schedule: still on time ?

Chamonix XV January 2006 S.Weisz 1

LHC Installation

Schedule: Still on time ?

Content:• Part I: status of installation and present delay

• What was planned a year ago• Status of the QRL, magnet transport and interconnect

• Part II: can we limit the increase of the delay?• The “hard limits”• Dates for hand over to the Hardware Commissioning

• Conclusions


LHC Installation

Situation a year ago:

• Civil Engineering:– Last underground area at Point 5 (RB/UJ56) delivered mid-November 04

• General services:– Close to completion in most sectors– Collimation region at Point 7 just being re-designed

• QRL: – Sector 7-8: all elements to be repaired and re-installed– Sector 8-1: 2 validation cells installed

• Cryo-dipoles:– 480 magnets to store at the surface– Struggling to find storage space

New installation strategy:• Compressed schedule – beams in summer 2007• Skip QRL cold tests (except 7-8 & 8-1)• Install cryo-magnets (transport & interconnect) in parallel with QRL installation and leak tests


LHC Installation

Sectors 7-8 & 8-1: installation validation

QRL (re-)Installation & Cold tests


LHC Installation

Status of QRL installation:

• QRL in sector 7-8:– Sub-sector A & B expected ready in July, cold tests started mid-September– Completion of the full sector expected for September, done in December

• QRL in sector 8-1:– Cold tests expected in September, done in December

• On-going installation: – Sector 4-5: installed and pressure tested (except JR) – Sector 3-4: about to finish, pressure test scheduled for February 18-19– Sectors 5-6 & 6-7: in progress

3 months delay with respect to last year estimate


LHC Installation

LSS8L power tests:Postponed, DFBM were not available …

Impact on HW commissioning(short circuit tests in July - on time)


LHC Installation

Short term: schedule for DFBs of sector 7-8 and 8-1

Sector IR Code N chim.

Baseline LHC

(04/2005)

Latest date to not

block LHC install Current schedule

7-87R DFBAN 1 13 Dec 05 Mar 06 08-Apr-068L DFBAO 2 34 Nov 05 Mar 06 15-Apr-068L DFBMA 3 7 Sep 05 Mar 06 24-Feb-068L DFBMC 4 5 Sep 05 Mar 06 24-Feb-067R DFBMH 5 1 Jan 06 Mar 06 24-Feb-06

8-11L DFBAA 6 21 Feb 06 Mar 06 30-Jun-068R DFBAP 7 31 Feb 06 Feb 06 15-Jul-061L DFBLA 8 13 Feb 06 Mar 06 17-Jun-068R DFBMB 9 7 Feb 06 Mar 06 22-Feb-068R DFBMI 10 5 Feb 06 Mar 06 11-Mar-06

DFB Project

DFBM for LSS8L5 months delay

A. Perin – MARIC, December 21st, 2005


LHC Installation

Magnet Transport


LHC Installation

Status of cryo-magnet transport:

• Sector 7-8:– LSS8L: expected magnet transport in October,

Low-/DFBX/D1/D2/Q4 installed in December, Q5 not ready– Arc: all magnet in place expected for September, 40 dipoles and 17 SSS

transported by December 22th, 2006

• Sector 8-1:– Arc: all magnet in place expected for September, 111 dipoles and 18 SSS

transported by December 22th, 2005– No installation during 6 weeks of QRL cold tests

• Sector 4-5: – Arc: all magnet in place expected for December, 48 dipoles and 9 SSS

transported by December 22th, 2005

Expected to transport ~600 cryo-magnets in 2005, 249 done

4 months delay assuming a rate of 20 magnets/week*

*20 transports/week achieved during wk 2 & wk 3, 2006


LHC Installation

Problems with cryo-magnet transport:

• Slot availability:– QRL sub-sectors not ready, leak tests much longer than anticipated in sector 7-8– Slots for SSS with jumper not available: cold tests and repair of SM modules in

sector 8-1, new leaks in sector 4-5

• Magnet availability:– Dipoles non-conformity problem now solved– SSS with plugs are late (required for partial leak tests of interconnect)– Special quadrupoles for LSS and DS are also very late

• Reliability of transport system: – Problem with EL power distribution line replace all breakers (~1 month)– Problem with safety valve of unloading equipment (risk to drop a magnet!)

test and replace all valves (~1 month)

– Problems with overheat, guiding line, oil for axle, etc…

“Small incidents” create discontinuities and have severe consequences on the organisation of co-activities in the tunnel


LHC Installation

Cryo-magnet Interconnect


LHC Installation

Status of cryo-magnet interconnect:

• Sector 7-8:– LSS8L: expected for November, not started yet– Arc: expected 50% done by end of year, 29 in progress (14%)

• Sector 8-1:– Arc: expected 70% done by end of year, 52 in progress (25%)

• Sector 4-5: – Arc: expected 25% done by end of year, about to start …

~3 months delay assuming 6 months* to interconnect a sector

*foresee 7 months for the 1st sector, then 5 months per sector


LHC Installation

Part I: status of installation and present delay

Still on time?

No, minimal delay of 3 months, up to 5 months on procurement of certain elements

What did we learn?

Experience with new activities: QRL pressure & cold tests, magnet transport & interconnect, installation & test of power converters, etc…

Leak tests and leak finding are very delicate, they consume more time than expected

Co-activities versus efficiency, we are close to saturation!


LHC Installation

Part II: can we limit the increase of the delay?

• The “hard limits”:– Present schedule for QRL installation– Magnet transport rates– Procurement of the special SSS– Present schedule for the DFBs

• Hand over to the Hardware Commissioning:– Interconnect, global leak tests & cryostat closure scenario– Dates when sectors are ready for Hardware Commissioning


LHC Installation

New schedule for QRL installation:

Last sector (sector 1-2) expected by August 06, now scheduled for November

maintain present delay on QRL installation

Durée Début Fin

10 jours Lun 21/11/05Ven 02/12/05

29 jours Lun 21/11/05Ven 06/01/06

55 jours Lun 09/01/06Ven 24/03/06

2 sms Lun 21/11/05Ven 02/12/05

81 jours Lun 21/11/05Mar 21/03/06

30 jours Lun 02/01/06Ven 10/02/06

101 jours Mar 10/01/06Mer 07/06/06

68 jours Lun 27/02/06Jeu 08/06/06

40 jours Lun 21/11/05Lun 23/01/06

96 jours Mar 21/03/06Jeu 24/08/06

55 jours Lun 23/01/06Ven 07/04/06

91 jours Mer 14/06/06Ven 03/11/06

101 joursMer 31/05/06Lun 06/11/06

Secteur 4-5 hors JR

Secteur 3-4 hors JR

JR 3-4 et 4-5

Supportage 5-6 hors JR

Secteur 5-6 hors JR

Supportage 6-7/A,B hors JR

Secteur 6-7 hors JR

JR 5-6 et 6-7


Secteur 2-3 hors JR


Secteur 1-2 hors JR

JR 2-3 et 1-2

383940414243444546474849505152 1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394041424344454647Sep Oct Nov Déc Jan Fév Mar Avr Mai Jui Jul Aoû Sep Oct Nov

2005 2006


LHC Installation

Cryo-magnet transport rate:

• Cryo-magnet transport vehicles:– 2 “CTV” convoys for dipoles only– 2 “MCTV” convoys for dipoles and long special SSS– 2 “STV” convoys for arc SSS and short special SSS

• Transport with CTV & MCTV convoys:– 1232 MB, 24 Low-, 24 long special SSS, 16 D1/2/3/4 = 1296 elements– 240 are now in place 1056 to go– Assume transport rate with CTV & MCTV at 15/week until Easter, then

at 18/week takes 61 weeks in total March 2007*

• Transport with STV convoys:– 376 arc SSS and 74 short special SSS = 450 elements– 52 are now in place 398 to go (7.5 on average over 61 weeks!)

SSS(arc + short special) for sector 5-6 & 6-7 will come through Point 6 (storage & final preparation in UX65, could reach 2 transports/day/STV)

*assuming no interference with QRL installation in UJ22 Reduce delay with respect to present schedule to 3 months


LHC Installation

Special SSS dashboard previsions at increased rate Rate of cryostating of special SSS in 904 has to increase (1.15 S4/week)Rate of cold tests of special SSS has to go up to 1.25 S4 /week. Last special SSS installed in the tunnel at the end of March 07.

Special SSS assembled at CERN

048

121620242832364044485256606468727680

Jul-03 Jan-04 Jul-04 Dec-04 Jun-05 Dec-05 Jun-06 Dec-06 Jun-07

un

its

Cold masses finished (181) SSS cryostated

SSS Cold tested SSS Stripped

SSS Allocated by MEB Ready for installation

SSS Installed

N. Catalan Lasheras, S4 coordination – January 13th, 2006


LHC InstallationDFB Project

Sector IR Code N chim.

Baseline LHC

(04/2005)

Last date for nor

delaying LHC

install Current schedule

7-87R DFBAN 1 13 Dec 05 Mar 06 08-Apr-068L DFBAO 2 34 Nov 05 Mar 06 15-Apr-068L DFBMA 3 7 Sep 05 Mar 06 24-Feb-068L DFBMC 4 5 Sep 05 Mar 06 24-Feb-067R DFBMH 5 1 Jan 06 Mar 06 24-Feb-06

8-11L DFBAA 6 21 Feb 06 Mar 06 30-Jun-068R DFBAP 7 31 Feb 06 Feb 06 15-Jul-061L DFBLA 8 13 Feb 06 Mar 06 17-Jun-068R DFBMB 9 7 Feb 06 Mar 06 22-Feb-068R DFBMI 10 5 Feb 06 Mar 06 11-Mar-068R DFBMJ 11 3 Feb 06 Mar 06 24-Mar-06

4-54R DFBAH 12 32 Mar 06 Mar 06 09-Sep-065L DFBAI 13 21 Mar 06 Mar 06 15-Sep-065L DFBLD 14 13 Mar 06 Mar 06 17-Jul-064R DFBMG 15 3 Mar 06 Mar 06 11-Apr-064R DFBMK 16 3 Mar 06 Mar 06 30-Apr-064R DFBML 17 5 Mar 06 Mar 06 25-May-06

3-43R DFBAF 18 2 Apr 06 Apr 06 25-Jul-064L DFBAG 19 32 Apr 06 Apr 06 30-Jul-063R DFBLC 20 11 Apr 06 Apr 06 07-Aug-063R DFBMD 21 1 Apr 06 Apr 06 25-Jun-064L DFBME 22 3 Apr 06 Apr 06 22-Jul-064L DFBMF 23 5 Apr 06 Apr 06 11-Aug-064L DFBMG 24 3 Apr 06 Apr 06 11-Jul-06

5-65R DFBAJ 25 21 Jun 06 Jun 06 30-Aug-066L DFBAK 26 29 Jun 06 Jun 06 20-Aug-065R DFBLE 27 13 Jun 06 Jun 06 07-Sep-066L DFBMM 28 3 Jun 06 Jun 06 19-Aug-066L DFBMM 29 3 Jun 06 Jun 06 03-Sep-06

6-76R DFBAL 30 29 Jul 06 Jul 06 06-Sep-067L DFBAM 31 13 Jul 06 Jul 06 23-Oct-066R DFBMM 32 3 Jul 06 Jul 06 15-Sep-066R DFBMM 33 3 Jul 06 Jul 06 23-Sep-067L DFBMH 34 1 Jul 06 Jul 06 25-Sep-06

1-2

1R DFBAB 35 21 Sep 06 Sep 06 28-Sep-062L DFBAC 36 34 Sep 06 Sep 06 02-Dec-061R DFBLB 37 13 Sep 06 Sep 06 07-Oct-062L DFBMA 38 7 Sep 06 Sep 06 16-Oct-062L DFBMC 39 5 Sep 06 Sep 06 24-Nov-06

2-32R DFBAD 40 34 Nov 06 Nov 06 04-Feb-073L DFBAE 41 13 Nov 06 Nov 06 01-Nov-062R DFBMB 42 7 Nov 06 Nov 06 09-Nov-062R DFBMC 43 5 Nov 06 Nov 06 24-Nov-06

A Perin – MARIC December 21st, 2005

7-8

8-1

4-5

3-4

5-6

6-7

1-2

2-3

15-Apr-06

15-Jul-06

15-Sep-06

11-Aug-06

07-Sep-06

23-Oct-06

02-Dec-06

04-Feb-07

Latest DFB in sector


LHC Installation

ID

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Sector 7-8

Magnet Transport

DFBs installation

Sector 8-1

Magnet Transport

DFBs installation

Sector 4-5

Magnet Transport

DFBs installation

Sector 3-4

Magnet Transport

DFBs installation

Sector 5-6

Magnet Transport

DFBs installation

Sector 6-7

Magnet Transport

DFBs installation

Sector 1-2

Magnet Transport

DFBs installation

Sector 2-3

Magnet Transport

DFBs installation

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec2006 2007

DFB versus Cryo-magnet Installation

Up to 4 months lag behind

magnet transport


LHC Installation

Interconnect Phase I:Welding V1, V2, E, X, C’, K2, Brazing BP, spools, Y - ic/ic - 8 days - CRI

Partial Assembly Qualification - 2 cell / 2 cell - 1day - MEL

Line N insertion - 2 cell / 2 cell - 3 days - CRI

Line N cabling - 2 cell / 2 cell - 1 day - CRI

Welding : M1, M2, M3, K1 - 2 cell / 2 cell - 1day - CRI

AIV - 2 cell is tested with its successor and predecessor - 3 days - MEL

Provisionnal closure - ic/ic - 4 days - CRI

Vacuum tests - Between 2 SSS with plugs - 2 wks - VAC

9 weeks between transportof cryo-magnets and end of

Interconnect Phase I

6 weeks for a late

isolated element


LHC Installation

Interconnect, global pressure & leak tests, and cryostat closure

• Interconnect Phase I:– Requires at least 9 weeks after transport of cryo-magnets– Allocate 6 weeks after the transport of a late and isolated DFBA

• Global pressure & leak tests:– Requires all cryo-magnets and DFB’s connected– 2 weeks allocated in present schedule (probably very optimistic)

• Cryostat closure - Interconnect Phase II: – Re-open the cryostat to install thermal shield and MLI– Close and check leak tightness of the external compensators– 8 weeks allocated in present schedule (probably pessimistic)

Assume a minimum of 95 days between end of magnet transport and availability of sector for HW commissioning Assume a minimum of 80 days between installation of DFBA’s and availability of sector for HW commissioning


LHC Installation

ID

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

Sector 7-8

Magnet Transport

DFBs installation

HW Commissioning earliest start date

Sector 8-1

Magnet Transport

DFBs installation


Sector 4-5

Magnet Transport

DFBs installation


Sector 3-4

Magnet Transport

DFBs installation


Sector 5-6

Magnet Transport

DFBs installation


Sector 6-7

Magnet Transport

DFBs installation


Sector 1-2

Magnet Transport

DFBs installation


Sector 2-3

Magnet Transport

DFBs installation


Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec2006 2007

Sectors ready for Hardware Commissioning

5 sectors readywithin 4 months


LHC Installation

Conclusions:

• Ramping-up of many new activities in 2005:– Repair, installation and tests of the QRL– Surface logistics, preparation and underground transports of magnets – Alignment, interconnect in a difficult environment (space & co-activities)

• Status of installation versus planning:

– We are not on time, actual delays spans from 3 to 4 months– We are worried by the late procurement of DFB’s, Special SSS’s, and SSS’s with

plugs, where peak delays of 5 months with respect to planning occurred – Cryo-magnet transport approaching nominal rates, SSS installation through

Point 6 should allow to catch-up the SSS backlog– Leak test and leak finding require more time than expected

• Hardware commissioning:– Sector 7-8 should be ready for hardware commissioning by August 2006– The hardware commissioning of Sector 8-1 will not be finished this year– Last Sectors (1-2 & 2-3) should be ready for HW commissioning by August 2007– The present schedule of the DFB’s will impose drastic time & geographical

constraints for the hardware commissioning

Situation radically different from last year

schedule: still on time ?

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