2. SMACC Tenth report [15 min] 13/09/2013
Jean-Philippe Tock (TE-MSC)
On behalf of the SMACC project

3. Activities since last LSC (30/08/2013)
By Activities
By sectors
SIT
DFBA
Dashboards
Brief ElQC update
Activities for the next 2 weeks
Conclusions

4. SMACC Main activities for the next 2 weeks
Sector 56 :
Work on non-conformities
Sector 67
Installation of insulation boxes and injection
Rewelding of M sleeves
Leak test of M lines
Reclosure of interconnections
DFBA consolidation
Sector 78
Desoldering and resoldering of splices
Installation of shunts
Sector 81
ElQC of existing splices
Other sectors:
S12: Opening of M lines
S23: Opening of interconnections and installation of DN200
S12, 23, 34 & 45 : Reconnection of replacing magnets
Advanced opening for outliers and CSCM segments
Inspection of connection cryostats
From last LSC ( ) 
On-going, 52 ICs reclosed, leak test of beam lines completed succesfully 
In progress, critical activity 
In progress, > 1/3 of sector rewelded
Jeune Genevois … 
Started, 2/14 vac subsectors validated 
Started, 14 ICs reclosed 
On-going
Desoldering completed, starting in 81  
On-going, > 1/3 of the sector equipped 
On-going 
On-going, > ¼ completed, see further
> 80% open, DN200 installation completed
Good progress    
On-going 

5. SMACC Progress report by activity
Opened interconnections in 8 sectors, > 6 sectors-eq are opened
Back on schedule

6. SMACC Progress report by activity
M line cutting : > 4.5 sectors equivalent (S12 well advanced)
Replacing team leader at CERN since beginning of August
Courtesy JM Hubert

7. SMACC Progress report by activity
Desoldering : Completed in S56 & 67 & 78
Resoldering completed in S56 & 67 & at 75 % in S78 59
Desoldering: Nominal was 53/week; Now we need 95/week
Increasing is seen (Effect of new staff and tooling)
W36 included Jeune Genevois
W37 not completed (preliminary: 85)
Resoldering : Improving, not yet there
1 person of the team prepares intervention on overheated cable in 56 with a staff
Courtesy H Prin

8. SMACC Progress report by activity
Shunts are installed in > 2 sectors-eq.
50 ICs behind schedule (About one week at nominal rate)
Delay effect of the reinforcement of resoldering teams
Non-consecutive interconnections
About shunts installed (30% of the LHC)
«Last 10% effect» in 2 sectors

9. SMACC Progress report by activity
Installation of insulation box: Good progess in 67 ( 50 %)
2 phases : Minimum required: 45 ICs/ week (9 per day) Installation (time consuming, continuous) & Injection (By batch of ≈ 15 ICs)
Installation completed in 56 and 55 % of 67
Injection completed in 56 and 45 % of 67 : Inject every 2 days by batch of 15 (37.5/wk)
Bottleneck is still the installation of the electrical insulation
 Work sequence is optimised
 Resources are redirected FSUs and 3 COAS (PAEC) in October
THE critical activity
Courtesy H Prin / M Duret

10. SMACC Progress report by activity
Quadrupole diodes
> 5 sectors are opened / 2 sectors are almost consolidated (1 diode to be exchanged because of too high internal resistance)
Globally almost on schedule BUT
One diode has to be replaced because of too high diode to heatsink resistance (Q31R6)
Some components were delivered, allowing to barely complete S67; some pieces have to be reworked at CERN
Not critical YET
Alternative supply still under investigation to check that it can meet the requirement OK for the material certificate, price to be renegotiated, manufacturing method still to be confirmed (Delivery time of at least 2 months)
Courtesy L Grand-Clement / F Savary

11. SMACC Progress report by activity
M Welding : 290 ICs welded, ≈ 1.35 sec-eq:
Reduced team, extrapolating: nominal rates seem achievable
Limited by release rate, not by the team capacity (Presently 30/week)
In-line with forecast of last LSC
Delay wrt baseline
Required rate to end according to baseline : 45 IC/week
Team sized for 53-60
Margin for the «last 10%» has been eaten
Situation to be monitored for a possible reaction in October.
Courtesy S Atieh

12. SMACC Progress report by activity
M sleeves leak testing : All possible subsectors (200 ICs) are leak tested
All possible subsectors of S56 (11/14) are released and leak tested
Starts in S67 : 3 subsectors released. 2 are leak tested
In-line with forecast of last LSC
Delay wrt baseline
Required rate to end according to baseline : 3.1 subsec/week
Foreseen for subsec/week
Margin for the «last 10%» has been eaten
Situation to be monitored for a possible reaction
Courtesy P Cruikshank / L Mourier

13. SMACC Progress report by activity
Reclosure of interconnections : On-going in 67 (priority) and 56,
52 ICs are reclosed in 56 and 14 in 67
Stopped in 56 during beam lines leak test; contraint relaxed this week by VSC
S56 will be delayed (Overheated cable, DFBAK bellows)

14. SMACC Progress report by activity
Final leak test: 1st one STARTED 
16 consecutive interconnections closed in 56
Final leak test started
Results in 2 weeks, on schedule

15. SMACC Progress report by sector
Main activities are on non-conformities
Was temporarily stopped for beam lines leak testing
Reclosure as a an activity to smooth work load (priority given to S67)
Repair of overheated cable will start next week, with a completion by end of October
One PIM to be exchanged for protruding RF fingers (QQBI.29R5): Re-rewelding capability will be limited – specific procedure (was consolidated in 2009)

16. SMACC Progress report by sector
All non-problematic ICs are shunted
Main activities are installation of insulation system and welding of M lines
Leak test of M lines is on-going (2/14 subsectors validated)
Reclosure started

17. SMACC Progress report by sector
Main activities are:
desoldering of splices (just completed),
resoldering of splices,
installation of shunts
and related QC/QA

18. SMACC Progress report SIT
2 cryomagnets are reconnected, the other ones are under reconnection and it has started for Q5L8
Standard reconnection will be done by the train when it will arrive
PIMs: Rewelded in 6 sectors, 2nd RF ball test done successfully in S56 (Only one more to change in 56)
2 Y-line leaks are repaired and validated, only the closure of IC remains, by the train, end of 2013
To start : Interventions on SAM (Tooling under checking in workshop) and IT
Courtesy N Bourcey, S Le Naour

19. SMACC Progress report DFBA
M Bellows: See report by L Tavian
Splices consolidation has restarted at a good rate, with reinforced team
Courtesy TE-CRG, TE-MSC and EN-MME

20. SMACC Dashboards

21. SMACC Dashboards
Opening is back ahead of schedule despite closure of interconnections
Shunting starts to improve with reinforcement and optimisation of critical activities
Welding: Limited by release rate, confident that nominal rate can be achieved, margin has been eaten up
M leak test : Limited by release rate, confident that nominal rate can be achieved, margin has been eaten up
ReClosure: started ahead of schedule, now in S67
Final leak test started (Results in 2 weeks)

22. SMACC Dashboards Will be completed by beginnig of November
Baseline: 26.1 % (22.3 %)
Completed: 23.0 % (20.0 %)
Delay (9) days
Baseline: 47.0 % (41.1 %)
Completed: 33.0 % (29.7 %)
Delay (17) days
Baseline: 42.9 % (35.7 %)
Completed: 23.0 % (22.3 %)
Delay 41 (36) days
Baseline: 100 % (100 %)
Completed: 82.4 % (72 %)
Delay 64 (52) days
Will be completed by beginnig of November

23. SMACC Dashboards Progress: Baseline: 31.8% (27.2 %)
Completed: 25.6% (22.4 %)
Delay 18 (15) days

24. The impact of the summer period on the planning was 3 weeks
SMACC Summary on progress
Main 13 kA Splices:
 Started a week in advance, now 2 weeks delay (stable)
Special Interventions:
 27 days delay, non-conformities start to impact
DFBA:
 > 1 month delay: should recover for end of the year
Bellows issue could have a large impact
DN200:
 ≈ 2 months delay: not critical
SMACC:
 About 3 weeks (stable)
The impact of the summer period on the planning was 3 weeks
Can recover next year when resources are freed by finishing activities

25. Preliminary results of existing splices quality control (7.09.2013).
SMACC ElQC Status
Preliminary results of existing splices quality control ( ).
Sector
Sector 56
Sector 67
Sector 78
Sector 81
LHC
Measured [%]
100 25 40
To redo [%] 28 32 29 31 30
30 % seems confirmed as more solid number
Dedicated presentation in October with half of the LHC measured
Courtesy C Scheuerlein, S Heck

26. SMACC Main activities for the next 2 weeks
Sector 56 :
Work on non-conformities including repair of overheated cable
Reclosure (not in priority)
Sector 67 (Priority sector)
Installation of insulation boxes and injection
Rewelding of M sleeves
Leak test of M lines
Reclosure of interconnections
DFBA consolidation
Sector 78
Complete resoldering of splices
Installation of shunts
Sector 81
ElQC of existing splices
Start desoldering of splices
Other sectors:
S12: Complete opening of M lines
S23: Opening of interconnections
S12, 23, 34 & 45 : Reconnection of replacing magnets
Advanced opening for outliers and CSCM segments
Inspection of connection cryostats

27. Conclusions So far, not so bad … Issues:
New activity: Start of final leak testing (The last one )
About to start to repair the overheated cable in 56 in-situ
The ratio of 30 % of splices to redo seems confirmed for 40% of the LHC
Reduced ElQA test frequency allows to cope with > 3 sectors in //
Global delay of 3 weeks due to summer period and technical issues under solving ; difficut to recover this year
Margin has been eaten up for some activities (M welding, M leak test)
Issues:
Reach nominal rate for arc splices consolidation (Ramp up with de/re soldering and optimise installation of insulation box)
DFBA busbar bellows
Components for diodes consolidation
So far, not so bad …

28. SEQUENCE AND STATUS Availability of components Install DN200 ≈ 80%
OK to open
Open ICs
Open M sleeves
8 sectors
> 6 sectors
≈ 4.5 sectors
Undo / Redo splices
ELQC (new splices)
≈ 2.5 sectors
≈ 2.5 sectors
ELQC (old splices)
Machine Cu
ELQC after Cu mach.
> 3 sectors
> 2 sectors
≈ 2 sectors
Consolidate Q diodes
Availability of components
≈ 1.7 sectors
Install shunts
ELQC after shunt
Insulate splices
Weld M
Leak test M
Close IC
Final LT
> 2 sectors
> 2 sectors
≈ 1.7 sectors
≈ 1.3 sectors
≈ 1 sector
≈ 1/4 sector
Started