

-

Low

Actions : Vérifier à quelle vitesse descend le collimateur. Ajout d’une vanne a main permettant d’étanchéifier le circuit et de bloquer la charge.

Low Dépose lente du TCSC sur la table

Translation

Une panne du PRATT cause une descente de la charge non voulu pendant la translation. Le TCSC va redescendre entre la table plugin et le PRAT

-

Low

Action : Ajouter des cales entre le PRATT et la table plug in pour permettre une dépose d’urgence entre le PRATT et la table

LowDépose lente du TCSC sur les cales

1ere étape : Retrait du TCSC

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Probability of occurence

Measures to be taken

Final probability

Failing scenario

LevageEndommagement des éléments en amont et aval du TCSC

400mm de distance de part et d’autre du TCSC

Low vérification visuelle Very low

Endommagement du TCSC et élément environnant

Levage/translation/

roulage

Panne d’un vérin ou rupture d’un vérin

Le dimensionnement des vérins + les tests de charges (Réalisées à 150% de la charge nominale en statique et 110% de la charge nominale en dynamique). Les vérins neuf.

Very Low

-

Very low

Le système dispose d’un réservoir d’huile permettant une certaine autonomie du système en cas de fuite.

Levage/Translation/

roulage

Panne électrique du PRATT

Rénovation complète du PRATT.

Very Low

-

Very Low

Possibilité d’amener un set de batterie de secours sur place pour pallier à une panne des batteries. Batteries de rechange disponibles.

Levage/translation/

roulage

Panne du groupe hydraulique

Rénovation complète du PRATT

Very Low

-

Very Low

Le système hydraulique (pompe + moteur) du PRATT sera isolé et les vérins ou les moteurs seront directement alimentés via le système hydraulique de secours. (simulation à réaliser)


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Probability of occurence

Measures to be taken

Final probability

Failing scenario

Levage/translation/

roulagePanne des vannes de pilotage

Rénovation complète du PRATT Very Low - Very

lowCommandes manuelles possible depuis le poste de conduite

Levage/translation/

roulage

Panne de la radiocommande


Very Low

-

Very low

Connecter la radiocommande avec des câbles. Ou alors piloter le Pratt depuis le poste de pilotage.

Levage/Translation/

roulage

Panne électrique du PRATT

Rénovation complète du PRATT.

Very Low

-

Very Low

Possibilité d’amener un set de batterie de secours sur place pour pallier à une panne des batteries. Batteries de rechange disponibles.

Translation

Panne du groupe hydraulique


Very Low

-

Very Low

Le système hydraulique (pompe + moteur) du PRATT sera isolé et les vérins ou les moteurs seront directement alimentés via le système hydraulique de secours. (simulation à réaliser)


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Probability of


takenFinal

probability

Failing scenario

Roulage Panne du PRATT Cf. premiere etape

RoulageChoc du collimateur sur le trajet

Entrainement en surface, manipulation a petite vitesse Low

Verification visuelle des passages critiques

Very low Endommagement du TCSC

2eme étape : Roulage jusqu’en TCC2

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Probability of


takenFinal

probability

Failing scenario

Levage Panne du PRATT Cf. premiere etape

LevageMauvaise dépose du TCSC sur la remorque.

Grande dimension de la remorque pour réception du collimateur

LowVérification visuelle Very low Endommagement du

TCSC

3eme étape : Reprise avec la remorque en TCC2

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Probability of


takenFinal

probability

Failing scenario

Roulage Panne du tracteur Volk Materiel standard CERN. Low - Low Remplacement du

tracteur par un autre

Roulage

Choc du collimateur sur le trajet

Entrainement en surface, manipulation à petite vitesse. Plateforme stable. TA801 completement vide

Low

Verification visuelle des passages critiques Very low Endommagement du

TCSC

4eme étape : Roulage jusqu’en bas du PA80

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Probability of


takenFinal

probability

Failing scenario

Accroche au pont

Mauvaise accroche du collimateur au pont Procedure a definir

Levage au pont Panne du pont (PA80 et 954)

Analyse de risque à realiser

5eme étape : Reprise au pont puis stockage au 954

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Conclusion

• Temps de réflexion du LS1• Une grosse défaillance semble très

improbable une fois toutes les mesures prises.• Les dangers les plus probables mènent à une

situation non critique.

E. HARROUCH EN/MEF

Risk analysis : - Splitters replacement - TCSC replacement WG TDC2/TCC2 18 th June 2013 E. HARROUCH...

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