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Second LHC Splices Review

Second LHC Splices Review. Work Organisation for LS1. Outline. What has to be done ? Main splices Other activities Organization chart and roles Planning Resources Conclusions. Work reported here is the continuation of the tremendous and detailed work done by F Bertinelli.

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Second LHC Splices Review

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  1. Second LHC Splices Review Work Organisation for LS1 Outline • What has to be done ? Main splices Other activities • Organization chart and roles • Planning • Resources • Conclusions Work reported here is the continuation of the tremendous and detailed work done by F Bertinelli Work Organisation for LS1 Second LHC Splice Review

  2. Second LHC Splices Review What has to be done …? To consolidate the superconducting circuits • Main splices in the arc • DFBA circuits (A Perin) • Replace cryomagnets • Consolidate connection cryostats • NB: Other activities not linked directly to SC circuits: PIMs, Helium level gauges, Y lines, DN200, … Work Organisation for LS1 Second LHC Splice Review

  3. Second LHC Splices Review Replace cryomagnets Work Organisation for LS1 Second LHC Splice Review Courtesy S Izquierdo

  4. Second LHC Splices Review Replace cryomagnets 14 cryodipoles, 3 SSSs Q7R3 High internal splice resistance [ ] Under assessment : Cryomagnets with wrong beam screens types Work Organisation for LS1 Second LHC Splice Review

  5. Second LHC Splices Review Replace cryomagnets Courtesy A Musso Cryomagnets coordination workspace : https://espace.cern.ch/cryomagnet-coordination/default.aspx Work Organisation for LS1 Second LHC Splice Review

  6. Second LHC Splices Review Consolidate connection cryostats Details in ECR: LHC-LE-EC-0003 • 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 Work Organisation for LS1 Second LHC Splice Review

  7. Second LHC Splices Review Installation of DN 200 To be installed during LS1 in 23, 45 (part), 78 & 81: About 600 units Work Organisation for LS1 Second LHC Splice Review

  8. Second LHC Splices Review Other interventions (not exhaustive) • Consolidation of SAM Helium level gauges and DN160 It 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) • PIMs (# 45 to be replaced) • Buckled during warm-up ≈ 18 (RF ball test) • Heavily damaged : ≤ 10 • Preventive replacements :+ Arc extremities 18/32 in baseline Work Organisation for LS1 Second LHC Splice Review

  9. Start at P5 / clockwise 5 4 6 SSS Cryo-dipole High inner splice Highest leak Electrical integrity issue Beam optics 3 7 DS Coll.(For mem.) SAM (He, DN160) Y-lines repair CC Consolidation / Inspection DN 200 installation Triplet braid (End of LS1 for radprot) Circuit and splices issues Spread all around : work on leaks, PIMs, 2 8 1 Goal : Special interventions completed before the train arrives : To be checked Work Organisation for LS1 Second LHC Splice Review

  10. Organisation Chart Long Shutdown 1 F. Bordry Consolidation of the superconducting circuits: JPh Tock Main arc splices cons. “The train” F Savary #52 Quality Assurance R Ostojic #39 Open/Close IC [DN200] A Musso #32 • 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 • Continuity • HV test • Sleeves cutting • BB surfacing • Shunt installation • Splice de-&resoldering (15%) • Beam lines • Cryogenics lines • Insulation vacuum ELQA TE-MPE N Catalan #23 Leak Test TE-VSC P Cruikshank #19 DFBA A Perin [#12 (TBC)] TIG welding S Atieh #14 Special interventions “SIT” N Bourcey #15 - Orbital & manual • Splices and BB • Cryomagnets exchange • Connect. Cryostat cons. • PIMs • Specific issues • Heavy NC 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 • Opening/ Closure of IC Partial and complete W bellows & ther. shields • Installation of DN200 Work Organisation for LS1 Second LHC Splice Review

  11. 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 Open/Close IC [DN200] A Musso #32 • Opening/ Closure of IC Partial and complete W bellows & ther. shields • Installation of DN200 Work Organisation for LS1 Second LHC Splice Review

  12. Detailed roles Main arc splices cons. “The train” F Savary #52 • Was covered in details by previous presentations • Ensure coordination from opening to readiness for reclosure of M sleeves [Individual IC] • Sleeves cutting • BB surfacing • Shunt installation • Splice de-&resoldering Work Organisation for LS1 Second LHC Splice Review

  13. Detailed roles • Was covered in previous slides • Polyvalent team • Will intervene on heavy NC to avoid slowing down the work of the main train DFBA A Perin [#12 (TBC)] Special interventions “SIT” N Bourcey #15 • Cryomagnets exchange • Connect. Cryostat cons. • PIMs • Specific issues • Heavy NC • Splices and BB • See presentation by A Perin tomorrow • Still to be defined Work Organisation for LS1 Second LHC Splice Review

  14. Detailed roles • The QA manager will: • Coordinate QA activities • Ensure that an adequate level of Quality Assurance is applied, especially in terms of traceability (MTF) and documentation • Ensure a timely management of the non-conformities, minimizing the impact on the overall schedule • Ensure 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 Assurance R Ostojic #39 • Electrical QC: C Scheuerlein #17 See presentation • Welding QC: JM Dalin • Operators, tooling, procedures qualification • QC 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 inspection • Protection of critical surfaces • -QA manager supportTooling, inspection, reporting Work Organisation for LS1 Second LHC Splice Review

  15. Planning Rate: 4 weeks for each activity so 53 IC/week Dimensioned to 60 IC/week: 10% margin Remember : Series installation at 30 IC/week ! Courtesy P Fessia Work Organisation for LS1 Second LHC Splice Review F Bertinelli @ 1st splices review

  16. One typical sector Work Organisation for LS1 Second LHC Splice Review Courtesy K Foraz

  17. Global Planning • Preliminarypowering tests • Warm-up • Opening • Splice consolidation • (incl. internalleak tests) • Closure • Leak tests (Ins vacuum) • Preparation for cool-down • Cool-down • ELQA@cold • Powering tests 14 months Consolidation of main splices in 4 sectors in parallel (13 km) 1st sector cold tested (2nd one), one year after the start of LS1 ! Work Organisation for LS1 Second LHC Splice Review Courtesy K Foraz

  18. Resources • 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) Work Organisation for LS1 Second LHC Splice Review

  19. Resources > 60% have to be trained ! Some rotation in staff (Collaborations) > 200 individuals Challenge to have this in parallel with work in tunnel Work Organisation for LS1 Second LHC Splice Review

  20. Second LHC Splices Review 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 Work Organisation for LS1 Second LHC Splice Review

  21. Work Organisation for LS1 Second LHC Splice Review

  22. Spare slides Work Organisation for LS1 Second LHC Splice Review

  23. Work Organisation for LS1 Second LHC Splice Review Courtesy S Izquierdo

  24. Resources status for splices train More needs to supervise PAEC : 2 trained for open/closure to identify and 1 extra for cutting Work Organisation for LS1 Second LHC Splice Review

  25. Resources for Other activities Work Organisation for LS1 Second LHC Splice Review

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