Second LHC Splices Review

Technology Department

Second LHC Splices Review

Outline

What has to be done ?Main splicesOther activities

Organization chart and roles Planning Resources Conclusions

28th of November 2011

Work Organisation for LS1Second LHC Splice Review

Work reported here is the continuation of the tremendous and detailed work done by F Bertinelli

Work Organisation for LS1

1/20J.Ph. Tock



What has to be done …?

To consolidate the superconducting circuits



Main splices in the arc DFBA circuits (A Perin) Replace cryomagnets Consolidate connection cryostatsNB: Other activities not linked directly to SC circuits:

PIMs, Helium level gauges, Y lines, DN200, …

2/20J.Ph. Tock



Replace cryomagnets


Work Organisation for LS1Second LHC Splice Review Courtesy S Izquierdo

3/20J.Ph. Tock



Replace cryomagnets



14 cryodipoles, 3 SSSs

[ ]

High internal splice resistance

Under assessment : Cryomagnets with wrong beam screens types

Q7R3

4/20J.Ph. Tock



Replace cryomagnets



Courtesy A MussoCryomagnets coordination workspace :

https://espace.cern.ch/cryomagnet-coordination/default.aspx

5/20J.Ph. Tock



Consolidate connection cryostats



The plan is :•Measure and if necessary consolidate the CC 11L8•Consolidate the CC in 11L3 & 11L1•Measure / inspect all the CCs to check no displacement

Details in ECR: LHC-LE-EC-0003

6/20J.Ph. Tock



Installation of DN 200



To be installed during LS1 in 23, 45 (part), 78 & 81: About 600 units

7/20J.Ph. Tock



Other interventions (not exhaustive)



• PIMs (# 45 to be replaced)

-Buckled during warm-up ≈ 18 (RF ball test) -Heavily damaged : ≤ 10-Preventive replacements :+ Arc extremities 18/32 in baseline

•Consolidation of SAM Helium level gauges and DN160It is planned to consolidate the 2 remaining ones: Q6R2&L8 Support from MME

•Repair of leaking Y-lines

It is planned to consolidate the 2 known cases (S78:17-19R7 & S81:19-22R8)

8/20J.Ph. Tock




Start at P5 / clockwise

5

1

82

3

4

7

6

High inner splice

SSS

Highest leakElectrical integrity issue

Beam opticsDS Coll.(For mem.)

Spread all around : work on leaks, PIMs,

SAM (He, DN160)

Y-lines repairCC Consolidation / InspectionDN 200 installation

Triplet braid (End of LS1 for rad prot)

Cryo-dipole

Circuit and splices issues

Goal : Special interventions completed before the train arrives : To be checked 9/20

J.Ph. Tock




Long Shutdown 1F. Bordry

Consolidation of the superconducting circuits: JPh TockMain arc splices cons.

“The train”F Savary #52

Open/Close IC [DN200]A Musso #32

-Sleeves cutting-BB surfacing-Shunt installation-Splice de-&resoldering (15%)

Special interventions “SIT”N Bourcey #15

-Cryomagnets exchange-Connect. Cryostat cons.-PIMs-Specific issues-Heavy NC

-Opening/ Closure of IC Partial and complete W bellows & ther. shields-Installation of DN200

Quality AssuranceR Ostojic #39

-Electrical QC: C Scheuerlein #17 See presentation-Welding QC: JM Dalin-Beam vacuum QC: C Garion-Open/close IC QC: D Bodart-QA manager support

ELQATE-MPE

N Catalan #23-Continuity-HV test

Leak TestTE-VSC

P Cruikshank #19-Beam lines-Cryogenics lines-Insulation vacuum

Project Office M Pojer #11

-Radiation protection-Safety-Access

-Coordination with Survey, Instrumentation, Transport, LS1 planning, QPS, cryogenics,… Test teams on a chain of IC -Reporting tools

DFBAA Perin [#12

(TBC)]-Splices and BB

Organisation Chart

10/20J.Ph. Tock

TIG weldingS Atieh #14

- Orbital & manual




Open/Close IC [DN200]A Musso #32

-Opening/ Closure of IC Partial and complete W bellows & ther. shields-Installation of DN200

Detailed roles

Open interconnections for : Consolidation of main splices Installation of DN200

Partial opening first Recovery of RP samples (LHC-LI-EC-

0001) Special interventions

Install DN200 (3,5 sectors)Reclose interconnections

11/20J.Ph. Tock




Detailed roles

Main arc splices cons. “The train”F Savary #52

-Sleeves cutting-BB surfacing-Shunt installation-Splice de-&resoldering

Was covered in details by previous presentationsEnsure coordination from opening to readiness for reclosure of M sleeves [Individual IC]

12/20J.Ph. Tock




Detailed roles

Special interventions “SIT”N Bourcey #15

-Cryomagnets exchange-Connect. Cryostat cons.-PIMs-Specific issues-Heavy NC

Was covered in previous slidesPolyvalent teamWill intervene on heavy NC to avoid slowing down the work of the main train

DFBAA Perin [#12

(TBC)]-Splices and BB

See presentation by A Perin tomorrowStill to be defined

13/20J.Ph. Tock




Detailed roles

The QA manager will:Coordinate QA activitiesEnsure that an adequate level of Quality Assurance is applied, especially in terms of traceability (MTF) and documentationEnsure a timely management of the non-conformities, minimizing the impact on the overall scheduleEnsure that production parameters are analysed in time to give an early warning in case of drift. Identify as early as possible critical issues that could jeopardize the consolidation work

Quality AssuranceR Ostojic #39

-Electrical QC: C Scheuerlein #17 See presentation-Welding QC: JM DalinOperators, tooling, procedures qualificationQC during production (Visual inspection)Off-line samples-Beam vacuum QC: C GarionProtection and inspection of Bellows, PIMsEndoscopy of beam lines-Open/close IC QC: D BodartVisual inspectionProtection of critical surfaces-QA manager supportTooling, inspection, reporting

14/20J.Ph. Tock




Planning

Rate: 4 weeks for each activity so 53 IC/weekDimensioned to 60 IC/week: 10% marginRemember : Series installation at 30 IC/week !

F Bertinelli @ 1st splices review

Courtesy P Fessia

15/20J.Ph. Tock




ID Task Name Duration

130 Point 8 90 days131 Cryo maintenance 18 wks132 Sector 81 210 days133 Preliminary powering tests - ph.2 4 edays134 ELQA before warm-up 4 days135 Preliminary PT78 4 edays136 Preliminary PT12 4 edays137 Warm-up 5 ewks138 Interconnections train 70 days139 Opening W 3 wks140 Bellows inspection & protection, cryo-thermometers3 wks141 Cutting PIMs 4 wks142 Endoscopy beam lines 4 wks143 Repair, reinstall & tack PIMs 4 wks144 Cutting M sleeves 4 wks145 Removal of IC splices insulation 4 wks146 QC, R8, busbar resistance 4 wks147 Busbar surface machining 4 wks148 Solder shunt 4 wks149 Desolder/resolder/shunt splices 4 wks150 Spools 4 wks151 QC splices/shunts 4 wks152 Mounting & QC insulation 4 wks153 ELQA 4 wks154 Welding M sleeves & PIMs 6.6 wks155 QC welding & leak testing 6.6 wks156 Closure 4 wks157 VAC sectors leak test 6 wks158 IC Non Conformities 3 wks159 Pressure test 2 edays160 DN200 6 wks161 Possible transport of magnet for sector 78 12 wks162 Cool-down 5 ewks163 ELQA 2 wks164 Powering tests - ph.2 6 wks165 PT78 6 wks

Interconnections train

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12

Courtesy K Foraz

One typical sector

16/20J.Ph. Tock




Global Planning

•Preliminary powering tests•Warm-up

•Opening•Splice consolidation(incl. internal leak tests)

•Closure•Leak tests (Ins vacuum)•Preparation for cool-down•Cool-down

•ELQA@cold

•Powering tests

Courtesy K Foraz

14 months

1st sector cold tested (2nd one), one year after the start of LS1 !

Consolidation of main splices in 4 sectors in parallel (13 km)

17/20J.Ph. Tock




Resources

LHC LS1(#195)

TE(#146)

EN(#21)

BE(#15)

PH(#7)

Not ID(#6)

New resources have been identified since the last review

Collaboration agreement under finalisation with PAEC for:-Opening/Closure of IC (#21)-Busbar machining (#11)-Welding (#6)

18/20J.Ph. Tock




Resources

> 60% have to be trained !Some rotation in staff (Collaborations) > 200 individualsChallenge to have this in parallel with work in tunnel

TrainedIdent, To trainNew FSUMssing

19/20J.Ph. Tock



Conclusions



• Organisation chart defined and most of the key roles are assigned• Workplan almost defined

DFBA consolidation definition is starting nowResources to be identified

• Most of resources are identified • BUT: Commitments to be kept

To be reviewed with tooling optimization and test

with updated durations

•The production rate (53 IC/week) is ambitious• QA/QC will be implemented to ensure the required quality level• No (very little) margin for extra work, bad surprises 20/20

J.Ph. Tock




21/20J.Ph. Tock




Spare slides

22/20J.Ph. Tock




0 5 10 15 20-2

0

2

4

6

8

10

Electric resistance (n)

Fru

ptu

re (kN

)

Cable 02 oxidized RTCable 02 no oxidized 4.3KCable 01 no oxidized, pretinned 4.3KCable 01 oxidized, no pretinned 4.3KCable 01 no oxidized, no pretinned 4.3K

Courtesy S Izquierdo23/20

J.Ph. Tock




Resources status for splices train

Activity Trained Id, TBT Missing TOT Remark

Open/Close IC 8 21 22 20 PAEC, (7 DUBNA), 2 MSC

IC op/clos QC 4 4 3 BE-OP, 1 MSC-MNC

Cut M sleeves (PIMs) 2 10 12 10 PAEC

Busbars surfacing 7 7 7 MSC-MNC

Elec conn (shunt/splice) 8 9 3 20 MSC

Splice QC 4 13 17 MSC, 10 BE-OP

ELQA 13 10 23 3 MPE, 20 Krakow

Weld M sleeves (PIMs) 6 9 15 MME

Weld QC 6 6 MME

Leak test 12 7 19 VSC

TOTAL 46 96 3 145

More needs to supervise PAEC : 2 trained for open/closure to identify and 1 extra for cutting

24/20J.Ph. Tock




Resources for Other activities

Activity Trained Id, TBT Missing TOT Remark

Bellows insp, prot, end 3 5 8 VSC, 6 Krakow

Repair, tack PIMs 1 1 2 VSC, 2 FSU

DN 200 7 1 8 7 DUBNA

Special Interv Team 10 5 15 Was 20

Logistics 3 3 MSC-LMF

Coordination 2 6 3 11 MSC, 2 BE-OP

QA 1 3 1 5 TE-HDO,…

TOTAL 27 18 5 50

Grand total 73 114 8 195

25/20J.Ph. Tock

Documents

Second LHC Splices Review