OPERATION FOR LHC CRYOMAGNET TESTS: CONCERNS, CHALLENGES & SUCCESSFUL COLLABORATION CERN, Geneva, Switzerland Asian Particle Accelerator Conference Indore, India 30 January 2007
Outline Introduction Concerns & Hurdles Early Performance Operational Strategies & Tools Results Concluding Remarks APAC 07, January 2007, Indore, India 2
LHC Requires: Introduction 1232 Dipoles (~19 km out of 27 km ring) 360 Short Straight Sections (MQ - SSS) 114 Insertion Region SSS (IR-SSS) Testing & Qualification (& Training!) of each of them for: Cryo, mechanical & electrical insulation Quench performance Field Quality Total of ~ 1900 magnets (incl. spares & repeats) to be tested before early 2007! APAC 07, January 2007, Indore, India 3
Massive Effort! 15 m long dipoles SSS Test facility called SM 18 APAC 07, January 2007, Indore, India 4
SM18 Test Facility With 12 test benches & Cryogenic infrastructure Testing of first series magnets: early 2001 with only 2 test benches All 12 benches ready only by June 2004! APAC 07, January 2007, Indore, India 5
Various Teams of SM18 Magnet Tests Team (OP Team) Mainly consists of associates from DAE, India Cryogenics Team Magnet Connect / Disconnect Team Magnet Transport Team Industrial consortia APAC 07, January 2007, Indore, India 6
Magnet Tests.. What do we do? New magnet arrives.. Insulation test, connection to CFB Preparatory tests (functioning of protection systems & instrumentation, insulation ) Final warm tests Electrical integrity Resistance measurements.. Final insulation tests Disconnection from CFB Cool down to 1.9K Warm up Preparatory tests (tuning DAQ..) Insulation tests Functioning of protection systems Power tests (&Training) Magnetic measurements Final insulation tests @cold APAC 07, January 2007, Indore, India 7
SM18 Magnet Tests : What it s all about Project Management Magnet Production Demands on SM18 Operation LHC Beam Running in & Minimum di, de provision Accelerator Physicists APAC 07, January 2007, Indore, India 8
Concerns & Hurdles APAC 07, January 2007, Indore, India 9
Who s & How s of Tests 1. Novelty Aspects Early R&D culture lack of transparency! Magnets trained to ultimate field, Extensive magnetic measurements, Qualification of poor magnets.. 2. Infrastructure Limitations Cryogenics, Water, Electronics, Power Converter.. 3. Personnel Logistics Minimum staff strength of 4 per shift (24 hr operation, 45 weeks..) 4. Co-ordination of Work & Teams Indian Staff & Language barrier! 5. Nature of Industrial Contracts Work slowed down during weekends, lack of adequate technical support beyond normal hours.. APAC 07, January 2007, Indore, India 10
Early Performance APAC 07, January 2007, Indore, India 11
Early Performance Only 21 magnets in 2001~02! Only 95 magnets till end 2003! Finish testing of remaining ~1800 magnets by early 2007??? APAC 07, January 2007, Indore, India 12
Operational Strategies & Tools APAC 07, January 2007, Indore, India 13
Strategies 1.Addressing Manpower Issues Who? 2.Addressing Technical Issues How? APAC 07, January 2007, Indore, India 14
Addressing Manpower Issues APAC 07, January 2007, Indore, India 15
Staffing Profile 2003 7 from CERN 5 from India APAC 07, January 2007, Indore, India 16
40 35 30 25 20 Manpower Issues Staff strength : 4 per shift ( total 24) 7 from CERN (up to 12 in 2005) 45 Cern Rest from India BUT on strict 1 year rotation (2005) CERN CERN FTE FTE ~ 12 12 INDIA INDIA FTE FTE ~ 14 14 Hence careful (2005) planning was necessary.. Cern-New India-New India 15 10 5 (2006) (2006) CERN CERN FTE FTE ~ 6 6 INDIA INDIA FTE FTE ~ 20 20 0 APAC 07, January 2007, Indore, India 17
Addressing Technical Issues APAC 07, January 2007, Indore, India 18
Operational Strategies 1. To-Do List Describes minimum set of tests on each magnet 2. Magnet Test Report (MTR) Paper log of test results 3. Get higher throughput Training rules: Two-Quench Rule Three Quench Rule Reduced magnetic measurements 4. Rapid On-Bench Thermal Cycle (ROBTC) Thermal cycle of a poor magnet without disconnection from test bench 5. Overall & Cryo priority setting 24 hour priority decision by OP team for effective & clash-free utilization of resources APAC 07, January 2007, Indore, India 19
Tests numbered sequentially To-Do List & MTR Obeys To-Do List Prefixes define type of test Checklists & notes appended APAC 07, January 2007, Indore, India 20
Training Rules & ROBTC Most of the good magnets crossnominal field (11850A ~ 8.33T) in the second training ramp.. 13350 12850 12350 ALL ramp2 80% magnets cross nominal in 2 nd ramp! Two-Quench Rule: Accept the magnet if it crosses nominal field in Second training with small margin! 11850 11350 10850 10350 Three-Quench Rule: Accept the magnet if it crosses 12250 A (~8.66 T) in third training, even if it had not passed the preceding rule.. 1001-1st run run 3002-2nd 1002 run 3002-1002-3rd 3rd run run 3001-3rd 1003 run 1004-1st 1002-3rd run run 1006-1st 1005 run 1006-1st 1008-ist run run 1007-1st 1012 run 1008-ist 1013 run 1008-2nd 1017 run 1009-1st 1018 run 1010-1st 1031 run 1011-1st 1032 run 1012 1035 1013 1038 1014 1045 1015 1039 1016 1042 2003-1st 1017 run 3001-4th 1018 run 3002-4th 1019 run 1021 3004 1026 3006 1026-3007 2nd 1022 3008 1023 3014 1024 3027 1025 3028 3046-2nd 1027 run 1028 3054 1029-1st 3070 run 1029-2nd 3001-2nd run 1004-1st 1020 run 1031 2008 1010-1st 1032 run 1034 1016 1050-2nd 1035 run 1007-1st 1038 run 1045 1015 1039 1003 1008-2nd 1042 run 1009-1st 1049 run 1050 2007 1050-2nd 1052 run 1052 1028 1048 1034 2008-2nd run 2001-1st 3045 run 2001-2nd 2006 run 2001-3rd 3034 run 2002 3041 2003-1st 1023 run 2004 3047 1029-2nd 2008 run 2008-2nd 2004 run 2022-2nd 2007 run 2026-2nd 2006 run 2010 2009 2009 3044 2012 2020 2017 3012 1011-1st 2018 run 2020 1024 2021 1002 2022 1050 2022-2nd 3013 run 2025 3042 2025-2nd 1049 run 2023-2nd 2023 run 2023-2nd 3011 run 2026 1021 2026-2nd 3038 run 2027 1014 2029 1025 2001-2nd 2024 run 2001-3rd 2024 run 3001-1st 2054 run 3039 3001-1st 3065 run 3001-2nd 3043 run 1026-3001-3rd 2nd run 3002-3001-4th 1st run 3002-1st 2054 run 3002-2002 2nd 3002-3rd 1048 run 3002-4th 1029-1st run 3004 3005 2017 3005 2017 2024 2025-2nd 3006 2024 run 2025-2nd 3007 1027 run 3008 1027 2012 3011 2012 2029 3012 2029 1022 3013 1022 3046 3014 3046 2018 3027 2018 3055 3028 3055 2026 2001-1st 3034 2026 run 2001-1st 3041 1026 run 3038 1026 2010 3039 2010 1019 3042 1019 1020 3044 1020 2025 3043 2025 2021 3045 2021 2023 3046 2023 2024 3046-2nd 2024 run 2022 3047 2022 2027 3054 2027 1005 3055 1005 3065 3070 ROBTC: Rapid thermal cycle of a poor magnet without disconnection from test bench Saves disconnection & connection time. And mounting the quench location devices (often a futile exercise!) APAC 07, January 2007, Indore, India 21
Overall & Cryo Priority Setting Ensure that magnets follow the desired cryogenic phase distribution, within the limits of possibilities due to the varying training performance ( a priori not known) APAC 07, January 2007, Indore, India 22
Operational Tools 1. SM18 Test Management System (SMTMS) All relevant test data stored in it 2. E-traveller Web based electronic work flow manifest with mobile phone interface 3. Integrated Resource Display On-line display of usage of various resources 4. E-logbook 5. MAPS Maintains log of activities, categorizes & records faults Single page record of rule based magnet goodness evaluation 6. Operations Web page Easy access to all tools & documents APAC 07, January 2007, Indore, India 23
SMTMS & E-Traveller Saves all test data into the system Smooth team interaction Tracks test progress & test statistics Automatic generation of test reports Interface with mobile phones alert teams Minimizes verbal communication.. Maintains automatic record of test flow APAC 07, January 2007, Indore, India 24
Other Tools Integrated Resource Display E-log book MAPS Operations Web page APAC 07, January 2007, Indore, India 25
APAC 07, January 2007, Indore, India 26
Results APAC 07, January 2007, Indore, India 27
Early performance With new strategies & tools APAC 07, January 2007, Indore, India 28
Annual Statistics Total Magnets Tested 800 703 700 648 600 456 500 400 300 200 100 0 21 76 2002 2003 2004 2005 2006 Special SSS tests, Train to ultimate Time consuming! APAC 07, January 2007, Indore, India 29
Repeat Rates & Magnetic Measurements Repeat Rate Mag. Meas. (MM) Repair/ Rejection % % % Dipoles 9 18.36 ~ 3 SSS 12.5 13.32 ~ 6 IR-SSS 12.8 30.85 -- APAC 07, January 2007, Indore, India 30
Concluding Remarks 1. Magnet tests completed ~Feb 2007 2. Major contributions of Indian Associates: Unique, large scale international Development of strategies, tools & collaboration in the accelerator domain! procedures (in human resources: ~90 persons in 5 years) Dedication, Sincerity and Hard work And much more. APAC 07, January 2007, Indore, India 31
Indian Associates in SM18 (2002 2006) Collaborators from Bhabha Atomic Research Centre (BARC), Mumbai, India: Clement Verghese, Prem Kumar Kavalan, Laddha Anand, Maurya Beachai, Malhotra Sanjay, Perupayikkad Daniel Babu, Shetty Satish Shankar, Narayanan Ramkumar, Satyanarayana Arunkumar, Nair Kesavan, Awale Prashant Kamalakar, Patil Mahesh Balasaheb, Dubey Krishna, Roy Amitava, Thota Venkatesulu Shyam, Gupta Rakesh Kumar, Mascarenhas Martin Lucio, Surendran Puthiyedath, A Kasbekar, J Mishra, P Motiwala, P Adibabu, P Joshi, P Kashyap, Naushad Ali, D Roy, Jacob John, K Ambastha, Jaydeep Gore, Vasu Kakkat, Sanjeev Sharma, D Bhattacharjee, Sudheer Singh, Surajit Sen, Manna, Swagat Mukherjee, Vikas Chauhan, Mukesh Sharma, Vikas Telang, Subrat Kaushik, Sumeet Maity, Sampath Kumar, Charudatta Kulkarni, S. Padmakumar, P. K. Panda, N.S. Dalal, Sunil G Kulkarni, Sreyas R Shimjith, Sushil K Bahuguna, Vijendra Sinha, Kuldeep Joshi, E Kandaswamy, M Y Dixit, Amit Tikaria, R I Bhaktsingh, B V Rama Rao, S T Sonnis, N G Tayade, Vivek Yadav G Aravamuthan, S. Gomu, Gangoor, Vineet Sinha, M Naskar,Y Chaudhari, A Basu, P Behere Collaborators from Centre for Advanced Technology (CAT), Indore, India: Gandhi Manoj, Marathe Ravindra G, M Jathar, Radheshyam Pramod, A Kasliwal, Khare Krishna Mohan, Pareek Prashant, Jain Akhilesh, Pagare Anand, Yash Pal Singh, Mandar Joshi, Praveen Deshpande, Jitendra Patil, Rajkumar Gupta, Seshnath Singh S Kane, S Pralod, Vimal Bhatnagar Collaborators from Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, India: T S Selvakumaran, R Dhandapani, Sethumadhavan Sridhar, B Rao, K Palanisami Collaborators from Variable Energy Cyclotron Centre (VECC), Kolkata, India: Bhunia Uttam, Bhole R, Sandip Pal, J Debnath APAC 07, January 2007, Indore, India 32
Making it possible.. APAC 07, January 2007, Indore, India 33
It is pretty cool APAC 07, January 2007, Indore, India 34
With food for thought.. APAC 07, January 2007, Indore, India 35
With a little workout.. APAC 07, January 2007, Indore, India 36
& Bit of aerobics for health! APAC 07, January 2007, Indore, India 37
Thank You! APAC 07, January 2007, Indore, India 38
Extra Slides APAC 07, January 2007, Indore, India 39
Statistics: Actual Vs. Predicted Throughput For the dipoles actual throughput has coincided with the prediction. For the special SSS and arc SSS the actual throughput is better then the prediction. APAC 07, January 2007, Indore, India 40
Ramp 1 [To 12850A] Rules : 15 April 04 magnet trained! Generate.u file at 12850A & SPA Min. NRJ at 11.85 ka MM*, CDAP CDAP No Yes Min. NRJ at 11.85 ka MM*, CDAP If shafts? No No Generate.u file at 12850A & SPA Yes CDAP at 4K Warm-up on 10 th Quench at 4K (SSL) Quench? Ramp 2 [To 12850A] Quench? Yes Iq<12kA Yes Iq<12kA Train to 12850A (see rules) # 8 ramps No PT8 Ramp 9 [To 12850A] Quench? Yes Iq>12kA Yes No Generate.u file at 12850A & SPA MM*, CDAP Yes Iq>12kA MM*, PT8, CDAP MM*, PT8, CDAP Ramp 2 [To 12850A] No Quench? Generate.u file at 12850A & SPA Yes Min. NRJ at 11.85 ka Min. NRJ at 11.85 ka Warm-Up
# Max 9 Ramps to 12850A; If this terminated in <= 9 ramps Then follow flowchart, else: magnet is poor & do warmup on 10th with 4K quench Instead of PT10 THEN: Thermal Cycle if AntiC exist & so put in shafts ELSE(( if no AntiC) Magnet removed & Standby MM* If Shafts Are Present! PT8 = Ramp to 12 ka & SPA Min CDAP NRJ =HV@ = Quench cold provoked Final FPA Disabled Thermal Cycle Rules with Shafts Inserted : In the 2 nd Run: if 1 st Q above (8.4 T) 12000A then MB accepted if 2 st Q above (8.6 T) 12350A then MB accepted ELSE MAGNET REJECTED WITH poor perf non-conformity but with the rules : if Quenches are localised only in 2 nd run (with shafts inserted only in the 2 nd run ): perform 5 quenches only And END the Tests. if Quenches were localised in first RUN : then perform max 2 localized quenches only in 2 nd run APAC 07, January 2007, Indore, India 42
Typical magnet test times (For the week starting 26 th July 2005) Fatigue tests ICS new connection problems Connection cryostat (B1) ROBTC Reference Times Light green : Connect (up to Cryo pump down) Blue : Wait + Cool down Ivory: Tests at Cold Red : Wait + Warm up Dark Green: Disconnect 24 h 26 h 36 h 12 h 12 h APAC 07, January 2007, Indore, India 43
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 APAC 07, January 2007, Indore, India 44
Utilities : Cryogenics Capacity Cryogenics capacity (in 2005) and limits : 3 to 5 Magnets @ 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 2004 ) 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 APAC 07, January 2007, Indore, India 45
Magnet work flow at CERN before beam test Courtesy: L.Rossi To be connected: Arrival CM Arrival CM Beam tubes Pipes for helium Cryostat Thermal shields Beam screen Beam screen Vacuum vessel Superconducting cables Store Store limited number limited number 6 superconducting bus bars 13 ka for B, QD, QF quadrupole Reception Reception Store Store 4 areas 4 areas Extra-work 13 Extra-work ka Protection (30% dip) (30% dip) diode Stripping Stripping Fiducials Fiducials th Connections Tunnel 1st dipole Alignment lowered : 7 March 2005 Tunnel Alignment Connections Beam test Beam test December 2007 20 superconducting bus bars 600 A for corrector magnets (minimise dipole field Cryostat Cold test harmonics) Cold test Cryostat Hardware Commissioning Hardware 42 sc bus bars 600 A Commissioning for corrector magnets (chromaticity, tune, etc.) 2007 Start January + 12 sc bus bars for 6 ka (special quadrupoles) APAC 07, January 2007, Indore, India 46
Cost structure of the LHC Courtesy: L.Rossi Magnet+cryogenics = 66% APAC 07, January 2007, Indore, India 47
LHC tunnel 2002
LHC tunnel 2006
Regular arc Magnets 1232 main dipoles + 3700 corrector (spool pieces) APAC 07, January 2007, Indore, India 50
Regular arc Magnets 392 main quadrupoles + 2500 corrector magnets Installed dipole SSS being transported APAC 07, January 2007, Indore, India 51
Connection via service module and jumper Supply and recovery of helium with 26 km long cryogenic distribution line Static bath of superfluid helium at 1.9 K in cooling loops of 110 m length APAC 07, January 2007, Indore, India 52
Beam vacuum for Beam 1 + Beam 2 Beam vacuum for Beam 1 + Beam 2 Insulation vacuum for the Insulation cryogenic vacuum for distribution the cryogenic line distribution line Insulation vacuum for the magnet Insulation cryostats vacuum for the magnet cryostats APAC 07, January 2007, Indore, India 53
Beam vacuum for Beam 1 + Beam 2 quench protection, power converters for orbit correctors and instrumentation (beam, vacuum + cryogenics) APAC 07, January 2007, Indore, India 54
Inner triplet magnets APAC 07, January 2007, Indore, India 55
Courtesy: L.Rossi Accelerator magnets issues In iron dominated magnets the pole shape dictates field quality In superconducting magnets the conductor position dictates the accuracy of the field. Coils not self-supporting Beam will circulate 500 Millions times in the LHC! Field accuracy: 10-100 ppm Necessity to have all dipoles equal in length within ~ 100 ppm (1.5 mm over 15 m of the LHC dipole length!) LHC main dipoles Quantity: 1232 dipoles 15 m = 18.5 km Operated at same current: 154 circuits Extremely high current density: operation 85% of Ic (on load line), little stabilizer to increase J Training. BUT we cannot train them at long (it costs too much) and they should not retraining. After the cool down the worst magnet will determine the energy of the accelerator. APAC 07, January 2007, Indore, India 56
The historical outlook Courtesy: L.Rossi APAC 07, January 2007, Indore, India 57
Dipole cross section: yoke & shrinking cylinder 275.10 275.05 275.00 274.95 274.90 Radius average Grinding Operation Curvature released from ± 1 to ± 2.5 mm: Solution: pairing Two half shells, welded on the magnet Courtesy: L.Rossi APAC 07, January 2007, Indore, India 58
Courtesy: L.Rossi Dipole -end part end plate APAC 07, January 2007, Indore, India 59
Courtesy: L.Rossi Dipole-end part Bus Bars APAC 07, January 2007, Indore, India 60
Courtesy: L.Rossi Dipole -end part Shrinking cyilinder APAC 07, January 2007, Indore, India 61
Courtesy: L.Rossi Dipole -end part Cu HXT APAC 07, January 2007, Indore, India 62
Courtesy: L.Rossi Dipole -end part Corrector Magnets APAC 07, January 2007, Indore, India 63
Courtesy: L.Rossi Dipole -end part Cold foot, Bellows and N-line APAC 07, January 2007, Indore, India 64
APAC 07, January 2007, Indore, India 65