M. BAJKO AT MAS on the behalf of the ANSALDO follow up team:

V Session October 2004 M. Bajko

For the LHC Superconducting Cable and Magnet Production Review

M. BAJKO AT MAS

on the behalf of the ANSALDO follow up team: F. Savary, A. Musso,and J. Herr (ISQ)

STATUS AND SPECIFIC ISSUES IN ASG



Status of the PRODUCTION Overview of the contract Production rate Problems

CONTENTStatus and specific issues at ASG

QUALITY Non Conformity Reports @ ASG Non Conformity Reports @ CERN

Conclusions

PERFORMANCE Specific Issues

Short Circuits Quench Heater Performance



STATUS OF THE CONTRACTStatus and specific issues at ASG

26.0

20.4

1.2

9.1

5.5

0.0

5.0

10.0

15.0

20.0

25.0

30.0

DELIVERED TESTED REJECTED ACCEPTED aftercold test

PROVISIONALLYACCEPTED

without cold test

% of the whole production of 416 cold masses

416 cold masses ORDERED108 cold masses DELIVERED

85 cold masses TESTED 5 cold masses REJECTED

38 cold masses ACCEPTED after cold test23 cold masses PROVISIONALLY ACCEPTED without cold test




Courtesy of P. Lienard

Ansaldo Production Status01/10/2004

0

20

40

60

80

100

120

140

1.sep.021.oct.021.nov.021.déc.021.jan.031.fév.031.mars.031.avr.031.mai.031.juin.031.juil.031.aoû.031.sep.031.oct.031.nov.031.déc.031.jan.041.fév.041.mars.041.avr.041.mai.041.juin.041.juil.041.aoû.041.sep.041.oct.04

Time

Units

Total Equiv. Dipoles

Total Collared Coil Accepted

Total C.M. Welded

Total C.M. Delivered




PRODUCTION

Time from June 2002 to SEPTEMBER 2006Time from June 2002 toJUNE 2006

To be done

Time left Time

left



NEEDED PRODUCTION RATEStatus and specific issues at ASG

3.3

3.7

3.3

00.5

11.5

22.5

33.5

4

In MARCH 2004 FORDELIVERY IN JUNE

2006

IN OCTOBER 2004 FORDELIVERY IN JUNE

2006

IN OCTOBER 2004 FORDELIVERY IN

SEPTEMBER 2006

COLD MASSES / WEEK



REAL PRODUCTION RATEStatus and specific issues at ASG

0

1

2

3

4

janvier.04février.04mars.04avril.04mai.04juin.04juillet.04août.04

septembre.04octobre.04

novembre.04décembre.04janvier.05février.05mars.05avril.05

delivered cold mass/ weekneded limit for JUNE 2006

0

1

2

3

4

janvier.04février.04mars.04avril.04mai.04juin.04juillet.04août.04

septembre.04octobre.04

novembre.04décembre.04janvier.05février.05mars.05avril.05

delivered cold mass/ weekneeded limit for SEPTEMBER 2006



Production: COLARED COILS, COLD MASSESStatus and specific issues at ASG

Production of collared coils and cold masses

0

2

4

6

8

10

12

14

jan.03fév.03mars.03

avr.03mai.03juin.03juil.03aoû.03sep.03oct.03nov.03déc.03jan.04fév.04mars.04

avr.04mai.04juin.04juil.04aoû.04sep.04oct.04

time staring from Jan 2003

production/month

Collaring

Cold mass delivery

2 per. Mov. Avg. (Collaring)Problem of performance;

waiting for feed back from cold test

Problem of coil geometry detected by

magnetic measurements **

** See presentation of E. Todesco and C. Voellinger

Intervention on the collaring press



Production: history and prevision

Status and specific issues at ASG

Courtesy of P. Lienard

Costruzione Collarati ASG

0

50

100

150

200

250

300

350

400

450

gen-01apr-01lug-01ott-01gen-02apr-02lug-02ott-02gen-03apr-03lug-03ott-03gen-04apr-04lug-04ott-04gen-05apr-05lug-05ott-05gen-06apr-06lug-06

Prev.tot.

Tot. ASG

Courtesy of ASG

Higher rate of production starting from

Sept 2004

ASG delivered the number of cold masses

foreseen by ASG

In spite of all problems,



QUALITY :Non Conformity Reports in ASGStatus and specific issues at ASG

NC distribution after March 31st, 2004 in ASG

9%

18%

24%0%

20%

29%

alignment

component

electrical

irriversible damage

mechanical

welding

Before March 31st, 2004

12%9%

17%

7%32%

23%alignment

component

electrical

irriversible damage

mechanical

welding

3.3 NC/ magnet

0.9 NC/ magnet

the QUALITY is better

Personal for Quality Control

0

4

8

12

16

déc.03 jan.04 fév.04mars.04

avr.04 mai.04 juin.04

time

number of controlers




NC on electrical and magnetical measurements (Normalised for delivered magnet numbers)

0.00

0.05

0.10

0.15

0.20

0.25

Quenchheater

Coil Wiresconnections

Temperaturesensor

Magnetic

NC/ magnet number

Until March 31st

After March 31st




NC on welding and alignment (Normalised for delivered magnet numbers)

0.0

0.3

0.6

0.9

Welding twist shape cold feetpads

assembly

NC/ magnet number

Until March 31st

After March 31st

The present NC on welding are mainly on short repairs and weld projections. The reduction of the extent of the radiographic examinations of the longitudinal welding has been started.



QUALITY : Non Conformity Reports in ASGStatus and specific issues at ASG

NC on Components (Normalised for the delivered magnet numbers)

0.00

0.05

0.10

0.15

collars bus bars copperwedges

endspacers

half shells interlayerspacer

cable polymide Correctors

NC/ magnet number

Until March 31st

After March 31st



QUALITY : Non Conformity Reports @ CERNStatus and specific issues at ASG

NC/cold mass

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

alstom ansaldo noell

NC/cold mass



QUENCH PERFORMANCE 1Status and specific issues at ASG

0

15

30

45

60

75

90

105

120

135

150

165

0 1 2 3 4 5 6 7 not reachedNumber of quenches to reach 8.33T

Number of Cryo-dipoles

01 Ansaldo 03



Quench performance is GOING BETTER!!!

6.00

7.00

8.00

9.00

1 11 21 31 42 57 74 86103

Magnet number

Field level [ T ]

1st quench

2nd quench

3rd quench

4th quench

5th quench

6th quench

7th quench

8th quench

9th quench

1st qu. ATC

2nd qu. ATC

3 per. Mov.Avg. (1stquench)

Quench history for Ansaldo Magnets

9 T

8.4 T

8.6 T

Courtesy of Quench Performance WU




Quench performance is GOING BETTER!!!

0

10

20

30

40

50

60

1 QUENCH 2 QUENCHES 3 QUENCHES

FOR 8.33 T

% of magnets tested

MARCH 2004

OCTOBER 2004




Specific issues Status and specific issues at ASG

Inter turn short circuits in the headsIdentify the most critical points: heads, end spacers; introduce extra insulation, take care during winding, insulate the end spacers; CERN helps ASG to identify by magnetic measurements before de collaring the sh .c . position

Quench heater damages during collaringReview the winding and collaring operations, reinforce quality control on QH

Quench performance: to open 2069To open the cold masses where well identified local weakness was detected during cold test; and learn from that

Keep quality control, reinforce the system following recommendations of the QA Audit

Magnetic field quality: a4, b.6 movements, a3Together with CERN continue the investigations to fix the cause and then to avoid a4 trend ; study the reasons of the bloc 6 movements in the series 208x and 209x.



CONCLUSIONSStatus and specific issues at ASG

PRODUCTION RATE is still not sufficient even with the new dead line, but the level of confidence for their planning presently is good. Starting from September the production rate have increased as foreseen… to be checked if they followed in 6 mounts.

QUALITY is better : less NC at the firms and lowest rate at CERN

QUENCH PERFORMANCE is going better: more magnet having 1 quench below 8.3T less magnets having 3 quenches

MAGNETIC FIELD QUALITY in generally is good but a4 has a trend for which no explanation up to today, b3 stabilized and some explanation for the b.6 movement were given but still not clarified

Refused magnets with well localized weak points should be opened AS SOON AS POSSIBLE to learn for them

ELECTRICAL incidents: as inter turn shorts and quench heater defects should be avoided by more quality control and review of the critical points of the assembly

Documents

M. BAJKO AT MAS on the behalf of the ANSALDO follow up team: