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SM-18 Magnet Test Operation – Status & Outlook

SM-18 Magnet Test Operation – Status & Outlook. V.Chohan CERN, Geneva, Switzerland Review of the Tests of Superconducting Magnets in SM18 , 8 February 2006. Talk Outline. Operation Overview Available Resources Constraints Current Status Statistics for 2005 Outlook for 2006

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SM-18 Magnet Test Operation – Status & Outlook

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  1. SM-18 Magnet Test Operation – Status & Outlook V.Chohan CERN, Geneva, Switzerland Review of the Tests of Superconducting Magnets in SM18 , 8 February 2006

  2. Talk Outline • Operation Overview • Available Resources • Constraints • Current Status • Statistics for 2005 • Outlook for 2006 • Special SSS issues • Constraints & Solutions • Conclusion SM18 Magnet Tests Review, February 06

  3. Operation Overview

  4. Magnets Tested in SM18 704 1257 456 97 SM18 Magnet Tests Review, February 06

  5. SM18 Test OperationAvailable Resources • Test Equipment • Fixed • 12 Test Benches arranged in pairs so, 6 clusters( A to F) • 6 Main Power Converters • 6 sets of Electronics for testing 1 per cluster • Mobile • For Q-location & MM special 15 m Shafts to be installed in magnets • Mobile Racks for HV insulation tests & Magnetic Measurements • SSW Units • Shared Utilities • Water for 4 magnet powering at the same time • Cryogenics capacity and limits • Manpower [24 hr Tests Operation Staff] in 2005 • 14 CERN staff ( ~12 FTE ) on loan from CERN Accelerator Operation ( some only part-time) • 20-25 persons on exact 1 year contracts from India & constantly rotating, so (~16 FTE) • ICS “Magnet connectors/disconnectors” working 24 hours ( but ROCLA not) • Cryogenic Support staff • Technical Support • Equipment support for magnet test equipment and electronics SM18 Magnet Tests Review, February 06

  6. Constraints in Operation For parallel test operations on all benches, constant monitoring and allocation of shareable resources is required. This imposes following constraints: • Equipment for Testing • Juggling of mobile resources between benches • Constant switching of rack electronics for testing 2 magnets in a cluster • Shared utilities • Constant monitoring & allocation considering capacity limits for cryogenics, water and power • Connection/Disconnection ‘ICS’ limits • Limited staff on separate contractual agreement with limited provisions for handling ‘overload’ times Manpower constraints - Staff with frequent & rapid turnover • Knowledge management issues • Facilitation and training of rotating staff • Some experienced CERN staff returning to start-up of respective accelerator operations in 2006 SM18 Magnet Tests Review, February 06

  7. Utilities : Cryogenics Capacity Cryogenics capacity (in 2005) and limits : • 3 to 5 Magnets @ 1.9K and under cold tests, • Up to 2magnets in 300K to 90 K(Cool down) phase , • Up to 2magnets in Last (Warm up) Quench to 300K phase, ( but not exceeding 3 magnets in cool-down or warm-up phase altogether - this limit was 2 up to end 2004 ) • 1magnet in 90K to 1.9 K phase Cryogenics capacity was enhanced in 2005, with • Faster cooling & warming times • Better quench recovery • Increased limits on number of quenches • However it still requires a judicious and optimized setting of bench cryo priorities by OP crew SM18 Magnet Tests Review, February 06

  8. Setting Priorities from Tests Operation SM18 Magnet Tests Review, February 06

  9. Status & Highlights - 2005

  10. Overall Results ‘Cleared’ => Signed for STRIPPING by the Operation Team SM18 Magnet Tests Review, February 06

  11. HighlightsNotable points from 2005 Tests Operation • Enhanced cryo capacity, reflected in: • Reduced Dipole & ARC-SSS testing times hence, increased magnet test rate • High magnet test rate achieved despite additional tests and dynamic behaviour studies (MM, fatigue tests) conducted in some magnets in 2005. • OP proposals from last year’s review, which were implemented and helped in improving the overall testing rate: • Reduced connection time for ARC-SSS • Modifications in quench training rules for optimized magnet training • Introduction of Rapid on-bench Thermal Cycle for poorly performing magnets hence, reduced ICS & logistics efforts & enhanced ‘stripping’ efficiency • Reduced number of Stretched Wire measurements for ARC-SSS at warm & at cold • Dedicated benches for magnetic measurements • Better Planned MM programme on dipoles, resulting in proper anti-cryostat mounting on selected magnets • Greater OP Efficiency thanks to SMTMS additions and SSW Software efforts from OP Team SM18 Magnet Tests Review, February 06

  12. Tested Dipoles: 2005 • A total of 513 Dipole magnets were tested during the year 2005. These include ~ 9 % of repeat magnets (was 11% end 2004) SM18 Magnet Tests Review, February 06

  13. Tested ARC-SSS: 2005 • A total of 166 ARC-SSS magnets were tested during the year 2005. These include ~ 9% of repeat magnets (was 11% end 2004) Dip in number of ARC-SSS tested during July-Sep 2005 due to • Production stoppage - welding problems on ‘collarette’ • Special endurance tests on remaining ARC-SSS’s • ICS problems SM18 Magnet Tests Review, February 06

  14. Tested Special SSS : 2005 2 benches for Sp-SSS • A total of 25 Sp-SSS magnets were tested during the year 2005. (with 5 repeats) SM18 Magnet Tests Review, February 06

  15. Cold Tests in 2004 - 2005 SM18 Magnet Tests Review, February 06

  16. Cumulative Total: All Magnets SM18 Magnet Tests Review, February 06

  17. Summary 2005: Raw Cold Tests SM18 Magnet Tests Review, February 06

  18. Further Statistics • ICS Times • Cryo Times • Magnetic M’ments Times • Average no. of quenches

  19. Average Connect, Cold test & Disconnect times for Dipoles Extra tests (including MM) in Dec on Magnets 2202, 2259 & 3370 SM18 Magnet Tests Review, February 06

  20. Average Connect, Cold test & Disconnect times for ARC-SSS Extra tests on magnets SM18 Magnet Tests Review, February 06

  21. Extra Tests / delays on ARC-SSS magnets in July - Sep ‘05 SM18 Magnet Tests Review, February 06

  22. ICS: Average WAIT + Connection Time for MB & Arc SSS(always > 12 hrs) • ICS effort degradation • from summer 2005 • No of persons on shift • ROCLA support • Special rules on hours HIGHLY DESIRABLE that ICS IMPROVE ON CONNECT TIMES in 2006 !! SM18 Magnet Tests Review, February 06

  23. Cryo times for Dipoles in 2005 Cryo times for Dipoles in 2004 SM18 Magnet Tests Review, February 06

  24. Cryo times for ARC-SSS in 2005 Connection cryostat delays Delays due to life-time tests by cryo SM18 Magnet Tests Review, February 06

  25. Typical magnet test times (For the week starting 26th July 2005) ICS new connection problems Connection cryostat (B1) Fatigue tests ROBTC Reference Times • Light green : Connect (up to Cryo pump down)24 h • Blue : Wait + Cool down26 h • Ivory: Tests at Cold 36 h • Red : Wait + Warm up12 h • Dark Green: Disconnect12 h SM18 Magnet Tests Review, February 06

  26. Magnetic Measurement times for Dipoles in 2005 Tests with MM on Magnets 2202, 2259 & 3370in Dec On average, Magnetic Measurements take at least 20 hrs in addition SM18 Magnet Tests Review, February 06

  27. Average no of Quenches carried out - Dipoles Each Quench costs ~ 3 hrs (recovery time) SM18 Magnet Tests Review, February 06

  28. Average no of Quenches carried out – ARC-SSS Each Quench costs ~ 2 to 2.5 hours (recovery time) SM18 Magnet Tests Review, February 06

  29. Comparison of test times for various magnets in 2005 To complete the magnet tests programme, we have to sustain the fast testing rate for Dipoles and ARC-SSS and FOCUS our attention on Special IR-SSS issues which affect its test rates and to provide solutions to “accelerate”Sp-SSS testing to the required levels SM18 Magnet Tests Review, February 06

  30. IR-SSS Issues(To be addressed separately later) SM18 Magnet Tests Review, February 06

  31. Outlook for 2006

  32. Countdown to LHC :Projections for completion of Tests • Sustain the current test rates per benches allocated for Dipoles and ARC-SSS, ie.,bench allocation related overall output such that the global yield of everything is: ie. around 60 Cryo Magnets per month • Accelerate the testing rate for Sp-SSS to around 6-7 magnets per month Note: The figure assumes an average of ~10% of magnets which get tested again (repeats) SM18 Magnet Tests Review, February 06

  33. Magnet Test Statistics SM18 Magnet Tests Review, February 06

  34. Detailed Projections 2006 Assumption : Testing Time (Upto May-05) : Dipole -131 hrs;SSS- 143 hrs, After Jul-05, Dipole - 120 Hrs, ARCSSS - 115 Hrs, IR SSS - 10 days Magnets Tested 2005 Projections - 2006 SM18 Magnet Tests Review, February 06

  35. Detailed Projections 2006 Assumption : Testing Time (Upto May-05) : Dipole -131 hrs;SSS- 143 hrs, After Jul-05, Dipole - 120 Hrs, ARCSSS - 115 Hrs, IR SSS - 10 days Magnets Tested 2005 Projections - 2006 SM18 Magnet Tests Review, February 06

  36. Outlook 2006 –Facts & Figures for completion • Dipoles Number required = 1232. Number including 10% repeats = 1355 Can be completed by Nov 2006 • ARC-SSS Number required = 392 (including 32 IR-SSS which are not ‘Special’) Number including 10% repeats = 431 Can be completed by Dec 2006 • Sp-SSS Number required = 82 Number including 11% repeats = 91 Can be completed by Dec 2006, with 24 hours operation The above projection assumes • Desired bench configuration, with no bench breakdowns • No major delays due to magnet delivery and • No delays due to additional unforeseen tests ( e.g. fatigue in ‘05) SM18 Magnet Tests Review, February 06

  37. Contingencies • We have no formal contingencies in this ‘tight finish’ (remember we lost 1 bench for 1 month in Oct ‘05) • We have taken ‘liberties’ in considering DS being similar to MQ ARC-SSS • Our only fall-back is : • We will still have 24 hrs OP staff ( India + CERN) till end March 07 { Hence, NO SHUTDOWN JAN-FEB ‘07 in case of need } SM18 Magnet Tests Review, February 06

  38. Why Op Planning must be respected to maintain Momentum & Motivation • ICS turnover • Cryo ALLS turnover (& Experts too) • Indian Associate Collab. Limits • AB-Op Staff Limits & Rotation SM18 Magnet Tests Review, February 06

  39. Manpower CERN + IndiaNew & Experienced (2005) CERN FTE ~ 12 INDIA FTE ~ 14 (2006) CERN FTE ~ 6 INDIA FTE ~ 20 SM18 Magnet Tests Review, February 06

  40. Manpower-TotalNew & Experienced SM18 Magnet Tests Review, February 06

  41. CONCLUSION • An overview of the results of the SM18 Magnet Tests in 2005 has been presented, leading us to be cautiously optimistic about the outlook for 2006 • A PROJECTION chart, based on management’s goals of completing the tests programme so as to permit the eventual machine readiness for beam collisions in LHC by 2007 has been made • This projection envisages sustaining the current testing rates for Dipoles and ARC-SSS and an accelerated testing rate of Special-SSS’s. SM18 Magnet Tests Review, February 06

  42. IR-SSS Issues : Problems & Solutions • Outline • Chamonix -2005& how it was foreseen • What It Is All About • 4 Main Concerns • Way Forward & 3 Main Proposals • (including resolution of Technical & Organizational Issues) SM18 Magnet Tests Review, February 06

  43. from Chamonix Workshop Jan’05:Possible Concerns & Worries for installation • The testing of Insertion Region SSS is an uncharted territoryto date and we need to ensure we have sufficient time for these within the existing boundary conditions. • From our present limited experience, it takes us up to 1 week to modify the bench to permit IR-SSS mechanical & electrical connections. • 82 IR SSS are individually powered so one needs to provide at least the transfer function for powering & machine energycorrelationeven if detailed magnetic measurements are not done • IR-SSS also need special Magnetic test cycles • Logistics, Transport (avoid all issues that plagued Arc SSS in 2004) SM18 Magnet Tests Review, February 06

  44. Introduction: IR-SSS Tests in 2005 How was Testing Foreseen at startup in Jan 05: • 24 hr OP Team was Not Required to TEST the IR-SSS’s • 1 bench (D2) was designated for this work in hands of experts • Work restricted to normal hrs & no weekends SM18 Magnet Tests Review, February 06

  45. Introduction: IR-SSS Tests in 2005 How it turned out to be: • Issues of Cryo Priorities & Conflicts as well as in bench cohabitation • OP was requested to “HELP” ~ June 05 • Special OP Work Schemes had to be designed from July 05 to permit this within overall other constraints ( Who, How, Work hrs, Summer & CERN staff vacations planned etc) • 1 person per Mon-Fri week from AB-OP rotating in parallel with expert technicians, Experienced Indian Colleague in background for Tech & OP documentation preparation SM18 Magnet Tests Review, February 06

  46. Led to the ANALYSIS of the situation by the OPERATION TEAM in Oct 05 and Memoranda written highlighting the issues for IR-SSS Testing as well as associated Single-Stretch Wire Measurements (here, it is essentially a report of this analysis) • http://sm18-operation.web.cern.ch/sm18-operation/documents/Memo/Memo_S4_18Oct05.doc • http://sm18-operation.web.cern.ch/sm18-operation/documents/Memo/Memo_SSW_21Oct05.pdf SM18 Magnet Tests Review, February 06

  47. So What is it all about ?

  48. Comparison of Average Test Times for IR-SSS in 2005 Can we test the remaining IR-SSS : {59 + certain repeats}in the 11 months Feb-Dec ‘06? [ Of which at least 17 are deemed to need MM ] SM18 Magnet Tests Review, February 06

  49. Comparison of Test Times forall 3 magnet types in 2005 (hrs) SM18 Magnet Tests Review, February 06

  50. IR-SSS testing: what it’s about • A total of 114 Insertion Region (Matching and Dispersion Suppressor region) magnet assemblies integrated in Short Straight Sections -SSS • 114 SSS’s distributed into different types : • Magnet configuration • Magnet Geometry • Position in the ring • Powering & cryo regimes • 82of these SSS’s are individually powered • hence to be tested in a different powering & measurement regimes while the remaining 32(DS-MQ) can be tested similarly as an ARC-SSS(however we have not yet tested any of these 32). • These 82magnets are distributed into different types defined by the parameters listed above and are categorized as Special SSS (Sp-SSS from now on). SM18 Magnet Tests Review, February 06

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