SM-18 Magnet Test Operation – Status & Outlook

SM-18 Magnet Test Operation – Status & Outlook
V.Chohan CERN, Geneva, Switzerland Review of the Tests of Superconducting Magnets in SM18 , 8 February 2006

SM18 Magnet Tests Review, February 06
Talk Outline Operation Overview Available Resources Constraints Current Status Statistics for 2005 Outlook for 2006 Special SSS issues Constraints & Solutions Conclusion V. Chohan SM18 Magnet Tests Review, February 06

Operation Overview

Magnets Tested in SM18 (upto) 2003 2004 2005 Total done to date Total Magnet Tests 704 1257 97 456 V. Chohan SM18 Magnet Tests Review, February 06

SM18 Test Operation Available Resources
Test Equipment Fixed 12 Test Benches arranged in pairs so, 6 clusters( A to F) 6 Main Power Converters 6 sets of Electronics for testing 1 per cluster Mobile For Q-location & MM special 15 m Shafts to be installed in magnets Mobile Racks for HV insulation tests & Magnetic Measurements SSW Units Shared Utilities Water for 4 magnet powering at the same time Cryogenics capacity and limits Manpower [24 hr Tests Operation Staff] in 2005 14 CERN staff ( ~12 FTE ) on loan from CERN Accelerator Operation ( some only part-time) 20-25 persons on exact 1 year contracts from India & constantly rotating, so (~16 FTE) ICS “Magnet connectors/disconnectors” working 24 hours ( but ROCLA not) Cryogenic Support staff Technical Support Equipment support for magnet test equipment and electronics V. Chohan SM18 Magnet Tests Review, February 06

Constraints in Operation
For parallel test operations on all benches, constant monitoring and allocation of shareable resources is required. This imposes following constraints: Equipment for Testing Juggling of mobile resources between benches Constant switching of rack electronics for testing 2 magnets in a cluster Shared utilities Constant monitoring & allocation considering capacity limits for cryogenics, water and power Connection/Disconnection ‘ICS’ limits Limited staff on separate contractual agreement with limited provisions for handling ‘overload’ times Manpower constraints - Staff with frequent & rapid turnover Knowledge management issues Facilitation and training of rotating staff Some experienced CERN staff returning to start-up of respective accelerator operations in 2006 V. Chohan SM18 Magnet Tests Review, February 06

Utilities : Cryogenics Capacity
Cryogenics capacity (in 2005) and limits : 3 to 5 1.9K and under cold tests, Up to 2 magnets in 300K to 90 K (Cool down) phase , Up to 2 magnets in Last (Warm up) Quench to 300K phase, ( but not exceeding 3 magnets in cool-down or warm-up phase altogether - this limit was 2 up to end ) 1 magnet in 90K to 1.9 K phase Cryogenics capacity was enhanced in 2005, with Faster cooling & warming times Better quench recovery Increased limits on number of quenches However it still requires a judicious and optimized setting of bench cryo priorities by OP crew V. Chohan SM18 Magnet Tests Review, February 06

Setting Priorities from Tests Operation
V. Chohan SM18 Magnet Tests Review, February 06

Status & Highlights

Overall Results Required Tests completed so far Magnets ‘Cleared’ for LHC Dipoles 1232 1009 (including ~ 9% repeats) > 900 √ ARC-SSS (IR-SSS) 220 (including ~ 9% repeats) > 200 Sp IR-SSS 82 28 (including ~ 18% repeats) ~ 20 ? ‘Cleared’ => Signed for STRIPPING by the Operation Team V. Chohan SM18 Magnet Tests Review, February 06

Highlights Notable points from 2005 Tests Operation
Enhanced cryo capacity, reflected in: Reduced Dipole & ARC-SSS testing times hence, increased magnet test rate High magnet test rate achieved despite additional tests and dynamic behaviour studies (MM, fatigue tests) conducted in some magnets in 2005. OP proposals from last year’s review, which were implemented and helped in improving the overall testing rate: Reduced connection time for ARC-SSS Modifications in quench training rules for optimized magnet training Introduction of Rapid on-bench Thermal Cycle for poorly performing magnets hence, reduced ICS & logistics efforts & enhanced ‘stripping’ efficiency Reduced number of Stretched Wire measurements for ARC-SSS at warm & at cold Dedicated benches for magnetic measurements Better Planned MM programme on dipoles, resulting in proper anti-cryostat mounting on selected magnets Greater OP Efficiency thanks to SMTMS additions and SSW Software efforts from OP Team V. Chohan SM18 Magnet Tests Review, February 06

Tested Dipoles: 2005 A total of 513 Dipole magnets were tested during the year These include ~ 9 % of repeat magnets (was 11% end 2004) V. Chohan SM18 Magnet Tests Review, February 06

Tested ARC-SSS: 2005 A total of 166 ARC-SSS magnets were tested during the year These include ~ 9% of repeat magnets (was 11% end 2004) Dip in number of ARC-SSS tested during July-Sep 2005 due to Production stoppage - welding problems on ‘collarette’ Special endurance tests on remaining ARC-SSS’s ICS problems V. Chohan SM18 Magnet Tests Review, February 06

Tested Special SSS : 2005 2 benches for Sp-SSS A total of 25 Sp-SSS magnets were tested during the year 2005. (with 5 repeats) V. Chohan SM18 Magnet Tests Review, February 06

Cold Tests in V. Chohan SM18 Magnet Tests Review, February 06

Cumulative Total: All Magnets

Summary 2005: Raw Cold Tests
Year Dipoles (fresh) Repeat Dipoles ARC-SSS (fresh) Repeat ARC-SSS Sp-SSS (fresh) Repeat Sp-SSS up to 2003 95 NA 2 2004 356 45 49 3 2005 468 149 17 20 5 Cumulative Total 1009 (includes ~ 9% repeats) 220 28 (includes ~ 18% repeats) Required 1232 82 V. Chohan SM18 Magnet Tests Review, February 06

Further Statistics ICS Times Cryo Times Magnetic M’ments Times
Average no. of quenches

Average Connect, Cold test & Disconnect times for Dipoles
Extra tests (including MM) in Dec on Magnets 2202, 2259 & 3370 V. Chohan SM18 Magnet Tests Review, February 06

Average Connect, Cold test & Disconnect times for ARC-SSS
Extra tests on magnets V. Chohan SM18 Magnet Tests Review, February 06

Extra Tests / delays on ARC-SSS magnets in July - Sep ‘05
Month Magnet No Extra Tests Performed July ‘05 SSS 217 / 206 Fatigue tests SSS 199 (B2) Connection Cryostat (B1) - cohabitation SSS 204 (Delays due to ICS wrong/new connection/disconnection) July ’05 SSS 203 Magnetic Measurements with SSW Sep ’05 SSS 180 SSS 293 (D1) Large connection time (ICS?) & large cooling & cold test time (co-habitation?) V. Chohan SM18 Magnet Tests Review, February 06

HIGHLY DESIRABLE that ICS IMPROVE ON CONNECT TIMES in 2006 !!
ICS: Average WAIT + Connection Time for MB & Arc SSS (always > 12 hrs) ICS effort degradation from summer 2005 No of persons on shift ROCLA support Special rules on hours HIGHLY DESIRABLE that ICS IMPROVE ON CONNECT TIMES in 2006 !! V. Chohan SM18 Magnet Tests Review, February 06

Cryo times for Dipoles in 2005

Cryo times for ARC-SSS in 2005
Connection cryostat delays Delays due to life-time tests by cryo V. Chohan SM18 Magnet Tests Review, February 06

Typical magnet test times (For the week starting 26th July 2005)
ICS new connection problems Connection cryostat (B1) Fatigue tests ROBTC Reference Times Light green : Connect (up to Cryo pump down) 24 h Blue : Wait + Cool down h Ivory: Tests at Cold h Red : Wait + Warm up h Dark Green: Disconnect h V. Chohan SM18 Magnet Tests Review, February 06

Magnetic Measurement times for Dipoles in 2005
Tests with MM on Magnets 2202, 2259 & 3370 in Dec On average, Magnetic Measurements take at least 20 hrs in addition V. Chohan SM18 Magnet Tests Review, February 06

Average no of Quenches carried out - Dipoles
Each Quench costs ~ 3 hrs (recovery time) V. Chohan SM18 Magnet Tests Review, February 06

Average no of Quenches carried out – ARC-SSS
Each Quench costs ~ 2 to 2.5 hours (recovery time) V. Chohan SM18 Magnet Tests Review, February 06

Comparison of test times for various magnets in 2005
Average timings (in hours) Dipoles ARC-SSS Special IR-SSS Cold test 30 hours 31 hours 94 hours Overall magnet tests (bench occupancy) 120 hours 116 hours 245 hours To complete the magnet tests programme, we have to sustain the fast testing rate for Dipoles and ARC-SSS and FOCUS our attention on Special IR-SSS issues which affect its test rates and to provide solutions to “accelerate” Sp-SSS testing to the required levels V. Chohan SM18 Magnet Tests Review, February 06

IR-SSS Issues (To be addressed separately later)

Outlook for 2006

Countdown to LHC : Projections for completion of Tests
Sustain the current test rates per benches allocated for Dipoles and ARC-SSS, ie.,bench allocation related overall output such that the global yield of everything is: ie. around 60 Cryo Magnets per month Accelerate the testing rate for Sp-SSS to around 6-7 magnets per month Note: The figure assumes an average of ~10% of magnets which get tested again (repeats) V. Chohan SM18 Magnet Tests Review, February 06

Magnet Test Statistics

Detailed Projections 2006 Assumption : Testing Time (Upto May-05) : Dipole -131 hrs;SSS- 143 hrs, After Jul-05, Dipole Hrs, ARCSSS Hrs, IR SSS - 10 days Magnets Tested 2005 Projections V. Chohan SM18 Magnet Tests Review, February 06

Detailed Projections 2006 Assumption : Testing Time (Upto May-05) : Dipole -131 hrs;SSS- 143 hrs, After Jul-05, Dipole Hrs, ARCSSS Hrs, IR SSS - 10 days Projections Magnets Tested 2005 V. Chohan SM18 Magnet Tests Review, February 06

Outlook 2006 – Facts & Figures for completion
Dipoles Number required = 1232. Number including 10% repeats = 1355 Can be completed by Nov 2006 ARC-SSS Number required = 392 (including 32 IR-SSS which are not ‘Special’) Number including 10% repeats = 431 Can be completed by Dec 2006 Sp-SSS Number required = 82 Number including 11% repeats = 91 Can be completed by Dec 2006, with 24 hours operation The above projection assumes Desired bench configuration, with no bench breakdowns No major delays due to magnet delivery and No delays due to additional unforeseen tests ( e.g. fatigue in ‘05) V. Chohan SM18 Magnet Tests Review, February 06

Contingencies We have no formal contingencies in this ‘tight finish’ (remember we lost 1 bench for 1 month in Oct ‘05) We have taken ‘liberties’ in considering DS being similar to MQ ARC-SSS Our only fall-back is : We will still have 24 hrs OP staff ( India + CERN) till end March 07 { Hence, NO SHUTDOWN JAN-FEB ‘07 in case of need } V. Chohan SM18 Magnet Tests Review, February 06

Why Op Planning must be respected to maintain Momentum & Motivation
ICS turnover Cryo ALLS turnover (& Experts too) Indian Associate Collab. Limits AB-Op Staff Limits & Rotation V. Chohan SM18 Magnet Tests Review, February 06

Manpower CERN + India New & Experienced
(2005) CERN FTE ~ 12 INDIA FTE ~ 14 (2006) CERN FTE ~ 6 INDIA FTE ~ 20 V. Chohan SM18 Magnet Tests Review, February 06

Manpower-Total New & Experienced

CONCLUSION An overview of the results of the SM18 Magnet Tests in 2005 has been presented, leading us to be cautiously optimistic about the outlook for 2006 A PROJECTION chart, based on management’s goals of completing the tests programme so as to permit the eventual machine readiness for beam collisions in LHC by 2007 has been made This projection envisages sustaining the current testing rates for Dipoles and ARC-SSS and an accelerated testing rate of Special-SSS’s. V. Chohan SM18 Magnet Tests Review, February 06

IR-SSS Issues : Problems & Solutions
Outline Chamonix & how it was foreseen What It Is All About 4 Main Concerns Way Forward & 3 Main Proposals (including resolution of Technical & Organizational Issues) V. Chohan SM18 Magnet Tests Review, February 06

from Chamonix Workshop Jan’05: Possible Concerns & Worries for installation The testing of Insertion Region SSS is an uncharted territory to date and we need to ensure we have sufficient time for these within the existing boundary conditions. From our present limited experience, it takes us up to 1 week to modify the bench to permit IR-SSS mechanical & electrical connections. 82 IR SSS are individually powered so one needs to provide at least the transfer function for powering & machine energy correlation even if detailed magnetic measurements are not done IR-SSS also need special Magnetic test cycles Logistics, Transport (avoid all issues that plagued Arc SSS in 2004) V. Chohan SM18 Magnet Tests Review, February 06

Introduction: IR-SSS Tests in 2005
How was Testing Foreseen at startup in Jan 05: 24 hr OP Team was Not Required to TEST the IR-SSS’s 1 bench (D2) was designated for this work in hands of experts Work restricted to normal hrs & no weekends V. Chohan SM18 Magnet Tests Review, February 06

Introduction: IR-SSS Tests in 2005
How it turned out to be: Issues of Cryo Priorities & Conflicts as well as in bench cohabitation OP was requested to “HELP” ~ June 05 Special OP Work Schemes had to be designed from July 05 to permit this within overall other constraints ( Who, How, Work hrs, Summer & CERN staff vacations planned etc) 1 person per Mon-Fri week from AB-OP rotating in parallel with expert technicians, Experienced Indian Colleague in background for Tech & OP documentation preparation V. Chohan SM18 Magnet Tests Review, February 06

Led to the ANALYSIS of the situation by the OPERATION TEAM in Oct 05 and Memoranda written highlighting the issues for IR-SSS Testing as well as associated Single-Stretch Wire Measurements (here, it is essentially a report of this analysis) V. Chohan SM18 Magnet Tests Review, February 06

So What is it all about ?

Comparison of Average Test Times for IR-SSS in 2005
without MM 162 hours 6.8 days With MM – only SSW 269 hours 11.2 days With MM – SSW & Chaconsa 321 hours 13.4 days Can we test the remaining IR-SSS : {59 + certain repeats} in the 11 months Feb-Dec ‘06? [ Of which at least 17 are deemed to need MM ] V. Chohan SM18 Magnet Tests Review, February 06

Comparison of Test Times for all 3 magnet types in 2005 (hrs)
Average timings Dipoles ARC-SSS IR-SSS Cold tests 30 31 94 Overall magnet tests 120 116 245 V. Chohan SM18 Magnet Tests Review, February 06

IR-SSS testing: what it’s about
A total of 114 Insertion Region (Matching and Dispersion Suppressor region) magnet assemblies integrated in Short Straight Sections -SSS 114 SSS’s distributed into different types : Magnet configuration Magnet Geometry Position in the ring Powering & cryo regimes 82 of these SSS’s are individually powered hence to be tested in a different powering & measurement regimes while the remaining 32 (DS-MQ) can be tested similarly as an ARC-SSS (however we have not yet tested any of these 32). These 82 magnets are distributed into different types defined by the parameters listed above and are categorized as Special SSS (Sp-SSS from now on). V. Chohan SM18 Magnet Tests Review, February 06

Why Sp-SSS testing is different (from Dipoles & ARC-SSS)
A variety of different types Different currents for testing (nominal, ultimate, correctors) Different Cryo regimes for operation of some magnets (1.9˚K or 4.4˚K) Different connections and separate bench electronics V. Chohan SM18 Magnet Tests Review, February 06

Sp-SSS Types & Configurations
Total 82 V. Chohan SM18 Magnet Tests Review, February 06

11 Types in tabular form V. Chohan SM18 Magnet Tests Review, February 06

...Addressing the FOUR main Concerns (from Oct ’05 OP Memo)
Mechanical Electrical & Equipment Operational Cryogenics V. Chohan SM18 Magnet Tests Review, February 06

(1) Mechanical issues Preparation – special mechanical arrangements and fittings before magnet can be brought to the bench Mounting and alignment of anti-cryostats (for magnets requiring Chaconsa & SSW) is a time-consuming exercise Alignment issues after arrival on bench Space requirements in SM18 for parking & preparation of more than 1 Sp-SSS Special mechanical team ( NOT ICS) required for magnet preparation –available only Mon-Fri , 40 hrs a week. Special arrangements for transport : ROCLA not equipped for Sp-SSS ...so, transport etc not available in same manner V. Chohan SM18 Magnet Tests Review, February 06

(2) Electrical & Equipment
Some magnets require extra electrical fittings for connection to CFB; Special sets of adaptors required for HV insulation test on each type of magnet Takes long time for bench electronics connection and (re-)configuration Currently, all tests can only be launched manually from SM18 floor level local work-stations with manual configuration entries Special preparation, connections and procedure for testing correctors (120 A) – test commands not yet integrated with existing, known applications. V. Chohan SM18 Magnet Tests Review, February 06

Changing quench heater connections Changing PLCSE connections
…Why bench electronics re-configuration for Sp-SSS has been a nightmare for Op … Changing quench heater connections Changing PLCSE connections V. Chohan SM18 Magnet Tests Review, February 06

… bench electronics re-configuration …
Changing DAQ & Potaim card connections V. Chohan SM18 Magnet Tests Review, February 06

(3) Manpower and Operational Issues
Complexity and Knowledge for 24 hr Operation Very few people are knowledgeable for Sp-SSS testing because: the way it was foreseen in ‘early’ 2005 as well as, Equipment Issues (previous slides), & inability to draw similarities in usage to Dipole or Arc-SSS tests and so forth – an essential requirement for rotating staff Cohabitation Issues of Sp-SSS and ARC-SSS on the same cluster (with manual changeover of bench electronics) Delays due to complicated changeover process Possibility of errors affecting safety of personnel and magnet Sp-SSS testing delays indirectly affect testing time of adjacent (ARC-SSS) magnet because of hold-ups due to shared electronics and cryo priorities V. Chohan SM18 Magnet Tests Review, February 06

Effect on Arc-SSS test timings due to Co-habitation with Sp-SSS

(4) Cryogenics & Magnet Performance at 4.4 K
Cryo stability problems at 4.4 °K Magnet performance issues at 4.4 °K (e.g., MQM / MQML not reaching ultimate current during 1st test run) Slow Power Aborts during long-duration high current tests (MM & SSW) still a problem despite work-arounds (like H/W modification, cryo tuning etc) V. Chohan SM18 Magnet Tests Review, February 06

Way forward: 3 Main Proposals from OP ( Oct ‘05 Memo)
Increase number of benches dedicated for Sp-SSS tests (starting with both benches in a cluster used for Sp-SSS testing – not like it was - 1 on B1 and 1 on D1) Requires mechanical & electronics modifications on bench Would affect throughput of other magnets (meaning lower output for Dipoles & Arc-SSS because of fewer benches) Reduce preparation time for specialized tests mechanical alignment, magnetic measurement – Chaconsa, SSW Go to 24 hour operation for Sp-SSS testing Would improve the Sp-SSS magnet test rate to meet the deadline All these require SOLVING various Organizational and Technical issues V. Chohan SM18 Magnet Tests Review, February 06

Organizational & Technical Issues needing Urgent Resolution - 1
(1) Mechanical arrangements Configuring more number of benches (mechanically) for Sp-SSS.…(.. Will be so Feb’06) Rapid Anti-cryostat mounting and alignment : in & out-of-bench condition (for planned MM on selected magnets) 24 hr transport & preparation support for Sp-SSS magnets (2) Electrical/Equipment Issues Dedicate entire cluster (2 benches) for Sp-SSS magnets to reduce re-configuration time and maintain throughput of other magnets (will be so in 2006 for D cluster ) Automated launching of all tests with required configuration details from Test Master (in control room) – NOT at floor level like today ...(in progress for Feb ‘06 ) Easing of ‘changeover operation’ for electronics in case of cohabitation of Sp-SSS & ARC-SSS in one cluster (would be needed sometime during 2006 for cluster B ) Allocating warm tests like HV, continuity etc, to teams at Bldg 904 to save on-bench testing time at SM-18 (like it is done for ARC-SSS) ( …in progress for Feb ‘06 ) V. Chohan SM18 Magnet Tests Review, February 06

Organizational & Technical Issues needing Urgent Resolution - 2
(3) Manpower & Operational arrangements Completing testing of ‘one magnet of each type’ as soon as feasible to remove any ‘uncharted territory’, electrical or mechanical, from the tests domain Facilitation of 24 hrs Operation for Sp-SSS testing through established Methods and Tools (like it is for Dipoles & Arc-SSS handling DESPITE rotating staff) & Documentation (in progress) 24 hr support for Power & non–MM Issues 24 hr support for Magnetic Measurements, essentially SSW – with advance preparation of test equipment by experts for all SSW measurements ( 17 out of 59 still outstanding for MM , i.e., 33 % of Sp-SSS’s ) (4) Resolution of 4.4 K Cryogenic Issues V. Chohan SM18 Magnet Tests Review, February 06

Operation Team for Sp-SSS tests - ‘Preparedness’
Op team members on Sp-SSS ‘duty’ have handled almost all tests required for Sp-SSS (except ‘Chaconsa’!) Information exchange / dissemination among others in progress Test procedure docs and other info – available on SM18 website V. Chohan SM18 Magnet Tests Review, February 06

Latest Updates on Sp-SSS - Tests & Equipment (7Feb06)
Tests for Sp-SSS can now be launched from TEMA List of Test sequences prepared and loaded in TEMA Test types for Sp-SS magnets at 1.9°K & 4.4°K defined Corrector Powering Tests being automated Software for some tests (IAP, AQA) being updated for Sp-SSS Change-over of bench electronics – automated on D cluster with both benches catering to Sp-SSS B & C clusters (4 benches) prepared mechanically to handle ARC-SSS as well as Sp-SSS Continuity Tests and HV tests on Sp-SSS before connection are now being done at Bldg 904 V. Chohan SM18 Magnet Tests Review, February 06

Final Remarks Almost all magnet coil types (except MQT) tested – Possibly no outstanding issues for ‘R&D’, except preparing test equipment (H/W & S/W) for 24-hr test operation. Some magnets of particular geometric type have not been tested at all so far (eg. Type 1,2,3,5,8) . At least one type of each geometric class and magnet type should be tested at the earliest to remove ‘grey areas’ with respect to magnet alignment, leak proof-ness & internal magnet connections Some magnet types require much larger cold test times (Q5, Q6, Q7 – tested at 4.5 °K) than others (Q8, Q9, Q10 – tested at 1.9 °K) Special measurements like SSW and Chaconsa MM drastically increase the overall on-bench test time for the magnet V. Chohan SM18 Magnet Tests Review, February 06

Thank You Thanks are due to the whole OP Team for providing the Input for this talk. In particular, D.Roy & J.John have helped very significantly with all the relevant details of 2005 Operation for this Talk, continuing the tradition established by M.Mascarenhas in early 2005. Acknowledgements are also due to all the past & present members of the SM18 Operation Team from DAE-India & AB Dept, CERN to bring the Tests Programme to the level where it is today, together with all the other Support Teams ( MTM-Equipment, Cryogenics, ICS ) V. Chohan SM18 Magnet Tests Review, February 06

THE END The Future looks ”rosy” …..even without tinted glasses …but only if Special SSS concerns from OP Team are settled at the earliest.. V. Chohan SM18 Magnet Tests Review, February 06

11 Types in tabular form V. Chohan SM18 Magnet Tests Review, February 06

The famous 17 out of 59 for Magnetic Measurements

Operator Rota for Sp-SSS

Test timings for Sp-SSS tested in 2005

Sp-SSS Test Timings without SSW & Chaconsa

Sp-SSS Without SSW & Chaconsa

Preparation Time – Arc SSS vs Sp-SSS

SM-18 Magnet Test Operation – Status & Outlook

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