2. LS1 Committee January 24th, 2014
Status of DFBA LS1 consolidations A. Perin on behalf of all people participating to the project

3. Outline Overview of consolidations Main operations
Consolidation of splices
DFBAO/AK repair
Other consolidations & issues
Integration in LS1 global schedule

4. Status of DFBA splices consolidation
Disconnection of DFBAK
74 / 135 splices consolidated (55%), work completed on 4 DFBAs.
Global schedule has been redefined following decision to repair DFBAO in the workshop
4 DFBAs re-closed, 2 DFBA (sect. 6-7) pressure & leak tested

5. DFBA 13 kA splices consolidation: access to splices
111 /135 splices accessible (82%)
74 /135 splice s with shunts installed (54%)
4 DFBAs re-closed
2 DFBA (sect. 6-7) pressure & leak tested

6. DFBA LS1 consolidation: detailed dashboard
Work ongoing on 12 DFBAs
4 DFBAs re-closed
2 DFBA (sect. 6-7) pressure & leak tested

7. Consolidation of splices
Consolidation rate
74 / 135 splices consolidated (55%).
The team has been reinforced (from 2 to 6 people). Consolidation rate is now approx. 5 splices /week (baseline was approx. 2.5 /week).
Additional broaching tooling is being procured (delivery 24 Jan)
Disconnection / reconnection of DFBAK /AO has some impact.
Total splices that have required repairs due :
Not due to splice NC
= 15
DFBAK: 2 redone following broaching. 6 Undone following problem with gimbal bellows
DFBAO: PB 6 due to Short to ground in pigtail#6
DFBAO: 6, disconnection of SHM
Due to NC
5 splices (6.8 %)
DFBAN: PB1 , DFBAO PB5, DFBAP SH2, SH3, SH6

8. Repair of DFBAs gimbal bellows
upper bellows
Lower bellows
4 gimball bellows affected:
2 repaired in-situ (DFBAI & DFBAF): done
2 are being repaired in workshop (B112).
Current status:
DFBAK: bellows replaced. Cold mass leak checked. Cryostating.
DFBAO: SHM in B112. De-cryostating ongoing.
Impressive collaboration work for this complex job!
Double endoscope inspection of DFBAO

9. Status of DFBAK/AO gimbal bellows
10 spare units of gimbal bellows delivered end of December 2013
All have been checked for: leak tightness and welding quality
Difficult X-ray inspection because of configuration. But method found.
Non acceptable problems (tungsten inclusions) discovered on 4 units
6 units are acceptable, not perfect (some porosities present)
Strategy: keep 6 units, use 4 units (re-assembly of DFBAK SHM is already ongoing) and send back to manufacturer 3 non-acceptable units. 1 kept at CERN for destructive tests.
Progress in X-ray inspections

10. DFBAK Demounting & transport

11. DFBAK SHM in B112 for repair
21 November 2013
26 November 2013
21 November 2013
04 Dec 2013
26 November
21 Jan 2014

12. DFBAO gimbal bellows repair
20/01/2014
21/01/2014

13. DFBAO 13 kA pigtail#6 short to ground
Short to ground detected after welding
Identified to be in the pigtail side (small movement makes it appear/disappear) between the PB splice and the current lead
Production data show that the problem was present before installation btu considered acceptable at the time. No other pigtail showed a similar prolem at production.
Flexible hose demounted in-situ. Repair ongoing.

14. Other ongoing consolidations
CL line consolidation: 10/12 completed
HCM-LCM interconnection consolidation (12 IC): completed

15. Installation of clamps on busbar lyras inside of right-side SHM
Installation of clamps: delayed by a) inspection b) consolidation
12 /16 installed

16. Overview of DFBAs consolidation with LS1 schedule
(as presented on 17 Jan at LSC)
1-2
2-3
3-4
4-5
5-6
6-7
7-8
8-1 AL AM AJ AN AP AB AA AC AD AE AF AG AH AK AI AO
K. Foraz, LSC of

17. Impact of DFBAs on sectors
Just in Time
Weeks of delay
Vs baseline just in time J
Sector 56
28 Nov. 2013
+20 wks K L
Sector 67
18 Nov. 2013
+2wks M N
Sector 78
07 Feb. 2014
+15 wks O P
Sector 81
20 Feb. 2014
JUST IN TIME A B
Sector 12
13 March 2014
- 2 wks C D
Sector 23
10 Apr. 2014
-3 wks E F
Sector 34
25 May 2014
- 5 wks G H
Sector 45
18 June 2014
-4 wks I
E. Vergara, M. Bernardini, EN-MEF
Red: impact of the sector final date
Green: no impact on sector final date

18. Conclusions
Cutting operations, CL line replacement, HL interconnection consolidation, proceed as planned
Broaching / shunt installation
Team has been reinforced by additional 4 persons (were 2) and extra tooling.
Personnel was trained in Dec Impact already felt. Rate is twice the baseline.
Rate of broaching / shunt installation allows to catch up the schedule
Still perturbed by need to treat special cases (DFBAK/AO, pigtail)
Gimbal bellows problem
DFBAK SHM demounted, being repaired
DFBAO SHM demounted
DFBAF & DFBAI: in-situ consolidation done.
Impact on global schedule essentially for DFBAK (5-6) and DFBAO (7-8)

20. Non-nominal position of busbars on Q7 side of SHM
DFBAC M3 line out of position.
DFBAE M3 line IC to Q7 appears displaced

21. DFBA splice consolidation documentation
Documentation (ongoing)
Tracking and storage of all documents for the DFBA consolidation project.
Until 25 Nov.: 2188 documents stored
1785 photos
103 manufacturing/test reports
277 X-rays pictures
Presentations/minutes: 23

22. Gimbal X-Ray Tungsten inclusion 0.2 mm
Not permitted according ISO 5817 LB
Ref. ISO : 3041
Gimbal X-Ray
Porosities ø = 0.2 mm
Not permitted according ISO 5817 LB
Ref. ISO : 2011
S. Atieh, EN-MME

23. Status of DFBAK/AO gimbal bellows repair
10 spare units of gimbal bellows delivered end of December 2013
All have been checked for: leak tightness and welding quality
Difficult X-ray inspection because of configuration. But method found.
Non acceptable problems (tungsten inclusions) discovered on 4 units
6 units are acceptable, not perfect (some porosities present)
Strategy: keep 6 units, use 4 units (re-assembly of DFBAK SHM is already ongoing) and send back to manufacturer 3 non-acceptable units. 1 kept at CERN for destructive tests.
Progress in X-ray inspections

24. X-ray control report (EDMS 1345619 by EN-MME)

25. DFBAs final dates DFBA Baseline Actual Weeks of delay Vs baseline J
26 June 2013
18 Oct. 2013
+16, DONE K
4 Sept. 2013
5 May 2014
+33 L
10 July 2013
2 Dec. 2013
+21, DONE M
24 July 2013
+19, DONE N
2 Sept. 2013
22 Nov. 2013
+11, DONE O
17 Sept. 2013
22 May 2014 P
29 Oct. 2013
5 Feb. 2014
+12 A
21 Oct. 2013
18 Feb. 2014
+13 B
4 Nov. 2013
21 Feb. 2014 C
18 Nov. 2013
28 Feb 2014 D
9 Dec. 2013
12 March 2014 E
6 Jan. 2014
18 March 2014
+11 F
20 Jan. 2014
4 April 2014 G
3 Feb. 2014
15 April 2014
+14 H
12 May 2014 I
7 March 2014
20 May 2014