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SMACC Tenth report [15 min ] 13/09/2013

Jean-Philippe Tock (TE-MSC) On behalf of the SMACC project. SMACC Tenth report [15 min ] 13/09/2013. Activities since last LSC (30/08/2013) By Activities By sectors SIT DFBA Dashboards Brief ElQC update Activities for the next 2 weeks Conclusions.

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SMACC Tenth report [15 min ] 13/09/2013

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  1. Jean-Philippe Tock (TE-MSC) On behalf of the SMACC project SMACC Tenth report[15 min]13/09/2013

  2. Activities since last LSC (30/08/2013) • By Activities • By sectors • SIT • DFBA • Dashboards • Brief ElQC update • Activities for the next 2 weeks • Conclusions

  3. SMACC Main activities for the next 2 weeks • 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 existingsplices • Other sectors: • S12: Opening of M lines • S23: Opening of interconnections and installation of DN200 • S12, 23, 34 & 45 : Reconnection of replacingmagnets • Advanced opening for outliers and CSCM segments • Inspection of connection cryostats From last LSC (30.08.2013)  On-going, 52 ICs reclosed, leak test of beam lines completed succesfully  In progress, critical activity  In progress, > 1/3 of sector rewelded JeuneGenevois …  Started, 2/14 vac subsectors validated  Started, 14 ICs reclosed  On-going Desoldering completed, starting in 81   On-going, > 1/3 of the sector equipped  On-going  On-going, > ¼ completed, see further > 80% open, DN200 installation completed Good progress     On-going 

  4. SMACC Progress report by activity • Opened interconnections in 8 sectors, > 6 sectors-eq are opened • Back on schedule

  5. SMACC Progress report by activity • M line cutting : > 4.5 sectorsequivalent (S12 welladvanced) • Replacing team leader at CERN sincebeginning of August Courtesy JM Hubert

  6. SMACC Progress report by activity • Desoldering : Completed in S56 & 67 & 78 • Resolderingcompleted in S56 & 67 & at 75 % in S78 59 Desoldering: Nominal was 53/week; Now we need 95/week Increasing is seen (Effect of new staff and tooling) W36 included JeuneGenevois W37 not completed (preliminary: 85) Resoldering: Improving, not yet there 1 person of the team prepares intervention on overheatedcable in 56 with a staff Courtesy H Prin

  7. SMACC Progress report by activity • Shunts are installedin > 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

  8. SMACC Progress report by activity • Installation of insulation box: Good progess in 67 ( 50 %) • 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 : Injectevery 2 daysby batch of 15 (37.5/wk) • Bottleneckisstill the installation of the electricalinsulation •  Worksequenceisoptimised •  Resources are redirected 2 FSUs and 3 COAS (PAEC) in October THE critical activity Courtesy H Prin / M Duret

  9. 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 requirementOK 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

  10. SMACC Progress report by activity • M Welding : 290 ICswelded, ≈ 1.35 sec-eq: • Reduced team, extrapolating: nominal rates seem achievable • Limited by release rate, not by the team capacity (Presently 30/week) • In-linewithforecast of last LSC • Delay wrt baseline • Required rate to end according to baseline : 45 IC/week • Team sized for 53-60 • Marginfor the «last 10%» has been eaten • Situation to bemonitored for a possible reaction in October. Courtesy S Atieh

  11. SMACC Progress report by activity • M sleevesleaktesting : All possible subsectors (200 ICs)are leaktested • 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 bemonitored for a possible reaction Courtesy P Cruikshank / L Mourier

  12. 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)

  13. 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

  14. 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)

  15. 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

  16. SMACC Progress report by sector • Main activities are: • desoldering of splices (just completed), • resoldering of splices, • installation of shunts • and related QC/QA

  17. 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

  18. 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

  19. SMACC Dashboards

  20. SMACC Dashboards • Openingis back ahead of scheduledespiteclosure of interconnections • Shuntingstarts to improvewithreinforcement and optimisation of criticalactivities • Welding: Limited by release rate, confident that nominal rate canbeachieved, margin has been eaten up • M leak test : Limited by release rate, confident that nominal rate canbeachieved, margin has been eaten up • ReClosure: startedaheadof schedule, now in S67 • Final leak test started (Results in 2 weeks)

  21. 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 becompleted by beginnig of November

  22. SMACC Dashboards Progress: Baseline: 31.8% (27.2 %) Completed: 25.6% (22.4 %) Delay18 (15) days

  23. 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 impact DN200:  ≈ 2 months delay: not critical SMACC:  About 3 weeks (stable) The impact of the summer period on the planning was 3 weeks Can recovernextyearwhenresources are freed by finishingactivities

  24. SMACC ElQC Status • 30 % seems confirmed as more solid number • Dedicated presentation in October with half of the LHC measured Courtesy C Scheuerlein, S Heck

  25. SMACC Main activities for the next 2 weeks • 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 existingsplices • Start desoldering of splices • Other sectors: • S12: Complete opening of M lines • S23: Opening of interconnections • S12, 23, 34 & 45 : Reconnection of replacingmagnets • Advanced opening for outliers and CSCM segments • Inspection of connection cryostats

  26. 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 redoseemsconfirmed for 40% of the LHC • ReducedElQA test frequencyallows to copewith > 3 sectors in // • Global delay of 3 weeks due to summerperiod and technical issues undersolving ; difficut to recoverthisyear • Margin has been eaten up for someactivities (M welding, M leak test) • Issues: • Reach nominal rate for arc splices consolidation(Ramp up with de/resoldering and optimise installation of insulation box) • DFBA busbarbellows • Components for diodes consolidation So far, not so bad …

  27. SEQUENCE AND STATUS Install DN200 ≈ 80% Open M sleeves Open ICs OK to open ≈ 4.5 sectors >6 sectors 8 sectors Undo / Redo splices ELQC(new splices) ≈ 2.5 sectors ≈ 2.5 sectors Machine Cu ELQCafter Cu mach. ELQC(old splices) > 2 sectors > 3 sectors ≈ 2 sectors Consolidate Q diodes Availability of components ≈ 1.7 sectors Weld M Leak test M Close IC Final LT Insulate splices ELQCafter shunt Install shunts > 2 sectors ≈ 1.7 sectors > 2 sectors ≈ 1/4 sector ≈ 1.3 sectors ≈ 1 sector Started

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