1. Status of SMACC-QA 1.Recently resolved issues 2.Update from QC teams 3.Statistics S56 and S67 4.Auditors findings 5.4th Splice Review – 22/24 July Ranko Ostojic 28 June 2013

2. Inspection of ultrasound welding Change of ultrasound welding machine settings from CP=0.6 to 0.8 in 2009. Gauge used for inspection has 3.1 mm width and is too small for CP=0.8. Based on measurements of recently produced welds, modification of gauge width to 3.4 mm proposed and accepted. Test procedure (LHC-QBBI-TP-0003) updated.

3. Inspection of the shunts Visual inspection of the top and bottom shunts modified (criterion of continuity of fillets suppressed) New version of the test procedure released (LHC-QBBI-TP-0007).

4. Insulation boxes The problem

5. Insulation boxes Inspection procedure New inspection procedure was discussed, updated, went through the EDMS approval process and released. The procedure defines the role of the LMF-QC and ELQC teams in the inspection process at different times, when access to the box extremities differs due to presence (or lack) of Eccobond filling and compression tooling. The MME-welding team rechecks the clearance box-M-flange on the bellows side before welding.

6. Insulation boxes Modification of baseline All new splices will be realigned before soldering. Significant number of boxes will have rounded corners at the extremities (wall thickness reduced from 3 mm to 1.3 mm). New version of the assembly procedure (LHC-QBBI-TP-0024) in preparation.

7. Insulation boxes The standard repair In case of reduced clearance: Corners cut back so that the box cover is outside M-flanges. U-pieces (VP310), recovered from the existing insulation, reinstalled on busbars. The U-pieces are glued to the busbars and blocked by the box covers. They mechanically protect the busbars (VP310 is resistant to high temperatures) and improve electrical insulation.

8. Revisiting geometrical acceptance criteria Global alignment gauge Geometrical constraints of the insulation box were reanalyzed. The dimensions of the gauges are confirmed.

9. Revisiting geometrical acceptance criteria Height gauge A new type of gauge for checking the bottom surface of the busbars was tried out but with inconclusive result. The dimensions of the present C-gauges are confirmed.

10. Update from QC teams ICIT Resurgence of cases of equipment damage: – temperature sensor wires broken during diode opening – nested bellows scarred during M-line cutting ELQC (details in LSC#13 of 21 June) Investigations ongoing on the heavily damaged SC cable found in a quadrupole segment with an R cold outlier. ELQA Frequent test disruptions due to poorly insulated clamps. High humidity in the tunnel a concern. Up to now, only “technological” shorts. Frequency of ELQA tests: every day or every two days? Perform tests every day till completion of S56, then review procedure and frequency of tests. WELD DN200 weld inspections proceeding well. VAC M-leak checks yet to start when first vacuum subsector is ready.

11. Statistics QC of existing splices Sector 5-6 Final Inspected splices 1272% Conform95675.2 Non-conform31624.8 R8302.4 Splice alignment574.5 Splice height17814.0 Deformed lip151.8 Splice width60.5 Flange exchange221.7 Geometrical defects 20.8%

12. Statistics QC of existing splices Sector 6-7 27 June 2013 Inspected splices 720% Conform50470.0 Non-conform21630.0 R89713.5 Splice alignment466.4 Splice height679.3 Deformed lip40.6 Assembly20.2 Geometrical defects 16.3% 57% of S6-7

13. Auditor findings Cleanliness of surfaces is a standing concern Traces of glue and Kapton on machined surfaces and machining tools. Efficiency of cleaning (oxidization, glue) before soldering? Traceability of solder?

14. 4th Splice Review 22/24 July 2013 Purpose: – to review the quality of the consolidation activities of the LHC superconducting circuits and magnets (SMACC) – to analyse the trends, and to consider any changes in the procedures that may be required following the consolidation of the first sector(s).

15. 4th Splice Review - Agenda Monday 22 July 09:0001:00Committee training for tunnel tour 10:0003:00Committee tunnel tour 13:00Lunch 16:0001:30Committee preparation session 17:30Adjourn for the day

16. 4th Splice Review - Agenda Tuesday 23 July 08:3000:10IntroductionJ-P. Tock 08:4000:20Status of SMACC activitiesJ-P. Tock 09:0000:20Overview of SMACC-QAR. Ostojic 09:2000:10Discussion 09:3000:20Coffee Status of production activities and internal QC 09:5000:30The splice consolidation trainF. Savary 10:2000:20Welding activitiesS. Atieh 10:4000:20Discussion 11:0000:15Special intervention teamN. Bourcey 11:1500:20DFBA consolidationA. Perin 11:3500:25Discussion 12:00Lunch QC of consolidation activities 14:0000:15IC quality controlD. Bodart/C. Garion 14:1500:30Local splice quality controlCh. Scheuerlein 14:4500:20Weld quality controlJ-M. Dalin 15:0500:20Discussion 15:2500:20Tea 15:4500:20Quality control of electrical circuitsK. Dahlerup-Petersen 16:0500:20Quality control of vacuum systemsP. Cruikshank 16:2500:15Report from CERN AuditorsS. Feher 16:4000:20Discussion 17:0001:00Committee closed session 18:00Adjourn for the day 19:30Dinner

17. 4th Splice Review - Agenda Wednesday 24 July 08:3000:30Committee closed session 09:0003:00Response to reviewers questions, discussion 12:00Lunch 14:00Committee closed session 17:00Preliminary conclusionsJ. Strait

18. Summary A number of inspection criteria were re-discussed and the procedures updated. – A significant number of QC steps of the “train” (except welding) have been performed with updated procedures. In S56, 25% of the splices had to be redone, 20% due to geometrical defects. In S67, 30% of the splices are defective, 13% due to electrical defects (R8). Geometrical defects continue to dominate. The criteria for geometrical defects were re-examined and are confirmed. – A similar number of defective splices may be expected in other sectors. Heavily damaged SC cable was found in a quadrupole segment with an R cold outlier. A strategy of repair must be clarified before other defective splices of this type are opened. Protection of IC components and cleanliness during work remain a major concern.

19. Statistics Critical NCRs OpenClosed LMF train Internal QC-2 ICIT21 ELQC650 WELD-- ELQA-1 VAC115 Sector 5-6 27 June 2013