TD/Engineering & FabricationSpecification # 5520-TR-333482

November 4, 2005

Rev. F

f / Fermi National Accelerator Laboratory
Batavia, IL60510
LARGE HADRON COLLIDER
INNER WEDGE INSULATION
Reference Drawing(s):
Inner Wedge Insulation
(MC-369693)
Project/Task Number:
Released by: / Magnet/Device Series:
Date 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 / 11/7/05

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
A / 4.3 / Inspect for proper periods of insulation / 0995 / 7/13/00
B / 4.0 / Altered the Periods. / 1176 / 5/22/01
C / 3.9 / Verify the Idler Arm and Caterpillar is property adjusted during Insulation / 1197 / 7/9/01
D / 4.6 / Removed Step. "Verify the Kapton w/QIX (Stage 2) has the QIX coating facing outward after being applied to the Wedge by applying Xylene to one side, QIX will become milky after treatment with Xylene. Verify the Insulation is being applied at a rate of 56.7 6 1 periods per 9" section for the first stage and the second stage is at 18.4 6 1 periods per 9" section (2 mm gap)." Completed in step 4.4. Removed per MQXBi-081. / 1604 / 2/5/04
E / 1.5 / Removed Step. “All personnel performing steps in this traveler must have documented training for this traveler and associated operating procedures.” / 1698 / 1/7/05
2.1 / Modified step. Kapton (MA-106723) has been replaced by Kapton
(MA-292586) per production. DR No. HGQ-0515.
4.2 / Modified step. Kapton (MA-106723) has been replaced by Kapton
(MA-292586) per production. DR No. HGQ-0515.
4.3 / Modified step. Kapton (MA-106723) has been replaced by Kapton
(MA-292586) per production. DR No. HGQ-0515.
F / 2.1 / Modified step. Kapton (MA-369140) has been replaced by Kapton
(MA-344080) per LHC Production Engineer. / 1731 / 11/4/05
4.2 / Modified step. Kapton (MA-369140) has been replaced by Kapton
(MA-344080) per LHC Production Engineer.
4.3 / Modified step. Kapton (MA-369140) has been replaced by Kapton
(MA-344080) per LHC Production Engineer.

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):

Inner WedgeMC-369693(Insulated)

Insulation Tape MA-292586(Stage 1) (Kapton)

Insulation TapeMA-344080(STAGE 2) (Kapton w/QI)

3.0Preparation

3.1.The entire insulating line shall be vacuumed and cleaned with Isopropyl Alcohol (Fermi stock 1920-0300) and Heavy Disposable Wipes (Fermi stock 1660-2600) or equivalent to remove all foreign materials and tape residues from previous insulating.

Technician(s)Date

3.2.Clean Caterpillar Tracks with Isopropyl Alcohol (Fermi stock 1920-0300) and Heavy Disposable Wipes (Fermi stock 1660-2600) or equivalent to remove all dirt, dusts, and greases.

Technician(s)Date

3.3.Clean all wedges with Scotch Brite Pads (Fermi stock 1202-2020) Heavy Disposable Wipes (Fermi stock 1660-2600), Isopropyl Alcohol (Fermi stock 1920-0300) and Heavy Disposable Wipes (Fermi stock 1660-2600) or equivalent to remove all dirt, dusts, and greases.

Technician(s)Date

3.4.Verify the wedges and the insulating line have been acceptably cleaned for insulation.

Crew ChiefDate

3.5Verify 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 (MA-292586) will be loaded on Insulating Stage 1 and Kapton w/QI (MA-344080) will be loaded onto Insulating Stage 2.

Technician(s)Date

4.3.Attach the Kapton Tape without QI to the Wedge (MA-292586 Stage #1), and the Kapton with QI (MA-344080 Stage #2) to the Wedge and begin insulating the Wedge.

Technician(s)Date

4.4.Verify the Kapton w/QI (Stage 2) has the QI coating facing outward after being applied to the Wedge by applying Xylene to one side, QI will become milky after treatment with Xylene. Verify the Insulation is being applied at a rate of 56.7  1 periods per 9" section for the first stage and the second stage is at 18.4  1 periods per 9" section (2 mm gap).

Crew ChiefDate

4.5.Insulate the Wedges as per the Inner Insulated Wedge Assembly (MC-369693).

Technician(s)Date

5.0Production Complete

5.1.Process Engineering; verify that the Inner Wedge Insulation Traveler (TR-333482) 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

Inner Wedge InsulationWedge Kit Serial No.: «SerialNo»-«ReworkID»

Notes: «Notes»

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