1. Workshop on Appraisal of Disassembled Magnets: Lessons learned March 17 th, 2005 Boundary Conditions-Technical Specification Jos Vlogaert

2. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 2 Boundary Conditions-Technical Specification COLD MASS STATUS on MARCH 16 th DELIVERED CRYOSTATED COLD TESTED RETURNED CMA01 195 149 144 5 CAM02 145 120 117 6 CMA03 293 254 233 5 TOTAL 633 523 494 16 % of Delivered 83 78 2.52

3. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 3 Boundary Conditions-Technical Specification REMINDER of CONTRACTUAL ASPECTS of ACCEPTANCE/REJECTION of COLD MASSES COLD MASSES are REJECTED and RETURNED to the CMA because they did not pass the: “PROVISIONAL ACCEPTANCE at CERN” as specified in Chapter 9 of the “Technical Specification for the Supply of the Cold Masses of the S.C. dipole Magnets for the LHC Collider” Ref: LHC-MMS/98 Rev.2.0 and its Annexes

4. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 4 Boundary Conditions-Technical Specification 1.The acceptance criteria for the Acceptance Tests at Room Temperature The Acceptance tests at room temperature performed at CERN are the same as specified for the final tests at the Contractor’s premises as described in Annex B2 of the Techn. Spec.: Inspection and Test Plan for the Dipole Cold Mass The ITP contains 6 Positions for the Completed Cold Masses: Position 20: Geometry Measurement Position 21: Warm Magnetic Measurements Position 22: Safety Test (inspection of welds)

5. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 5 Boundary Conditions-Technical Specification Continued….. Position 23: Leak Test Position 24: Pressure Test Position 25 (a to p) : Final Electrical Tests The Cold Masses shall successfully pass all the tests at room temperature before the performance of the provisional reception tests at liquid helium temperatures.

6. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 6 Boundary Conditions-Technical Specification 2.Acceptance Test at liquid helium temperature. These tests are performed with the cold mass in a helium bath at 1.9 K or about 4.4 K and the coils in the superconducting state. 2.1 Leak Test To verify the cold helium leak-tightness across separate volumes of the cold mass: -cold mass to insulation vacuum -cold mass to beam vacuum -heat exchanger to insulation vacuum Should these tests show that cold leaks originate in welds and parts that are the responsibility of the Contractor, he will, at his expense take appropriate corrective actions.

7. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 7 Boundary Conditions-Technical Specification 2.2 Integrity and impedance of instrumentation and power circuits The list of the items to be tested, the tests to be carried out and their acceptance criteria are presented in Table 9.2.2 of the Techn. Spec. Cold Masses that do not withstand these tests are deemed to present faults due to poor workmanship and will be returned to the Contractor at his expense for implementation of corrective actions. The Contractor must seek CERN’s Approval before undertaking any corrective action in view to re-submitting the returned cold mass to the cold acceptance tests.

8. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 8 Boundary Conditions-Technical Specification 2.3 Performance of Quench Heaters. Before powering the dipole magnet to ultimate field, it must be ascertained that the protection system is in working order. Cold masses equipped with quench heaters showing anomalous performance will be returned to the Contractor at his expense for implementation of corrective actions.

9. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 9 Boundary Conditions-Technical Specification 2.4 Quench Performance Tests. As in technical specification: 1)The cryo-dipole shall reach the ultimate field (provisionally 9.0 T) after no more than eight quenches. 2)Cryo-dipoles that reach the ultimate field with a number of quenches between three and eight may be submitted to a thermal cycle after which they shall reach the field of 8.6 T without any quench. 3)The provisional acceptance of cryo-dipoles which reach the ultimate field after more than eight quenches will be temporarily suspended by CERN. If their number is limited to a few units, CERN will eventually declare their provisional acceptance, provided that they have satisfied the acceptance criterion 2)

10. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 10 Boundary Conditions-Technical Specification Continued …. 4) Cryo-dipoles that do not satisfy the acceptance criteria 1), 2) and 3) for reasons which can be traced back to manufacturing faults or damages due to transport, shall be replaced within six months at the Contractor's cost.

11. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 11 Boundary Conditions-Technical Specification Backlog Criteria: Case A: the cold mass reaches 8.4 T within two quenches: the cold mass is accepted and tests are stopped. Case B: the cold mass reaches 9.0 T within 9 ramps (8 quenches): the cold mass is accepted and tests are stopped. Case C: if case B is not fulfilled: the cold mass shall be submitted to a thermal cycle (second run) with quench location.

12. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 12 Boundary Conditions-Technical Specification Continued….. C1: if the first quench after thermal cycle is above 8.4 T: the cold mass is accepted and tests are stopped. C2: if the second quench after thermal cycle is above 8.6 T: the cold mass is accepted and the tests are stopped. C3: in remaining cases there is a probability that the cold mass be rejected: do at least five quenches. (apart when the quench location was present in the first run and localization was done for at least six out of the nine quenches. In this case only two quench locations are requested)

13. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 13 Boundary Conditions-Technical Specification List of Disassembled Magnets: % % % of Delivered Electrical Training NCs Performance CMA01 :5, 19, 26, 126, 143 2.62.52 2.09 CMA02 :2, 13, 23, 32, 49, 69 4.14 2.07 2.07 CMA03 :4, 136, 143, 224, 234 1.75 1.05.70 Total 2.53 1.11 1.42

14. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 14 Boundary Conditions-Technical Specification From the previous slide one can see that magnets were rejected and returned to the manufacturer for two different reasons: -Electrical Non Conformities detected, after delivery of the Cold Mass to CERN, before or during Cold Test. -Unacceptable Training Behavior.

15. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 15 Boundary Conditions-Technical Specification REMINDER of “PERFORMANCE BONUS CLAUSE” For CMA01: If a Cold Mass requires 2 training quenches to exceed the ultimate field of 9.0 T a performance bonus corresponding to 0.5 % of the unit price for the Cold Mass concerned shall be due If a COLD Mass requires 1 training quench to exceed the ultimate field of 9.0 T a performance bonus of 1 % of the unit price of the Cold Mass concerned shall be due If a Cold Mass exceeds the ultimate field of 9.0 T without any training quench, a performance bonus corresponding to 1.5 % of the unit price of the Cold Mass concerned shall be due.

16. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 16 Boundary Conditions-Technical Specification For CMA02 and CMA03: If a Cold Mass requires less than 3 training quenches to exceed the ultimate field of 9.0 T a performance bonus of 1 % of the unit price of Cold Mass concerned shall be due.

17. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 17 Boundary Conditions-Technical Specification BONUS EARNED TO DATE (PERFORMANCE BONUS CLAUSE is applied to date on fully tested COLD MASSES of the SERIES CONTRACTS) FULLY TESTED CMs Number of BONUS MAGNETS CMA01 29 19 CMA02 27 7 CMA03 108 54 Total 164 80

18. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 18 Boundary Conditions-Technical Specification

19. March 17th, 2005 Workshop on Appraisal of Disassembled Magnets: Lessons Learnt 19 Boundary Conditions-Technical Specification