SMACC Tenth report[15 min]

13/09/2013

Jean-Philippe Tock (TE-MSC)

On behalf of the SMACC project

Activities since last LSC (30/08/2013) By Activities

By sectors

SIT

DFBA

Dashboards Brief ElQC update Activities for the next 2 weeks Conclusions

JPh Tock4/28

Sector 56 : Work on non-conformities

Sector 67 Installation of insulation boxes and injection Rewelding of M sleeves

Leak test of M lines Reclosure of interconnections DFBA consolidation

Sector 78 Desoldering and resoldering of splices Installation of shunts DFBA consolidation

Sector 81 ElQC of existing splices

Other sectors: S12: Opening of M lines S23: Opening of interconnections and installation of DN200 S12, 23, 34 & 45 : Reconnection of replacing magnets Advanced opening for outliers and CSCM segments Inspection of connection cryostats

On-going, > 1/3 of the sector equipped

SMACC Main activities for the next 2 weeks

Jeune Genevois

…

Good progress

In progress, critical activity

Started, 14 ICs reclosed

Desoldering completed, starting in 81

On-going

On-going, > ¼ completed, see further

> 80% open, DN200 installation completed

On-going, 52 ICs reclosed, leak test of beam lines completed succesfully

On-going

From last LSC (30.08.2013)

In progress, > 1/3 of sector reweldedStarted, 2/14 vac subsectors validated

On-going

JPh Tock5/28

SMACC Progress report by activity

Opened interconnections in 8 sectors, > 6 sectors-eq are opened

Back on schedule

JPh Tock6/28

SMACC Progress report by activity

M line cutting : > 4.5 sectors equivalent (S12 well advanced) Replacing team leader at CERN since beginning of August

Courtesy JM Hubert

JPh Tock7/28

SMACC Progress report by activity

Courtesy H Prin

Desoldering : Completed in S56 & 67 & 78 Resoldering completed in S56 & 67 & at 75 % in S78

Desoldering: Nominal was 53/week; Now we need 95/weekIncreasing is seen (Effect of new staff and tooling) W36 included Jeune GenevoisW37 not completed (preliminary: 85)

Resoldering : Improving, not yet there1 person of the team prepares intervention on overheated cable in 56 with a staff

59

JPh Tock8/28

SMACC Progress report by activity

Shunts are installed in > 2 sectors-eq.

50 ICs behind schedule (About one week at nominal rate) Delay effect of the reinforcement of resoldering teams Non-consecutive interconnections About 8 000 shunts installed (30% of the LHC) «Last 10% effect» in 2 sectors

JPh Tock9/28

SMACC Progress report by activity

Installation of insulation box: Good progess in 67 ( 50 %)

Courtesy H Prin / M Duret

2 phases : Minimum required: 45 ICs/ week (9 per day)Installation (time consuming, continuous) & Injection (By batch of ≈ 15 ICs)

Installation completed in 56 and 55 % of 67 Injection completed in 56 and 45 % of 67 : Inject every 2 days by batch of 15 (37.5/wk) Bottleneck is still the installation of the electrical insulation

Work sequence is optimised Resources are redirected

2 FSUs and 3 COAS (PAEC) in October

THE critical activity

JPh Tock10/28

SMACC Progress report by activity

Quadrupole diodes > 5 sectors are opened / 2 sectors are almost consolidated (1 diode to be exchanged because of too high

internal resistance) Globally almost on schedule BUT One diode has to be replaced because of too high diode to heatsink resistance (Q31R6) Some components were delivered, allowing to barely complete S67; some pieces have to be reworked at

CERN Not critical YET Alternative supply still under investigation to check that it can meet the requirement

OK for the material certificate, price to be renegotiated, manufacturing method still to be confirmed (Delivery time of at least 2 months)

Courtesy L Grand-Clement / F Savary

JPh Tock11/28

SMACC Progress report by activity

M Welding : 290 ICs welded, ≈ 1.35 sec-eq:

Courtesy S Atieh

Reduced team, extrapolating: nominal rates seem achievable

Limited by release rate, not by the team capacity (Presently 30/week)

In-line with forecast of last LSC

Delay wrt baseline Required rate to end according to baseline :

45 IC/week Team sized for 53-60 Margin for the «last 10%» has been eaten Situation to be monitored for a possible

reaction in October.

JPh Tock12/28

SMACC Progress report by activity

M sleeves leak testing : All possible subsectors (200 ICs) are leak tested

All possible subsectors of S56 (11/14) are released and leak tested

Starts in S67 : 3 subsectors released. 2 are leak tested

In-line with forecast of last LSC

Delay wrt baseline Required rate to end according to

baseline : 3.1 subsec/week Foreseen for 3-3.5 subsec/week Margin for the «last 10%» has

been eaten Situation to be monitored for a

possible reaction

Courtesy P Cruikshank / L Mourier

JPh Tock13/28

SMACC Progress report by activity

Reclosure of interconnections : On-going in 67 (priority) and 56,

52 ICs are reclosed in 56 and 14 in 67 Stopped in 56 during beam lines leak test;

contraint relaxed this week by VSC S56 will be delayed (Overheated cable,

DFBAK bellows)

JPh Tock14/28

SMACC Progress report by activity

Final leak test: 1st one STARTED

16 consecutive interconnections closed in 56 Final leak test started Results in 2 weeks, on schedule

JPh Tock15/28

SMACC Progress report by sector

Main activities are on non-conformities Was temporarily stopped for beam lines leak testing Reclosure as a an activity to smooth work load (priority given to S67) Repair of overheated cable will start next week, with a completion by end of

October One PIM to be exchanged for protruding RF fingers (QQBI.29R5): Re-rewelding

capability will be limited – specific procedure (was consolidated in 2009)

JPh Tock16/28

SMACC Progress report by sector

All non-problematic ICs are shunted Main activities are installation of insulation system and welding of M lines Leak test of M lines is on-going (2/14 subsectors validated) Reclosure started

JPh Tock17/28

SMACC Progress report by sector

Main activities are: desoldering of splices

(just completed), resoldering of splices, installation of shunts and related QC/QA

JPh Tock18/28

SMACC Progress report SIT

SIT 2 cryomagnets are reconnected, the other ones are under reconnection and it has started for Q5L8 Standard reconnection will be done by the train when it will arrive PIMs: Rewelded in 6 sectors, 2nd RF ball test done successfully in S56 (Only one more to change in 56) 2 Y-line leaks are repaired and validated, only the closure of IC remains, by the train, end of 2013

To start : Interventions on SAM (Tooling under checking in workshop) and IT

Courtesy N Bourcey, S Le Naour

JPh Tock19/28

SMACC Progress report DFBA

DFBA M Bellows: See report by L Tavian Splices consolidation has restarted at a good rate, with reinforced team

Courtesy TE-CRG, TE-MSC and EN-MME

JPh Tock20/28

SMACC DashboardsSMACC summary status Updated 11-Sep-13

19-Apr-13 212 13-May-13 17-Jun-13 210 19-Jul-13 05-Jul-13 206 08-Aug-13 19-Jul-13 168 15-Aug-13 30-Aug-13 48 27-Sep-13 17-Sep-13 0 25-Oct-13-11 212 -6 -54 212 -41474 -58 212 -41494 4 212 -41501 -10 212 212

08-Apr-13 100% 07-May-13 24-Apr-13 99% 08-May-13 97% 23-Jul-13 79% 20-Aug-13 23% 0%

16-May-13 211 06-Jun-13 22-Jul-13 199 23-Aug-13 13-Aug-13 77 17-Sep-13 27-Aug-13 32 24-Sep-13 30-Sep-13 14 27-Oct-13 15-Oct-13 0 22-Nov-13-20 211 10 -31 211 -41509 8 211 -41534 -41513 211 -41541 -27 211 -41574 -41562 211 -41600

26-Apr-13 100% 16-Jun-13 21-Jun-13 94% 21-Aug-13 36% 15% 03-Sep-13 7% 0%

07-Jun-13 212 27-Jun-13 26-Aug-13 76 30-Sep-13 18-Sep-13 0 22-Oct-13 02-Oct-13 0 29-Oct-13 28-Oct-13 0 22-Nov-13 12-Nov-13 0 20-Dec-13-24 212 12 -3 212 -41547 -41535 212 -41569 -41549 212 -41576 -41575 212 -41600 -41590 212 -41628

14-May-13 100% 09-Jul-13 23-Aug-13 36% 0% 0% 0% 0%

28-Jun-13 212 18-Jul-13 01-Oct-13 0 04-Nov-13 23-Oct-13 0 26-Nov-13 06-Nov-13 0 03-Dec-13 27-Jan-14 0 21-Feb-14 11-Feb-14 0 21-Mar-14-38 212 8 -41548 212 -41582 -41570 212 -41604 -41584 212 -41611 -41666 212 -41691 -41681 212 -41719

21-May-13 100% 26-Jul-13 0% 0% 0% 0% 0%

19-Jul-13 212 08-Aug-13 05-Nov-13 0 09-Dec-13 27-Nov-13 0 14-Jan-14 11-Dec-13 0 21-Jan-14 24-Feb-14 0 21-Mar-14 11-Mar-14 0 22-Apr-14-53 212 21 -41583 212 -41617 -41605 212 -41653 -41619 212 -41660 -41694 212 -41719 -41709 212 -41751

27-May-13 100% 29-Aug-13 0% 0% 0% 0% 0%

09-Aug-13 166 29-Aug-13 10-Dec-13 0 27-Jan-14 20-Jan-14 0 21-Feb-14 31-Jan-14 0 27-Feb-14 24-Mar-14 0 22-Apr-14 08-Apr-14 0 21-May-14-67 212 -41515 -41618 212 -41666 -41659 212 -41691 -41670 212 -41697 -41722 212 -41751 -41737 212 -41780

03-Jun-13 78% 0% 0% 0% 0% 0%24-Feb-0025-Nov-13 55 13-Dec-13 29-Jan-14 0 04-Mar-14 24-Feb-14 0 28-Mar-14 07-Mar-14 0 03-Apr-14 24-Apr-14 0 22-May-14 07-May-14 0 20-Jun-14

-188 212 -41621 -41668 212 -41702 -41694 212 -41726 -41705 212 -41732 -41753 212 -41781 -41766 212 -4181021-May-13 26% 0% 0% 0% 0% 0%

06-Jan-14 37 24-Jan-14 05-Mar-14 0 08-Apr-14 31-Mar-14 0 07-May-14 11-Apr-14 0 13-May-14 22-May-14 0 20-Jun-14 06-Jun-14 0 18-Jul-14-255 212 -41663 -41703 212 -41737 -41729 212 -41766 -41740 212 -41772 -41781 212 -41810 -41796 212 -41838

26-Apr-13 17% 0% 0% 0% 0% 0%

19-Apr-13 1317 24-Jan-14 17-Jun-13 485 08-Apr-14 05-Jul-13 283 07-May-14 19-Jul-13 200 13-May-14 30-Aug-13 62 20-Jun-14 17-Sep-13 0 18-Jul-14-11 1695 -41663 -54 1695 -41737 -58 1695 -41766 4 1695 -41772 -10 1695 -41810 -41534 1695 -41838

08-Apr-13 78% 24-Apr-13 29% 08-May-13 17% 23-Jul-13 12% 20-Aug-13 4% 0%

S34

S45

LHC

S67

S78

S81

S12

S23

ICs Opening

S56

Sleeves Welding M lines Leak Test ICs closure Ins Vac LtestShunts Installation

JPh Tock21/28

SMACC Dashboards

Opening is back ahead of schedule despite closure of interconnections

Shunting starts to improve with reinforcement and optimisation of critical activities

Welding: Limited by release rate, confident that nominal rate can be achieved, margin has been eaten up

M leak test : Limited by release rate, confident that nominal rate can be achieved, margin has been eaten up

ReClosure: started ahead of schedule, now in S67 Final leak test started (Results in 2 weeks)

JPh Tock22/28

SMACC Dashboards

Baseline: 26.1 % (22.3 %)Completed: 23.0 % (20.0 %)Delay 10 (9) days Baseline: 47.0 % (41.1 %)

Completed: 33.0 % (29.7 %)Delay 27 (17) days

Baseline: 42.9 % (35.7 %)Completed: 23.0 % (22.3 %)Delay 41 (36) days

Baseline: 100 % (100 %)Completed: 82.4 % (72 %)Delay 64 (52) days

Will be completed by beginnig of November

JPh Tock23/28

SMACC Dashboards

Progress:Baseline: 31.8% (27.2 %)Completed: 25.6% (22.4 %)

Delay 18 (15) days

JPh Tock24/28

SMACC Summary on progress

Main 13 kA Splices: Started a week in advance, now 2 weeks delay (stable)

Special Interventions: 27 days delay, non-conformities start to impact

DFBA: > 1 month delay: should recover for end of the year

Bellows issue could have a large impactDN200:

≈ 2 months delay: not criticalSMACC:

About 3 weeks (stable)

The impact of the summer period on the planning was 3 weeks

Can recover next year when resources are freed by finishing activities

JPh Tock25/28

SMACC ElQC Status

Courtesy C Scheuerlein, S Heck

30 % seems confirmed as more solid number Dedicated presentation in October with half of the LHC measured

Preliminary results of existing splices quality control (7.09.2013).           

 Sector Sector 56 Sector 67 Sector 78 Sector 81 LHC  

Measured [%] 100 100 100 25 40  To redo [%] 28 32 29 31 30  

JPh Tock26/28

Sector 56 : Work on non-conformities including repair of overheated cable Reclosure (not in priority)

Sector 67 (Priority sector) Installation of insulation boxes and injection Rewelding of M sleeves Leak test of M lines Reclosure of interconnections DFBA consolidation

Sector 78 Complete resoldering of splices Installation of shunts DFBA consolidation

Sector 81 ElQC of existing splices Start desoldering of splices

Other sectors: S12: Complete opening of M lines S23: Opening of interconnections S12, 23, 34 & 45 : Reconnection of replacing magnets Advanced opening for outliers and CSCM segments Inspection of connection cryostats

SMACC Main activities for the next 2 weeks

JPh Tock27/28

Conclusions New activity: Start of final leak testing (The last one ) About to start to repair the overheated cable in 56 in-situ The ratio of 30 % of splices to redo seems confirmed for 40% of the LHC Reduced ElQA test frequency allows to cope with > 3 sectors in //

Global delay of 3 weeks due to summer period and technical issues under solving ; difficut to recover this year

Margin has been eaten up for some activities (M welding, M leak test)

Issues:Reach nominal rate for arc splices consolidation

(Ramp up with de/re soldering and optimise installation of insulation box)DFBA busbar bellowsComponents for diodes consolidation

So far, not so bad …

JPh Tock28/28

SEQUENCE AND STATUS

OK to open

8 sectors

Open ICs

> 6 sectors

Install DN200

≈ 80%Open M sleeves

≈ 4.5 sectors

ELQC(old splices)

> 3 sectors

Undo / Redo splices

≈ 2.5 sectors

ELQC(new splices)

≈ 2.5 sectorsMachine

Cu

> 2 sectors

ELQCafter Cu mach.

≈ 2 sectors

Install shunts

> 2 sectors

ELQCafter shunt

> 2 sectors

Insulate splices

≈ 1.7 sectors

Weld M

≈ 1.3 sectors

Leak test M

≈ 1 sector

Close IC

≈ 1/4 sector

Final LT

Started

Consolidate Q diodes

≈ 1.7 sectors

Availability of components