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CERN

LHC Project Document No.

CERN Part Identifier (19 chars)

CH-1211 Geneva 23 Switzerland

the

LHC-LQX-TP-0001 rev. 1.0

CERN Div/Group or Supplier/Contractor Doc No

HCLQXB_001-FL000004

Test Procedure Number

TD/FNAL/USA

EDMS Document No.

LQXB_Test_Plan

Large Hadron Collider

project

408010

Nonconformity Report

IDENTIFICATION

1. Originator's Name: Tom Nicol 2. Contractor/Supplier: Fermilab 3. Contract No: N/A 4. Project Engineer: Jim Kerby 5. Quality Manager: Jamie Blowers 10. Found during what activity: Incoming inspection In-process inspection Final inspection Other: 6. Date: 30-Jan-2006 7. Part description: LQXB (Q2) Inner Triplet 8. Qty: 1 9. Dwg No: 5520-ME-390206 rev. C

11. Description of nonconformity (use continuation page if necessary)

A number of the pipe locations are outside of the stated tolerance as defined in section 2.1.10 of the Acceptance Plan (reference section 4.1 of LHC-LQX-ES-0010). See attachment for details.

12. Action taken to prevent misuse (use continuation page if necessary)

None. IMPORTANCE

13. Non critical Critical

DISPOSITION

14. Repair Use-as-is Reject Description of proposed action (use continuation page if necessary) Rework Return to supplier

The magnet should be accepted as-is (see continuation page).

CORRECTIVE/PREVENTIVE ACTION

15. Description of proposed action (use continuation page if necessary)

Upon completion of the review by the CERN Vacuum Group, the FNAL magnet acceptance committee recommends the tolerances be re-visited on all of the pipes. APPROVAL OF NON CRITICAL NONCONFORMITIES

16 Project Engineer: Jim Kerby Date: 02-Feb-2006

APPROVAL OF CRITICAL NONCONFORMITIES

17 Project Management: Date:

CLOSURE OF THE NONCONFORMITY

Planned actions have been completed and corrective/preventive actions have been initiated For non critical nonconformities For critical nonconformities Quality Manager or Project Engineer Project Engineer Name: Jamie Blowers Name: Date: 02-Feb-2006 Date:

18

CERN Part Identifier (19 chars)

HCLQXB_001-FL000004

Page 2 of 3 NONCONFORMITY CONTINUATION PAGE Proposed action: For all the lines where the tubes are out of tolerance (with the exception of the V line ­ see the next paragraph below), neither the assembly of the interconnect flanges on the neighboring magnet assembly (including the interconnect pipe section which spans the ~1m gap between the two), nor the allowable motion due to the desired alignment of the magnets in the tunnel, nor the lifetime of the bellows associated with each individual tube are expected to be limited. We are reviewing the collected LQXB data to come up with more realistic targets.

CERN Part Identifier (19 chars)

HCLQXB_001-FL000004

Page 3 of 3

INSTRUCTIONS FOR COMPLETING THE NONCONFORMITY REPORT

1. Originator 2. Contractor/Supplier 3. Contract No 4. Project Engineer 5. Quality Manager 6. Date 7. Part description 8. Qty 9. Dwg No 10. Found during what activity 11. Description of the nonconformity Name of the person who identifies the nonconformity Organisation where the nonconformity is detected CERN's contract or order No Name of the CERN or Institute engineer in charge of the contract Name of the person responsible for quality control Date when the nonconformity is identified Name of the part such as it appears on drawing or contract or order Number of parts or lots affected Part drawing number and revision index Tick the appropriate box. If ticking Other explain the circumstances Describe the problem, identify the requirements that are not met, give references to specifications, procedures etc. If possible describe the possible causes of the nonconformity, such as inadequate procedure, wrong test set-up and so on. 12. Action taken to prevent misuse 13. Importance 14. Disposition 15. Corrective/preventive action Describe what steps have been taken to ensure that the item is segregated from the normal production while the nonconformity remains unresolved. P.E. to decide if the nonconformity is critical or not and tick appropriate box P.E. to decide on disposition, tick appropriate box and outline the details of the proposed actions. P.E. to decide what action should be taken with the design, the manufacturing process, the testing procedure or any other circumstance to prevent the reoccurrence of the problem. Complete with the name of the Project Engineer and the date of approval. Complete with the name of the Project Manager, the name of the approval list if appropriate, and the date of approval. For a non critical NC, complete with the name of the Quality Manager and the date of the verification. For a critical NC, complete with the name of the CERN Project Engineer and the date of the verification.

16. Approval of non critical nonconformities 17. Approval of critical nonconformities 18. Closure of the nonconformity

Note that points 16, 17 and 18 may be left blank for all nonconformities that are tracked using the EDMS system as described in chapter 3 of document LHC-PM-QA611.00 "Management of Nonconformities"

LHC IRQ Cryostat Pipe Location Survey Results

Magnet assembly number Magnet serial number Date measured LQXB04 HCLQXB_001-FL000004 10-Sep-04 Measured values Non-IP end connections EE LD1 L XBt FF M1 M2 M4 V W' IP end connections EE LD1 L XBt FF M1 M2 M4 V W' X -388.8 -240.8 -1.6 242.5 385.9 1.0 -149.7 0.3 0.0 -0.9 Y -218.5 -217.5 -217.9 -218.3 -217.8 -17.2 -17.1 -16.0 0.0 131.4 Z 72.6 276.4 377.9 275.4 71.0 -149.7 0.2 149.3 -1.4 77.9 Diam 74.8 74.6 199.6 133.7 74.8 126.2 126.0 126.2 114.4 1006.3 dX 0.8 -0.8 -1.6 2.5 -3.7 1.0 0.3 0.3 0.0 -0.9 Deviations from nominal dY 4.0 5.0 4.6 4.2 4.7 2.7 2.8 3.9 0.0 3.9 dZ -2.4 -1.1 1.0 -2.1 -4.0 0.3 0.2 -0.7 -1.4 2.9 dr 2.5 1.3 1.8 3.2 5.5 1.1 0.4 0.8 1.4 3.1 dX 0.5 1.7 Out of tolerance dY 2.0 3.0 2.6 2.2 2.7 0.7 0.8 1.9 0.9 dZ 0.4 0.1 2.0 0.4 dr 0.4 2.6 0.0 Disposition (see notes) Radial deviation (x and z) Axial deviation (y) Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2).

Use as is (1). Use as is (1).

-385.8 -236.1 0.4 246.7 389.0 -1.0 -151.4 -0.9 0.4 1.4

12865.9 12865.7 12867.2 12868.0 12866.8 12933.9 12932.7 12932.4 12638.9 12516.1

76.9 277.9 379.3 277.2 75.5 -147.1 1.8 152.4 0.2 79.2

74.8 74.6 199.7 133.7 74.8 88.6 88.5 88.5 114.1 1004.7

3.8 3.9 0.4 6.7 -0.6 -1.0 -1.4 -0.9 0.4 1.4

4.5 4.3 5.8 6.6 5.4 -2.5 -3.7 -4.0 0.0 4.7

1.9 0.4 2.4 -0.3 0.5 2.9 1.8 2.4 0.2 4.2

4.2 3.9 2.5 6.7 0.7 3.1 2.3 2.6 0.4 4.4

1.8 0.9 4.7 -

2.5 2.3 3.8 4.6 3.4 0.5 1.7 2.0 1.7

0.9 0.4 1.2

1.4 3.9 0.3 0.2

Use as is (1).

Use as is (1). Use as is (1).

Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2). Use as is (2).

Use as is (1).

Fiducial blocks Non-IP fiducial block - upper Non-IP fiducial block - lower IP fiducial block - upper IP fiducial block - lower

145.9 145.5 149.2 149.0

-15.2 -15.0 12655.3 12654.1

34.4 -40.6 24.9 -50.1

Notes: 1. Within range of bellows lateral installation range. 2. Within range of bellows allowed axial extension/contraction.

LHC IRQ Cryostat Pipe Location Nominal Values

All dimensions are in mm.

Nominal (as designed) dimensions Non-IP end connections EE LD1 L XBt FF M1 (1) M2 (1) M4 (1) V W' IP end connections EE LD1 L XBt FF M1 (2) M2 (2) M4 (2) V W' Diam (ref only) 75.0 75.0 201.0 134.0 75.0 124.5 124.5 124.5 114.0 1009.6 dX (+/-) 2.0 3.0 3.0 2.0 2.0 2.0 2.0 2.0 1.0 3.0

Allowed tolerance dY (+/-) 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.0 3.0 dZ (+/-) 2.0 3.0 3.0 2.0 2.0 2.0 2.0 2.0 1.0 3.0 dr (radial position tolerance) 2.8 4.2 4.2 2.8 2.8 2.8 2.8 2.8 1.4 4.2

X -389.6 -240.0 0.0 240.0 389.6 0.0 -150.0 0.0 0.0 0.0

Y -222.5 -222.5 -222.5 -222.5 -222.5 -19.9 -19.9 -19.9 0.0 127.5

Z 75.0 277.5 376.9 277.5 75.0 -150.0 0.0 150.0 0.0 75.0

-389.6 -240.0 0.0 240.0 389.6 0.0 -150.0 0.0 0.0 0.0

12861.4 12861.4 12861.4 12861.4 12861.4 12936.4 12936.4 12936.4 12638.9 12511.4

75.0 277.5 376.9 277.5 75.0 -150.0 0.0 150.0 0.0 75.0

75.0 75.0 201.0 134.0 75.0 88.9 88.9 88.9 114.0 1009.6

2.0 3.0 3.0 2.0 2.0 2.0 2.0 2.0 1.0 3.0

2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 1.0 3.0

2.0 3.0 3.0 2.0 2.0 2.0 2.0 2.0 1.0 3.0

2.8 4.2 4.2 2.8 2.8 2.8 2.8 2.8 1.4 4.2

Notes 1. Nominal in specification is -222.5. Value here is corrected to back of bellows assembly flange. See 202.6 mm dimension on drawing MC-390073. 2. Nominal in specification is 13011.4. Value here is corrected to reflect 75 mm cutoff dimension.

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