LHC Magnets: Cold Tests & Throughput V. Chohan SM 18 Operation CERN.

LHC Magnets: Cold Tests & Throughput

V. ChohanSM 18 Operation

CERN

V. Chohan LHC Project Workshop-Chamonix XIV, 17-21 Jan. 2005

2

Talk Outline

• The Environment– SM18 Operation – Boundary Conditions

• Current Situation– Results to Date – Summary

• Outlook– Projections – Concerns & Worries

(No Elaborate Status Report & Facts from the floor level !!!)

The Environment


4

SM18 Magnet Tests : What it’s all about

Demands on SM18 Operation

ProjectManagement

MagnetProduction

LHC Beam Running in &Minimum dI, dE

provision

AcceleratorPhysicists


5

Work Environment

• 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 we need to install Special 15 m Shafts• Shafts require Anticryostat mounting in magnets • Mobile Racks for HV insulation tests & Magnetic Measurements

• Utilities• Water for 4 magnet powering at the same time • Cryogenics capacity and limits

• Manpower [24 hr Tests Operation Staff special arrangements]• 7 CERN staff (up to end 2004) on loan from CERN Accelerator Operation• 15-20 persons on exact 1 year contracts from India & constantly rotating• Cryogenic Support staff ( 3 per shift) from Industrial Support contract • ICS “Magnet connectors” working 24 hours since June 2004, but not ROCLA operators

• SupportGeneralized Equipment support as opposed to specialized support as found in 24 Hr. OPERATION in CERN & “physics” is not at stake if specialist ‘fixing’ is delayed


6

Utilities : Cryogenics Capacity• Cryogenics capacity (in 2004) and limits :

3 to 5 Magnets @ 1.9K and under cold tests,

1 magnet in 300K to 90 K phase ,

1 magnet in Last (Warm up) Quench to 300K phase,

1 magnet in 90K to 1.9 K phase

with a further capacity constraint of not exceeding 9 recoveries of high field quenches or initial cooling from 4.2 K to 1.9 K per 24 h

We need to ensure that the magnets under the tests programme follow the cryogenic phase distribution as above, within the limits of possibilities due to the varying training performance ( a priori not known)

and respecting all the other environment constraints mentioned earlier

Current Situation


8

Magnets Tested: 2004

• A total of 396 Dipole & 55 SSS magnets were tested during the year 2004, these also include repeat magnets & IR-SSS.

• An estimate of 45 Dipole & 10 SSS magnets per month could be expected during year 2005, with the present environmental / test conditions

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37 36

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4341

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1015202530354045505560

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Cold Tests in SM18 in 2004

Total Dipoles

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Cold Tests in SM18 in 2004

TotalSSS


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Results to Date

Dipoles Dipoles Repeated

Arc-SSS Arc-SSS Repeate

d

IR-SSS

Year 2003 95 Not Applicable

2 Not Applicable

Not Applicable

Year 2004 358 38(about 11%)

49 3 3

TOTAL 2004 396Includes Rejects & Repeats

55Includes Rejects & Repeats

Cumulativ

e Total 491 57


10

Cumulative Total: All Magnets

(including Repeats & Rejects)

Cumulative Cold Tested Magnets

821

95 96120

157

193

223

260

297

340

381

428

476491

2 2 4 5 7 8 11 17 24 3142

53 57

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Outlook


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Countdown LHC : Simple Magnets Count

Basis • We are at the rate of ~ 55

Magnets tested per month (sustainable)The testing would end in April 07

• We need to go up to ~ 62 magnets per month . In this case,The testing would end in January

07 • It all depends on many factors but

principally for the sake of this simple calculation, one needs to consider what % of magnets get repeated & so forth leading to raw testing figure of : ( 1706 + x %)

• The cut-off around 1893 as an example assumes x =11 % in this Figure

Projection To Finish (assuming no cryo shutdown in Dec 06)

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Present-Rate 55 per Month

Rate 62 per Month


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Target 2007 : Simple Magnets Count

Basis • It would be judicious to

achieve a figure of ~ 69 magnets per month to finish by Nov 2006

• This rate of testing is desired to realise the objective of

“First LHC Collisions by Summer 2007”

&

Provide for contingencies

Projection To Finish (assuming no cryo shutdown in Dec 06)

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Present-Rate 55 per Month

Rate 62 per Month

Rate 69 per Month


14

How do we accelerate the testing of magnets ?

Our most precious resource is the bench occupancy time hence, one must

“Reduce the bench occupancy time”

• The bench occupancy time consists of

– Connect Time : Connection of Magnet to the CFB– Cooling Time : Cooling the Magnet to 1.9 K – Cold Test Time : Training the Magnet + Special Measurements– Warming Time : Warming the Magnet to 300 K– Disconnect Time : Disconnection of Magnet from the CFB (For a Dipole, this total should be theoretically 108 hrs.of which cold test time is 36

hrs. )

• To reduce the bench occupancy time, any OR all these times must be reduced


15

Bench Occupancy Reduction Schemes

• Enhanced Cryo-Capacity in 2005 & resulting optimism

• Moderate Proposals (Presented at MTM Review Jan 05)– Fewer Single Stretch Wire Measurements for Arc-SSS magnets – Reduced Training Quenches beyond 7 TeV: 3 Quench Rule– Improved Production Control at warm : Diode Tests– Reduced duplication : WP04 Insulation Tests

• Additional [Radical] Proposals that could still be done – Schemes that curtail training to currents upto 11 kA (~ 6.5 TeV

operation) ; implies ‘training’ in the tunnel to go up in Energy– Reduce “ Connect Time” by not doing certain tests at warm on the

bench


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Cryo-Capacity 2004 & Estimates 2005

• The Average Wait+Cooling time was 45 hours & Wait+Warming time was 20 hours

• We are told to expect a gain of 50 % in CWS unit of cryogenics in 2005. so at least 1 more magnet in 300K-90K or 30K-300K phase

• We predict a Wait+Cooling time of ~ 30 hours & Wait+Warming time of ~15 hours

Average (Wait+Cooling) & (Wait+Warming) Dipole Magnets

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SUMMARY: Time Saving Schemes

Average Time to Test magnets (hrs)

Details Dipoles Arc-SSS

Present Future Present Future

Connect Time 30 29 82 52

Wait +Cooling Time

45 33 32 30

Cold Test Time 34 28 75 35

Warming Time 20 15 12 14

Disconnect Time 8 8 8 8

Total test Time 137 113 209 137

• Based on Moderate Proposals & Cryo improvements

Cold Test times include Magnetic Measurements (Special & Non special)


18

• The gains only refer to Dipoles & Arc-SSS because we have No Experience with IR-SSS

• The calculation leads to 52 Dipoles & 16 Arc-SSS & i.e., 68 magnets could be tested per month, in a bench configuration of 8 Dipole +3 Arc SSS and leaving 1 Bench for IR-SSS

• However as it is obvious from above, the completion date cannot be based on a simple number count basis. The matter becomes much more complicated due to our boundary conditions…..throughput of Dipoles & Arc-SSS, matched bench allocation etc..

• An appropriate method to evaluate the projection date must take into account that the LHC ring is made up of different types of magnets which require appropriate bench mechanical & electrical configurations for testing

– 1232 Dipole Magnets– 360 ARC SSS Magnets– 82 IR SSS Magnets (DS + MS Type)– 32 IR SSS Magnets (DS_MQ Type)

1706 Total number of Magnets

Summary : Time Saved per magnet


19

Projections: Accelerated Rate for Dipoles & ARC SSS & Optimistic Rate for IR SSS

Date Magnets per

Month DipolesMagnets per

Month ARC SSSMagnets per

Month IR SSSCumulative

DipolesCumulative ARC SSS

Cumulative IR SSS

Cumulative Total

Magnets per Month

Configuration

Nov-04 48 11 476 51 2 529 59 D-9 / AS-2 / IS-1

Dec-04 15 3 1 491 54 3 548 19Feb-05 45 10 1 536 64 4 604 56 D-8/AS-3/IS-1Mar-05 50 12 2 586 76 6 668 64Apr-05 50 15 2 636 91 8 735 67

May-05 50 15 3 686 106 11 803 68Jun-05 50 15 3 736 121 14 871 68Jul-05 50 15 4 786 136 18 940 69

Aug-05 50 15 4 836 151 22 1009 69Sep-05 50 15 4 886 166 26 1078 69Oct-05 50 15 4 936 181 30 1147 69Nov-05 50 15 4 986 196 34 1216 69Jan-06 15 3 1 1001 199 35 1235 19Feb-06 34 16 6 1035 215 41 1291 56 D-6/AS-4/IS-2Mar-06 38 18 8 1073 233 49 1355 64Apr-06 38 21 8 1111 254 57 1422 67

May-06 38 21 8 1149 275 65 1489 67Jun-06 38 21 8 1187 296 73 1556 67Jul-06 38 21 8 1225 317 81 1623 67

Aug-06 38 21 8 1263 338 89 1690 67Sep-06 38 21 8 1301 359 97 1757 67Oct-06 38 21 8 1339 380 105 1824 67

Nov-06 29 1 8 1368 381 113 1862 38

Dec-06 7 1368 381 120 1869 7Jan-07 1368 381 120 1869 0Feb-07 1368 381 120 1869 0Mar-07 1368 381 120 1869 0

Apr-07 1368 381 120 1869 0May-07 1368 381 120 1869 0

Basic Targets 1232 360 114Re-Tested 135.52 21.6 6.84Probable Target 1367.52 381.6 120.84Total Magnets 1869.96

Assumption : Testing Time : Dipole 113 hrs; Arc SSS 137 hrs

114 (IR SSS)=50 (MS) + 32 (DS) + 32 (DS-MQ Type)


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Assumptions

• All the moderate proposals mentioned would be implemented

• It is assumed that a figure of 1869 magnets will have to be tested including retests.

Retest rates: 11% dipoles,6% Arc SSS, 6% IR SSS

• It assumed that the magnets will be available for testing as and when desired


21

Projections: Accelerated Rate for Dipoles & ARC SSS & Optimistic Rate for IR SSS

Highlights:

• Testing Time for Dipoles is ~113 hrs• Testing Time for ArcSSS is ~ 137 hrs•Testing Time for IR- SSS ~ 168 hrs?

Completion of testing of all MAGNETS

Dec 06

Assumption:

We can attain a figure of up to 69 magnets per month

Projection To Finish Dipoles(assumed no cryo shutdown in Dec 06)

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Cummulative Yield SSS

Cumulative Yield IR-SSS


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Projections: With ~ 62 to 65 Magnets per month

Date Magnets per

Month Dipoles

Magnets per Month ARC

SSS

Magnets per Month IR SSS

Cumulative Dipoles

Cumulative ARC SSS

Cumulative IR SSS

Cumulative Total

Magnets per Month

Configuration

Nov-04 48 11 476 51 2 529 59 D-9 / AS-2 / IS-1Jan-05 15 3 1 491 54 3 548 19Feb-05 46 10 1 537 64 4 605 57 D-8 / AS-3 / IS-1Mar-05 49 12 1 586 76 5 667 62Apr-05 49 12 1 635 88 6 729 62

May-05 49 12 2 684 100 8 792 63Jun-05 49 12 2 733 112 10 855 63Jul-05 49 12 4 782 124 14 920 65

Aug-05 49 12 4 831 136 18 985 65Sep-05 49 12 4 880 148 22 1050 65Oct-05 49 12 4 929 160 26 1115 65Nov-05 49 12 4 978 172 30 1180 65Jan-06 15 3 1 993 175 31 1199 19Feb-06 37 16 4 1030 191 35 1256 57 D-6 / AS-4 / IS-2Mar-06 37 17 4 1067 208 39 1314 58Apr-06 37 17 6 1104 225 45 1374 60

May-06 37 17 6 1141 242 51 1434 60Jun-06 37 17 6 1178 259 57 1494 60Jul-06 37 17 6 1215 276 63 1554 60

Aug-06 37 17 6 1252 293 69 1614 60Sep-06 37 17 6 1289 310 75 1674 60Oct-06 37 17 6 1326 327 81 1734 60Nov-06 37 17 6 1363 344 87 1794 60Dec-06 5 17 8 1368 361 95 1824 30Jan-07 17 8 1368 378 103 1849 25Feb-07 3 12 1368 381 115 1864 15 AS-2 / IS-4Mar-07 5 1368 381 120 1869 5Apr-07 1368 381 120 1869 0May-07 1368 381 120 1869 0

Basic Targets 1232 360 114Re-Tested 135.52 21.6 6.84Probable Target 1367.52 381.6 120.84Total Magnets 1869.96

Assumption : Testing Time : Dipole 116 hrs; Arc SSS 170 hrs

114 (IR SSS)=50 (MS) + 32 (DS) + 32 (DS-MQ Type)


23

Projections: With ~ 62 to 65 Magnets per month

Highlights:

• Testing Time for Dipoles is ~116 hrs• Testing Time for ArcSSS is ~ 170 hrs•Testing Time for IR- SSS ~ 240 hrs ?

Completion of testing of all MAGNETS

March 07

Assumption:

We can attain a figure of up to 65 magnets per month

Projection To Finish Dipoles(assumed no cryo shutdown in Dec 06)

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Concerns & Worries


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Possible Concerns & Worries for installation

1. IR-SSS – Testing :

• 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 a up to a 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)

– “OFF-THE-SHELF” Availability for installation ?


26

Possible Concerns & Worries

2. Manpower & Continuity– Indian Associates

• With fixed one year contracts, there is continuous rotation of people, hence some are always on the learning curve. This could be a problem in an accelerated magnet testing scenario which requires continuity & stability.

– CERN AB-OP Staff• In case of 2006 early Accelerators start-up how

would the SM18 Operation cope with reduced Stable CERN support?


27


3. Is the production reliable that our test programme remains stable – Will additional tests like “Diode test” at cold be

introduced or means found otherwise (at warm) for production control?

4. Other (newer) demands on SM 18 operation– Dynamic effects at injection, sufficient time

resolution for decay/snapback, degaussing cycles etc, all need new additional studies. Even if conducted on fewer magnets, they take long time and upset the normal tests rhythm because the magnet remains on the bench a long time at cold. (and keeps a higher priority). Will similar (newer) requests be made ?


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5. Can others cope with faster throughput?– ICS Consortium Contract Labour

• Do they have adequate manpower to absorb the increased work load

– Equipment Support• The fact that we have “Generalized Equipment

support as opposed to specialized support as found in 24 Hr. operation in CERN” causes delays in solving problems and hence reduces our ability to test magnets faster


29


6. ROCLA – ROCLA suffered from breakdowns in 2004, with dramatic effects;

similar issues would jeopardise our desired test rates – Presently the ROCLA operation staff do not work 24 hrs, but with the

projected magnets per month, it is imperative that a change in working hours will be required. Our experience with ICS says that these things do not happen overnight.

Connect, Total Bench Time per Dipole

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Conclusions

1. Different Projections with end-2006 goal in mind have been presented showing that testing of what we do know ( Dipoles & Arc-SSS) must go faster to permit more time for the unknown ( IR-SSS)

2. The IR SSS testing, particularly magnetic measurements will have to be based on sampled or Type testing and utilising all our known measurement systems and facilities both in SM18 and Block 4 on Prevessin site ( MAC Dec 04, Review Jan 05 )

3. Despite many unknowns we believe that there is a reasonable chance of terminating the test programme in time by end 2006 OR early months of 2007.

““Optimism is the faith that leads to achievement. Nothing Optimism is the faith that leads to achievement. Nothing can be done without hope and confidencecan be done without hope and confidence““

.....Helen Keller (American author and educator who was blind and deaf. 1880-

1968)


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Thank You

Thanks to the OP Team for providing the Input for this talk.

Acknowledgements are also due to 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, Power convertor)

LHC Magnets: Cold Tests & Throughput V. Chohan SM 18 Operation CERN.

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Transcript of LHC Magnets: Cold Tests & Throughput V. Chohan SM 18 Operation CERN.