Title Author Date

Fourth LHC Splices ReviewQuality Assurance ReviewStatus of SMACC activitiesUpdate since last review: Preceding activities Progress dashboards and broken line planning Organisation chart update Weekly meetingS(Main) issuesSafetyConclusions

22nd-24th of July 2013Fourth LHC Splice Review On behalf of a large competent and motivated team

1/34J.Ph. Tock1Fourth LHC Splices ReviewQuality Assurance ReviewStatus of SMACC activities22nd-24th of July 2013Fourth LHC Splice Review 15 %Done20 minutes to summarize > 100 000 hours of work in the tunnelA factor > 300 000 (The speed of light in km/s)1 minute accounts for 5 000 working hours

2/34J.Ph. Tock222nd-24th of July 2013Fourth LHC Splice Review Preceding activities

Mock-ups for test and training of new colleagues and collaborators and continuous process controlComponents (30000 shunts, 6000 insulation boxes, 12000 pockets) and tools (cutting and (de)soldering machines, jigs have been procured (Still on-going for some components and extra tooling)

3/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

Courtesy F Bordry4/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Preceding activitiesObjective:Identify possible limitations (other than the splices) on the superconducting circuits for operation at 7 TeV, that could eventually be fixed during LS1

Meetings were organized to prepare this powering campaign

A document was written, which contains the parameters to be used

The tests were started on Sat. 16th February as soon as the last beam of 2013 was dumpedPowering tests at the start of LS1Courtesy F Bordry, M Pojer 5/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Preceding activitiesCourtesy F Bordry, M Pojer 540 circuits were tested, including IPQs, IPDs, ITs, 600 A and some 120 A circuits, (almost) all powered up to 7 TeV equivalent current773 successful tests were executed in 10 daysMore than 1300 tests performed (including repetitions due to quenches or other kind of faults)Powering tests at the start of LS1

All circuits reached the nominal 7 TeV equivalent current, butRD3.L4, commissioning stopped at 5784 A (vs the nominal 5860 A) due to long (yet monotonous) training --> stopped at 6.9 TeV, but can be possibly pushed furtherRQ5.R2 I_Nom reduced to 4100 A from 4310 A (OK for 7 TeV)RCBYHS5.R8 Tested successfully to 20 A, but cannot be powered up to the nominal 72 A (a similar failure was observed on the same corrector in 8L and that was replaced with a normal conducting magnet)RQTL11.R5B1 I_Nom reduced to 450 A from 550 ARQTL11.L6B1 I_Nom reduced to 350 A from 400 ARCSSX3.L1 I_Nom reduced to 60 A from 72 ARQTL9.R3B2 I_Nom reduced to 425 A from 450 A

6/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Preceding activitiesCourtesy M BednarekRB.A12 double insulation fault to GNDRCS.A56B2 insulation problem, DFBAK

A long metallic piece (4.5cm) touched one of the half moon and the diode tube connected to ground

ELQA tests (See further presentation)7/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Preceding activities

8/34J.Ph. Tock

22nd-24th of July 2013Fourth LHC Splice Review SMACC Kick-off (3.04.2013)

9/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review OK to openWork sequence and status8 sectorsOpen ICs> 4 sectorsInstall DN200 50%Open M sleeves 3 sectorsELQC(old splices) 2.5 sectorsUndo / Redo splices>1 sectorELQC(new splices)> 1 sectorMachine Cu

1.5 sectorsELQCafter Cu mach. 1.5 sectorsInstall shunts

1.3 sectorsELQCafter shunt 1.3 sectorsInsulate splices

> 1/2 sectorWeld M

1/4 sectorLeak test M

This weekClose IC

Next monthFinal LT

Sept 13Consolidate Q diodes 1/4 sector10/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Overall schedule

Completed in the 8 sectors:ELQA at coldWarm-upELQA at warmOK to openFirst opening in 56 on 8.04.13

First M opening on 18.04.13

First shunt soldering on 24.04.13

First M welding on 8.05.13

First consolidated diode 12.07.1311/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Overall schedule

Whats next ?First subsector just delivered to VSC for M leak test (22.07.2013)Closure of first vacuum subsector (S56) in August 2013Final closure of 56 and LT in autumn 2013Pressure test in Jan 2014 in 56 &67First powering tests in S67 in June 2014!!

Rehearsal of new thermal shield installation in 56Time in first sectors to solve NCs but coactivity will have to be managed12/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

Courtesy K Foraz13/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

Courtesy K Foraz14/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

SMACC is divided in 4 main activities:13 kA Arc SplicesSpecial InterventionsDFBA consolidationsDN200

15/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

16/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

A few days ahead of schedule thanks to the early start of individual activities even if not the most efficient in terms of resourcesbut it allowed to identify issues ASAPSlope is too small but mainly due to 2 issuesHigher number of splices to redoInterference between insulation box and M linesShould become nominal in the coming weeks17/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

Some sectors are delayed but no impact on next activitiesOverall rate is well within forecastSome staffs are reinforcing ELQC and DN20018/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

Started ahead of scheduleOnly 3 ICs affected by NC are missing in 56Still ahead of schedule butWe start to see the last 10% effectThe rate is not YET nominal

19/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

20/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

Late wrt baseline due to Non availability of ICs to weld because of interference between insulation system and M linesOn the critical path

21/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

Start was delayed due to sectors unavailabilityRate is now OKSo far SIT is correctly dimensionedResources should be free for NC from Autumn 2013

22/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

Start was a little bit ahead of scheduleDelay due to issue with the broaching procedureSome expert resources are criticalOvertime doneTeam is under reinforcement for less critical tasksExamining the rate, should be able to catch up by the end of the year23/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review Dashboards

Start was delayed due to sectors unavailabilityDifficulties appeared at beginning of the activities in the tunnel (now solved) Sequence is fully validatedOvertime doneNo impact on general schedule and even with the delay, it should not interfere with the activities on the splicesPart of the resources available at the end of DN200 installation will be redirected towards other activities24/34J.Ph. Tock

22nd-24th of July 2013Fourth LHC Splice Review SMACC Organization Chart+6 for more splices to redo+2 for more splices to redo25/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review A typical weekMonday 8:30LS1 Management meetingMonday 15:30CSI On Off Site Meeting 1

Tuesday 14:00SMACC QA meeting 1

Wednesday 13:45SMACC meeting (Now 1/2 or following needs)Wednesday 15:30CSI On Off Site Meeting 2

Thursday 10:00SMACC QA meeting 2

Friday 10:00LS1 Committee (1/2 with SMACC status report)Friday 15:30CSI On Off Site Meeting 1

+ Daily coordination via WISh, emails, phone calls+ Ad-hoc meetings when necessary (Splices Task Force, TETM,)+ Visit in the LHC tunnel (AManyAP)

Presence of responsible operators on worksite almost 100%Allows reactivity based on correct information26/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review IssuesHigher number of splices to redo (> 15%) [1/2]Sector56677881Measured100%100%9%*8%*To redo25%30%25%35%*Could be biased: DS zones, SSS500MachiningSolderingInsulationSpliceProduction DevelopmentS #1: Straighten out the splice S #2: Adapt the shunts on the bus bar profile #1 S #3: Adapt the shunts on the bus bar profile #2S #4: Define a curved shunt profile S #5: By pass the bus bar local deformation S #6: By pass the bus bar global deformation S #7: De-solder and redo the splice Analysis and summary by Max Duret, TE-MSC-LMF27/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review IssuesHigher number of splices to redo (> 15%) [2/2]Conformity with ELQC criteria is mandatory to allow installation of the shunts in nominal conditions (Redundancy)

The only validated procedure NOW (and for the next months) is to unsolder/resolder the splices

To meet the quality requirements and keep the schedule, extra resources are needed for production and QASome staff temporarily available are redirected to un-/re-soldering teamsExtra FSUs are joining and are under trainingThe development a new more tolerant shunting procedure was assessed and not retained:Same quality level needs to be guaranteedRequires a (accelerated) validation processLikely to be more time consumingExpert resources were necessary during a critical phase28/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review IssuesInterference between consolidated insulation system and cryogenics pipes preventing welding of M Sleeves

Issue was identified, analysed. Several solutions proposed and comparedStrategy defined and endorsed on 12.07Under implementation with extra resources

Courtesy S Atieh, M Duret, F Lackner, H Prin, F Savary, 29/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review IssuesDFBA BroachingIssue was analysed and reproduced in the workshopProcedure and tooling were improved and validated on a mock-upSplices were redone and checkedBroaching restarted (> 1 month delay)Courtesy D Etiembre, A Lees, A Perin, R Principe

Operations stopped in the tunnel

In workshop, at 318 bars (Now pressure limited at 150 bars)

30/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review IssuesOverheated cableIdentified in an outlier segment at coldWas desolderedAnalysis on-goingNumber of spare magnets is limitedWill be treated in a dedicated WG next week (not THE priority)

31/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review * A few accidents* One directly linked to work (Non long term consequences)* Mainly during displacement (Driving, biking, walking,)

Reinforce use of PPEReinforce respect of proceduresContinue to limit schedule pressure on the operators

Safety

32/34J.Ph. Tock32

Quality

Safety > Quality > Schedule#/253322nd-24th of July 2013Fourth LHC Splice Review Concerns:Quality is given priority over schedule and budget; Finding extra adequate resources is difficultOperators should continue to be shielded from the pressure of the scheduleLast 10% effect starts to appearWorksite extends now over about > 10km! Supervision is a challengeConclusionsConcluding remarks: Continuous care has to be given to safetySMACC is ahead of schedule thanks to an as early start as possible strategyIssues are encountered and solved one by one thanks to competent and motivated staff and to the support of the managementThe principle of giving priority to quality over schedule and budget should remain. Integrating new resources is not immediateMargin on DFBA schedule has been eaten up, watched closelyThe supervision of such a long worksite is challenging34/34J.Ph. Tock3422nd-24th of July 2013Fourth LHC Splice Review Fourth LHC Splices Review35/34J.Ph. Tock3522nd-24th of July 2013Fourth LHC Splice Review

36/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

37/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

38/34J.Ph. Tock22nd-24th of July 2013Fourth LHC Splice Review

39/34J.Ph. Tock