TD/Engineering & FabricationSpecification # 5520-TR-333481

November 4, 2005

Rev. E

f / Fermi National Accelerator Laboratory

Batavia, IL60510

LARGE HADRON COLLIDER
OUTER CABLE INSULATION
Reference Drawing(s):
Outer Insulated Cable
(MC-369690)
Project/Task Number:
Released by: / Magnet/Device Series:
Dater Issued: / Scanned Pages:
Prepared by: M. Cullen, J. Szostak
Title / Signature / Date

TD / E&F Process Engineering

/

Bob Jensen

Bob Jensen / Designee / 11/4/05
TD / LHC Production Supervisor /

Jim Rife

Jim Rife / Designee / 11/4/05
TD / LHC Production Engineer /

Fred Nobrega

Fred Nobrega / Designee / 11/4/05
TD / LHC Program Manager /

Jim Kerby

Jim Kerby / Designee / 11/7/05

Revision Page

Revision / Step No. / Revision Description / TRR No. / Date
None / N/A / Initial Release / N/A / 6/8/2000
4.10 / 4.11 / N/A
A / 4.8 / Inspect for proper periods of insulation / 0977 / 7/13/00
B / 4.0 / Changed the Periods. / 1172 / 5/22/01
C / 4.9 / Verify the Idler Arm and Caterpillar is property adjusted during Insulation / 1196 / 7/9/01
D / 2.1 / Modified step. Kapton (MA-106723) has been replaced by Kapton
(MA-292586) per production. DR No. HGQ-0515. / 1700 / 1/7/05
4.7 / Modified step. Kapton (MA-106723) has been replaced by Kapton
(MA-292586) per production. DR No. HGQ-0515.
E / 1.5 / Removed Step. “All personnel performing steps in this traveler must have documented training for this traveler and associated operating procedures.” / 1789 / 11/4/05

Ensure appropriate memos and specific instructions are placed with the traveler before issuing the sub traveler binder to production.

1.0General Notes

1.1.White (Lint Free) Gloves (Fermi stock 2250-1800) or Surgical Latex Gloves (Fermi stock 2250-2494) shall be worn by all personnel when handling all product parts after the parts have been prepared/cleaned.

1.2.All steps that require a sign-off shall include the Technician/Inspectors first initial and full last name.

1.3.No erasures or white out will be permitted to any documentation. All incorrectly entered data shall be corrected by placing a single line through the error, initial and date the error before adding the correct data.

1.4.All Discrepancy Reports issued shall be recorded in the left margin next to the applicable step.

1.5.Personnel shall perform all tasks in accordance with current applicable ES&H guidelines and those specified within the step.

1.6.Cover the product/assembly with Green Herculite (Fermi stock 1740-0100) when not being serviced or assembled.

2.0Parts Kit List

2.1.Attach the completed Parts Kit for this production operation to this traveler. Ensure that the serial number on the Parts Kit matches the serial number of this traveler. Verify that the Parts Kit received is complete.

Process Engineering/DesigneeDate

Note(s):

Insulation Drawing No.MB-369690

Insulation Tape No.MA-292586(Stage 1) (Kapton)

Insulation Tape No.MA-369126(STAGE 2) (Kapton w/ QIX)

3.0Insulation Line Set-Up

3.1.The take-up Reel shall be cleaned with Isopropyl Alcohol (Fermi stock 1920-0300) and Heavy Disposable Wipes (Fermi stock 1660-2600) or equivalent. Also remove all previous labels, stickers and tapes, and install on the take up tensioner.

Technician(s)Date

3.2.The insulating line shall be vacuumed and cleaned with Isopropyl Alcohol (Fermi stock 1920-0300) and Heavy Disposable Wipes (Fermi stock 1660-2600) or equivalent. Clean the Caterpillar Tracks with Isopropyl Alcohol (Fermi stock 1920-0300) and Heavy Disposable Wipes (Fermi stock 1660-2600) or equivalent.

Technician(s)Date

3.3.Verify and fill as needed the Branson Cable cleaner with absol.

Technician(s)Date

3.4Verify the Idler Arm and Caterpillar is property adjusted during for Insulation.

Technician(s)Date

4.0Insulating

4.1.Operate the Insulating Line in accordance with the Insulating Line Engineering Specification (ES-301862)

Technician(s)Date

4.2.Load the assigned Tapes onto Insulating Machine. Kapton will be loaded on Insulating Stage 1 (1 extra roll minimum required) and Kapton w/QIX will be loaded onto Insulating Stage 2 (1 extra roll minimum required).

Technician(s)Date

4.3.Ensure the Cable thick side is facing the operator during the Cable loading.

Technician(s)Date

4.4.Thread the Cable through the Branson Cable cleaning Machine and the Cable Insulating Machine.

Technician(s)Date

4.5.All Lump Detectors shall be operable and adjusted to the Cable to be insulated.

Technician(s)Date

4.6.Set the footage counter to 0 Feet at the end of the leader and the beginning of Cable.

Note(s):

One end is to be attached to the take up reel and is not to be counted.

Technician(s)Date

4.7.Attach the Kapton Tape without QIX (MA-292586 Stage #1) to the Cable, and the Kapton with QIX (MA-369126 Stage #2) to the Cable and begin insulating the cable.

Technician(s)Date

4.8.Verify the Kapton w/ QIX (Stage 2) has the QIX coating facing outward after being applied to the Cable by applying Xylene to one side, QIX will become milky after treatment with Xylene. Verify the Insulation is being applied at a rate of 47.4  1 periods per 9" section for the first stage and at 45.6  1 periods per 9" section for the second stage.

InspectorDate

4.9.Insulate 600' of the Outer Cable per the Outer Insulated Cable Assembly (MB-369690).

Note(s):

The Sine Wave Spark Tester, set to 1.5 KV, will be operating only when cable is being processed to prevent insulation breakdown.

Technician(s)Date

4.10.When 600' Cable has been insulated for a Coil, stop the insulating line. Tin and cut the Insulated Portion at 600'. Record the footages insulated.

Beginning footage______

Ending Footage______

Technician(s)Date

5.0Packaging

5.1.Replace the Label on the Master Reel with the remaining Footage and Reel Serial Number.

Technician(s)Date

5.2.Label the insulated Cable with Coil Serial Number, Reel Serial Number, Footage and transport to the storage area.

Technician(s)Date

6.0Production Complete

6.1.Process Engineering; verify that the Outer Cable Insulation Traveler (TR-333481) is accurate and complete. This shall include a review of all steps to ensure that all operations have been completed and signed off. Ensure that all Discrepancy Reports, Nonconformance Reports, Repair/Rework Forms, Deviation Index and dispositions have been reviewed by the Responsible Authority for conformance before being approved.

Comments:

Process Engineering/DesigneeDate

Outer Cable InsulationCoil Serial No. «SerialNo»-«ReworkID»

Notes: «Notes»

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