Work Organisation for Splice Consolidation Francesco Bertinelli 20 minutes presentation, 10 minutes discussion: 12 slides First LHC Splice Review, CERN, October 18-22, 2010  The global picture: activities to be performed for splice consolidation  Planned resources and time schedule  Organisation of coordination and Quality Control

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 2 What activities are necessary?

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 3 What activities are involved for IC work?

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 4 (some) other activities involved before & after

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 5 How long will IC work take? The size of this new task compares to series production: will not require some activities (e.g. jumpers, N-line) … but will require to « undo » before « redoing » (e.g. cut welds, desolder, busbar surface machining): repair ≠ new on the good side: all magnets are in place (except if …) Resources used in IC series production: IEG (Main Contractor) ~100 workers activities were organised for 40 IC/week CERN ~100 workers for coordination, QC (including ELQA and VAC), troubleshooting, special activities years Resources used in IC shutdown: CERN ~100 workers

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 6 Series soldering experience 30 IC/week Courtesy P. Fessia

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 7 Duration of IC work  at 50 IC/week (!!!) for critical activities,  14 weeks for 1 st sector, 5 weeks later for 2 nd sector, 49 weeks for 8 sectors  2 shift work (on different activities), some overlap: 6h–10h/break/11h-15h 12h-16h/break/17h-21h  no learning curve, no built-in contingency, no account for holiday/closure periods  must work sequentially to adjacent sector, without access constraints (i.e. first cool-down and HWC powering)  big concern is the “other activities” to be done in parallel: more realistic is to consider an additional 2-3 months

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 8 Estimate of IC resources needed (i/ii)

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 9 Estimate of IC resources needed (ii/ii)  cf Chamonix 2010: respectively 46 and 72 for IC work alone  New consolidation activities (e.g. Surfacing busbars), more non-standard activities (within same time...)  Connected activities: Vacuum Cryo-thermometers Survey ELQA and QPS RP and general safety  “Missing resources” to be found inside CERN (e.g. stop of Injector operation), Project Associates, FSUs: need to start this commitment.

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 10 The current scenario  1 “train” only for standard activities  A Special Intervention team to prepare non-standard work before the arrival of the train

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli 11 Organisation  Magnet/interconnections work coordinators: between groups involved and with overall Shutdown coordination weekly meeting between groups continuous presence in tunnel 8h-12h30 to 13h30-18h  Quality Control (independent from production) and management of non-conformities: Specific to single electrical connections Specific to welding EN-MME Leak testing and ELQA overall integration to be organised / optimised Simplified traceability: recent contacts with MTF team

18 October, 2010 First LHC Splice Review - Work Organisation - F. Bertinelli Speed of work In the 300 K sectors 1-2, 3-4, 4-5, 5-6 and 6-7 we estimated the mean amount of work made per day and per team thanks to the date of welding: 12.2 splices/day. As for the bad splices observed with R16 measurements, the ratio is 30% higher: 15.9 splices/day. Hence a potential guideline for future work is to be attentive to the negative effect of high production speed on quality. ANALYSIS OF 13 kA MAGNET INTERCONNECTION SPLICE QUALITY WITH RESPECT TO PRODUCTION TRACEABILITY F. Bertinelli, C. Lorin, E. Todesco / TE Department Internal Note Speed warning …