2. SMACC Eighteenth report [20 min] 07/02/2014
Jean-Philippe Tock (TE-MSC)
On behalf of the SMACC project

3. Activities since last LSC (24/01/2014)
Arc splices installation
By Activities
By sectors
SIT
DFBA
Dashboards
Specials
Quadrupole diodes
Overheated splices
Activities for the next 2 weeks
Conclusions

4. SMACC Main activities for the last 2 weeks
Sector 56 :
Final leak test and surface work on DFBAK SHM
Investigation on dipole diodes
Sector 67 : Pressure test successfull
Purge, ElQA, Flushing (CRG/MPE): Not formally SMACC project
Sector 78 (Not priority)
Work on NC
Work on DFBAO at the surface
Sector 81 (Priority)
Complete the M leak tests of non problematic Ics
Progress on IC closure
Sector 12
Progress on M lines rewelding
Start M leak test
Sector 23
Progress on the installation of electrical insulation
Work on overheated splices
Complete preparation for Q diodes consolidation
Sector 34
Complete splices unsoldering
Installation of shunts
Sector 45
Start desoldering and resoldering of splices
All is reclosed but the IC with DFBAK,
DFBA SHM back in place
Insulation vacuum leak tested on >90% of S56
Diodes exchanged, to be reclosed
From last LSC ( )   
ElQA before flushing on-going… So far so good
> 98% M lines leak tested, > 95% reclosed, Ins vac test started  
SHM disconnected and at the surface 
> 90% M lines are leak tested 
> Half reclosed
> 75% welded 
QDiodes consolidation restarted 
> 30% leak tested 
>90 % done 
On-going, see later 
Stopped (See S12) 
Completed 
On-going, ≈ 90% done 
On-going, First shunts are installed

5. SEQUENCE AND STATUS Completed Completed Completed Completed Cancelled
Install DN200
Completed
100 %
Completed
Completed
Completed
OK to open
Open ICs
Open M sleeves
8 sectors
8 sectors
8 sectors
Undo / Redo splices
ElQC (new splices)
Cancelled
≈ 7 sectors
ElQC (old splices)
Machine Cu
ElQC after Cu mach.
≈ 7.5 sectors
> 7 sectors
≈ 7 sectors
Consolidate Q diodes
Restarted, see later
≈ 4.9 sectors
Install shunts
ElQC after shunt
Insulate splices
Weld M
Leak test M
Close IC
Final LT
> 6.8 sectors
> 6.5 sectors
≈ 6 sectors
> 4.7 sectors
> 4.2 sectors
≈ 3.5 sectors
≈ 2 sectors

6. Operator responsible : JM Hubert
Last M line opening (S45)
6th of February 2014
Operator responsible : JM Hubert
Pictures by M Struik

7. SMACC Progress report by activity
Desoldering / Resoldering: Completed in about 7 sectors equivalent 78 78
Still OK
Desoldering is completed in S34
About one week margin built wrt to Cu machining
Desoldering should be completed by end of February
Courtesy H Prin

8. SMACC Progress report by activity
Shunts are installed in ≈ 6.8 sectors-eq (ICs ≈ 85%)
Almost completed in 23
2 weeks ahead of schedule
Mind the last X% effect
Starts to saturate
9 Ics remains in the 6 first sectors
Starts in 45, not really good news
Shunt weekly installation rate (4 weeks sliding average)
*Estimate for W6

9. SMACC Progress report by activity
Insulation box: Installed in almost 6 sectors equivalent 92
(4 weeks sliding average)
*Estimate for W6
Baseline recovered
Only 24 ICs left in 6 first sectors (<2 %)
Buffer of >3 weeks wrt welding
Courtesy H Prin / G Maury

10. SMACC Progress report by activity
M Welding : Almost 1000 ICs welded, > 4.7 sec-eq:
Routinely 12 ICs/day
Work concentrated in 1 sector
Leaks investigations (See next slide)
As presented LSC
18 51
17 ICS behind forecast
(Eq to < 2 days ; Recovered in <2 weeks)
11 34

11. SMACC Progress report by activity
M Welding : Investigation on leaks: 4 leaks found Dec-13 (2 in S78 / 2 in S81)
Investigations are completed
Repair procedure to be applied in 78 defined, requires flange replacement (Cut of SC splices)
Leaks localised after heat treatment of 950 °C / 2 hours
QQBI.25R8 M1L
Leak rate mbar.l/s
Position 6H opposite to the weld seam in the base material of the flange.
Magnet HCLQOAO001-CR000095
Findings:
Numerous sulphides
No imperfection on the weld
Macro-inclusion at leak location
AISI 304 grade type with high S content (possible free machining grade)
QBBI.A27R8 M1R
Leak rate mbar.l/s
Position 3H opposite to the weld seam in the base material of the flange.
Magnet HCLBALA000-IN001059
Findings:
No imperfection on the weld
Macro-inclusion at leak location
Chemical composition analysis: on-going
Flange base material: Numerous sulphides
Risk of other cases like this
Inventory of cold masses produced in the same time period
No systematic replacement
Procedure to apply in similar cases is defined
Immediately apply it in case of such leaks are identified
Courtesy S Atieh / A Gerardin (EN-MME)

12. SMACC Progress report by activity
M sleeves leak testing : (889 ICs) are leak tested (> 4 sec-eq)
Following the M lines rewelding
About 1 month behind schedule
Under recovery as for the M welding
Courtesy P Cruikshank / L Mourier

13. SMACC Progress report by activity
Reclosure of interconnections : ≈ 3.5 sec equivalent are reclosed
Work in 2 sectors, mainly 81
On the baseline
OK with the modification of the thermal shields, just in time

14. SMACC Progress report by activity
Final leak test: Almost 2 sec equivalent completely validated
3 weeks to have results after repumping
S56: only DFBAK subsector remains
S67: fully validated
S78: 1 subsector validated, 11 under test (out of 14)
S81: 3 subsectors under test
About 4 weeks behind schedule

15. SMACC Progress report by activity
Final leak test: Leak discovered on DN200
Two leaks discovered on first subsector in 78
Repair procedure for the weld is likely OK
First time we see a leak in the material of the DN200 flanges
Repair procedure to be defined

16. W6 : He spill test during the nights (Access restrictions)
SMACC Sector 67
ElQA is on-going
To come:
Flushing
ElQA
Campaign to fix NCs (leaks, thermometer, possible short circuits in diodes, ?)
beginning of March 14
SMACC Sector 45
W6 : He spill test during the nights (Access restrictions)
First shunts installed
W7 : Reopening of the ICs that were temporarily reclosed

17. SMACC Progress report by sector
Main activities are :
Leak test of M lines
Reclosure of IC
Rate is OK with baseline forecast provided that almost continuous work
Main activities are :
The welding of M lines
Leak test of M lines

18. SMACC Progress report by sector
Main activities are :
Installation of electrical insulation > 90% completed
Work on overheated splices (More info in next slides)
Consolidation of Q diodes
Main activities are :
Splices redoing (Almost completed)
Cu machining
Shunt installation
Preparation of insulation

19. SMACC Dashboards Opening is completed
Shunting is ahead of schedule but will slow down (Difficult cases ahead)
The installation of insulation boxes has recovered the baseline
Welding and M leak test rates are more than required to recover baseline schedule
Reclosure: On baseline, nominal rate achieved
Insulation vacuum leak test : To follow-up, one sector equivalent under test

20.  Completed
New
New
New
New
 Completed

21. SMACC Progress report SIT
Team members are partially reinforcing the train and the DFBA activities
Activities linked to NC and overheated splices
Intervention on triplet braids has started on the two triplets at P2
Courtesy N Bourcey, S Le Naour

22. SMACC Progress report SIT : Interventions on triplets braid
Q1R1/Q1L5: Install braids (2009)
Q1L1/Q1R5: Remove braids (LS1)
Q1L2/Q1L8: Remove braids (On-going at L2) Q1R2/Q1R8: Install braids (On-going at R2)
D1L2/D1L8: Remove braids on DFBX side D1R2/D1R8: Remove braids on arc side
Consolidation of triplet braids
On-going at P2 (Supervised area)
Rehearsal for the procedures according the ALARA principle
Courtesy N Bourcey, S Le Naour

23. SMACC DFBA 94 / 135 splices consolidated (70%)
work completed on 4 DFBAs.
129 /135 splices accessible (96%)
Just in time for the splicing team
Courtesy A Perin

24. SMACC DFBA Repair of short on pigtail #6 @ DFBAO
Common effort of TE-MSC, TE-MPE, EN-MME, TE-CRG
Location of insulation problem (TE-MSC)
Pigtail after removing iinsulation(TE-MSC)
Pigtail being repaired (TE-MSC)
Repaired insulation
High voltage tests (TE-MPE)
Courtesy A Perin, R Principe

25. SMACC DFBA Specific support at DFBAL2: NC 1329774
Common effort of TE-MSC (CMI and LMF), TE-CRG
Splices were unsoldered to avoid stressing them
Badly positioned spider
Badly positioned spider removed
New support in position
Courtesy A Perin, A Vande Craen

26. SMACC Dashboards Decreasing delay  Delay stable Arc splices:
Baseline: 69.3 % (67.8 %)
Completed: 64.9 % (63.9 %)
Delay (24) days
Baseline: 70.6 % (66.5 %)
Completed: 70.1 % (64.4 %)
Delay 2 (7) days
Decreasing delay
 Delay stable
Arc splices:
Rates are stable
All activities are still on-going
Trend should remain in the next 1-2 months
Main delay is in S12
DFBA: Ahead of the new baseline

27. SMACC Dashboards Progress: Baseline: 71.8% (67.8 %)
Completed: 68.0% (63.7 %)
Delay 13 (15) days
Dercreasing ; Δbaseline <≈ Δcompleted

28. SMACC Quadrupole diodes (1/2)
Quadrupole diodes : Reminder of the consolidation
Courtesy L Grand-Clement, R Moron –Ballester, F Savary

29. SMACC Quadrupole diodes (2/2)
Quadrupole diodes : Production
Restarted thanks to a partially conform delivery of supplier 1 !
Sector 12 is completed but one NC case
Sector 23 is restarted, components OK up to mid of 23
With delivery of supplier 3 expected in the coming days, OK up to 85% of S23
Impact on welding is minimum, no impact on other activities so far
Could have large impact on VSC and CRG
Plates manufacturing launched with a 4th supplier via main workshop (Thanks to EN-MME) with material that was available at MSC
Several cases of un~ or badly coated BB in S23 to be analysed by diodes WG Report by F Savary in a next LSC
Planning : ?
Assuming that all pieces are conforming
Assuming that all suppliers respect the schedules
…..
We are OK for > 2 weeks so update at next LSC
Courtesy L Grand-Clement, R Moron –Ballester, F Savary

30. SMACC Overheated splices (1/6)
TE-TM on
Magnetisation measurements of 5 mm-long strand samples extracted from LHC busbar cables can provide a quantitative assessment of cable damage caused by overheating in a minimal invasive way [Journal of Physics: Conference Series 234 (2010) ].
Variation of the Nb-Ti/Cu strand magnetization (ΔM) at 4.2 K in magnetic field up to 6 T after different HT’s (a) and relative flux pinning reduction vs. annealing temperature at different magnetic field (b).
Strongly overheated and brittle busbar cable found in the LHC in 2009 [Non-conformity report EDMS No ].
Courtesy C Scheuerlein, F Savary

31. SMACC Overheated splices (2/6)
TE-TM on
Strongly overheated splices can be detected by visual control of the busbar insulation.
Degradation of max 50% at 0.7T
Extraction of 5 mm-long strand samples for magnetisation measurements
Busbar adjacent to splice QBBI.A21L6-M2-Int (NCR EDMS No ). The insulation has been degraded by excessive heating.
Courtesy C Scheuerlein, F Savary

32. SMACC Overheated splices (3/6)
TE-TM on
LS1 – Overheated Splices Repair procedure
N. Dalexandro, E. Grospelier, H. Prin, R. Principe, F. Savary, P. Voisin
Courtesy C Scheuerlein, F Savary

33. SMACC Overheated splices (4/6)
work
TE-TM on
LS1 – Overheated Splices Repair procedure
N. Dalexandro, E. Grospelier, H. Prin, R. Principe, F. Savary, P. Voisin
Courtesy C Scheuerlein, F Savary

34. SMACC Overheated splices (5/6)
TE-TM on
7.5 sectors are inspected so far
Electrical risk is limited (large margin on the Jc)
Mechanical risk has not to be underestimated
Procedure developped, avoiding to replace magnets, able to produce very high quality splice with some associated risk (Only expert technicians)
Capacity of 2-3 splices per month
Consider only splices that have not to be opened for another reason (R_8, geometry,
24 splices concerned (< 1/400), could be 26
6 have already been repaired (6th this week)
Courtesy C Scheuerlein, F Savary

35. SMACC Overheated splices (6/6)
TE-TM on
Category #
Splices repaired with new cables 6
Splices needing to be repaired with new cables 5
Overheated splices, pending decision 7
Slightly overheated splices, redone standardly 3
Splices not yet opened, could be consolidated as is
Strategy defined at TETM
Margin is high on Jc
Consolidate not yet opened splices “as is” (without opening)
Resolder slightly overheated splices in a standard way if solderability ensured
Based on this, identify other opened splices that could be repaired standardly
Complete inspection
Train new technicians for the less critical operations (Small effect on productivity)
Review the situation in the coming weeks
Courtesy C Scheuerlein, F Savary

36. Very slightly more than nominal rate achieved these last 19 weeks !
SMACC Summary on progress
Main 13 kA Splices:
 Delay reduces
 Availability of components for QDiodes consolidation  Overheated splices repair can become critical
Special Interventions:
 Delay stable, start last planned interventions (triplets)
DFBA:  Activities have started on all standard DFBAs
 DFBAK is back in the tunnel
 Back in the shadow of arc splices (except 56-78)
SMACC:
 About 2 weeks of delay
Delays are sligthly reducing
Very slightly more than nominal rate achieved these last 19 weeks !

37. SMACC Main activities for the next 2 weeks
Sector 56 :
Final leak test and start reconnection of DFBAK
Sector 67 : Pressure test successfull
Complete ElQA, Flushing (CRG/MPE): Not formally SMACC project
Sector 78 (Not priority)
Work on NC
Work on DFBAO at the surface
Sector 81 (Priority)
Complete the M leak tests of non problematic Ics
Progress on IC closure
Sector 12
Compete M lines rewelding
Continue M leak test
Sector 23
Progress on the installation of electrical insulation
Work on overheated splices
Continue Q diodes consolidation (as long as components allows)
Sector 34
Complete splices unsoldering
Installation of shunts
Sector 45
Continue desoldering and resoldering of splices

38. Conclusions Delays are reducing
Mind the last X % (S78 is at 93%) effect…
DFBA consolidation is progressing very well 
Issues:
Overheated splices
Other diodes issues (Diodes WG-MPE/MSC)
Components for consolidation of quadrupole diodes (More news in 2 weeks)
Repair of NCs in parallel with production work (March in 67)

39. Operator responsible : JM Hubert
Last M line opening (S45)
6th of February 2014
Operator responsible : JM Hubert
Pictures by M Struik