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E. HARROUCH EN/MEF
Risk analysis :- Splitters replacement
- TCSC replacement
WG TDC2/TCC2 18th June 2013
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
E. HARROUCH EN/MEF
Risk analysis for North Area splitters replacement
• Procedure• Hazard inventory, risk analysis and proposed
measures step by step
E. HARROUCH EN/MEF
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
E. HARROUCH EN/MEF
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
E. HARROUCH EN/MEF
12
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
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
2ere étape : Dépose du splitter dans le fond du TDC2
3eme étape : Réinstallation du splitter sur les tables plugins
Operation Risk Measures already taken
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.
E. HARROUCH EN/MEF
Risk analysis for the TCSC replacement
• Procedure• Hazard inventory, risk analysis and proposed
measures step by step
E. HARROUCH EN/MEF
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
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
Operation Risk Measures already taken
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)
1ere étape : Retrait du TCSC
E. HARROUCH EN/MEF
Operation Risk Measures already taken
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
Rénovation complète du PRATT
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
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)
1ere étape : Retrait du TCSC
E. HARROUCH EN/MEF
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
Operation Risk Measures already taken
Probability of
occurenceMeasures to be
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
E. HARROUCH EN/MEF
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