302 2 02 Strand Procurement Production Readiness Review

302. 2. 02 Strand Procurement Production Readiness Review (CD-3 b scope: verification and witness testing) Presentation 1 – Overview and Status Lance Cooley – L 3 Manager Strand Procurement

Outline of this review § Overview of the scope, workflow, deliverables, interfaces, quality plan, and present status of strand production § (this presentation) § QC testing at the supplier – Lance Cooley § Framework for verification testing § § Verification testing at NHMFL – Jun Lu Extracted strand witness testing at FNAL – Daniele Turrioni Cost and Schedule – Vito Lombardo, CAM Summary / Close – Lance Cooley Strand Production Readiness Review - 22 Aug 2019 2

Nomenclature § § § CD-xx: Department of Energy critical decision gate BCR: baseline change request PRR: production readiness review XS, VS: extracted strand, virgin strand QA, QC: quality assurance, quality control QP: quality plan approved by CERN Strand Production Readiness Review - 22 Aug 2019 3

Members of the team § § Strand CAM – Vito Lombardo - FNAL Strand record keeping: Brian Vail (student) - FSU Strand verification testing: Jun Lu and Jeremy Levitan – NHMFL Cabling: Ian Pong (L 3), Andy Lin, Charlie Sanabria (now CFS), Jonathan Lee (intern student), Hugh Higley § Witness samples: Danielle Turrioni and Al Rusy - FNAL MQXFA Superconductor Perf. , Production, QA/QC 4

Scope – Revised § LARP inventory has covered first 12 cables § CD-3 a: Buy Nb 3 Sn strand for 90 cables (102 total) § Unit Length UL = 500 m x 40 str. x 90 units = 1, 800 km, 9 tons § Vendor’s QC is included § CD-2/3 b: Verify vendor’s QC tests § 500 tests based on test yield, manufacturing yield, and CERN-AUP quality plan (QP) agreement (verify at 50% rate) § CD-2/3 b: Prepare and test coil witness samples (XS and VS) § Per Cable PRR: 307 100 VS tests based on # of coils, witness fixture, QP, and test yield § Per Cable PRR: XS tests only if coil underperforms upon cold test § BCR after Cable PRR: Prepare and test cable extracted strands § 230 tests based on remaining 60 cables x 3 XS per cable, test yield, and initial testing rate to establish XS statistics for process control Strand Production Readiness Review - 22 Aug 2019 5

Interfaces – Revised per Cable PRR outcome § Interfaces controlled by US-Hi. Lumidoc-219 and: § US-Hi. Lumi-doc-282: Strand to Cable (02 -03) § US-Hi. Lumi-doc-279: Strand to Coil (02 -05, 02 -06) § Deliver strand spools to cable team, 302. 2. 03, with QC reports certifying compliance with specification § Full traceability back to raw materials and QC (vector #464341, 464219, 464269) § Trace forward to cable QC (vector #464342) and cable MIP § Cable team acknowledges spool receipt § Deliver witness samples to coil teams, 302. 2. 05 & 06, and receive test samples back. § Two witness samples are VS taken from one reference spool for the entire production § Four XS witness strands are reacted and held until after coil test, usually not tested § Test report certifies proper reaction and coil margin § Report is entered into coil reaction traveler #464312 § Receive extracted strands from cable § Deliver coil reaction heat treatment team 302. 2. 03, react and test XS schedule to coil teams, 302. 2. 05 and § Test Report certifies coil margin, and is 302. 2. 06 § Reaction schedule US-Hi. Lumi-doc-109 entered into coil reaction traveler #464312 Strand Production Readiness Review - 22 Aug 2019 6

VECTOR § Primary uploads for each shipment: § 464219 – Billet pedigree report: all material information and nested assembly § 464269 – Strand spool report and certification: electrical and mechanical data § 464341 – Strand shipment traveler: collects all spools and billets in a shipment § 464234 – Cable manufacturing summary: collects pertinent information from cables § 464342 – Cable QC and witness sample preparation traveler: tracks RRR and witness samples § 464312 – Coil reaction traveler: contains outcome of witness sample measurements Strand Production Readiness Review - 22 Aug 2019 7

Discrepancies, Changes, Archives § Vector is used to open discrepancy reports and nonconformance findings § Each discrepancy is issued a unique identifier § Discrepancy closure process is tracked § Change control: § Documents are maintained under change control § Archives § Data are stored on Vector archive when process is completed § Unused strand lengths are archived at LBNL Strand Production Readiness Review - 22 Aug 2019 8

Risks RI-ID Title Risk Rank RT-302 -2 -02 -004 Variation in manufacturing rate affects strand delivery schedule 2 (Medium) RT-302 -2 -02 -002 Theft or disaster causes loss of entire strand inventory 2 (Medium) RT-302 -2 -02 -001 Problems in supply chain cause major disruption of strand delivery 2 (Medium) RT-302 -2 -02 -005 Additional QC requested by CERN 2 (Medium) RT-302 -2 -02 -003 Strand price is much higher than estimated 2 (Medium) RO-302 -2 -02 -003 Outsource QC of round wires to external qualified test facility 3 (High) RO-302 -2 -02 -002 Convert manufacturer guarantee into project risk to reduce strand price 3 (High) RO-302 -2 -02 -001 Accept multiple unit lengths for delivery to reduce strand price 3 (High) Threats - Schedule Threats – Cost Opportunities – Cost Risk management: RO-302 -2 -02 -002 closed Pending action after this PRR: Close RO-302 -2 -02 -003, 001, RT-302 -2 -02 -005 Strand Production Readiness Review - 22 Aug 2019 9

Superconductor Quality Plan APPROVED BY CERN AS PART OF CABLE PRR Lance Cooley – Florida State / NHMFL – Strand L 3 Vito Lombardo – FNAL – Strand Deputy L 3 and CAM Ian Pong – LBNL – Cable L 3 and CAM Charlie Sanabria – LBNL – Cable Deputy L 3 Quality Plan – Dec. 6 th 2018

Structure and relationships in the quality plan Strand Production Readiness Review - 22 Aug 2019 11

Workflow at strand contract § Proposal requirements included: § Disclosure Statement § Supplier MIP § Management Plan § Quality Plan § Delivery Schedule § Control point: Authorization to begin work § Can be halted § Plans can only be modified by change order Strand Production Readiness Review - 22 Aug 2019 12

Workflow: Supplier to Strand WBS § Control point: Authorization to deliver § Control point: Discrepancy resolution § QA Package: § All traceable certs § Mechanical QC § Electrical QC § Cert. of Conformance § Delivery notification 302. 2. 02 302. 2. 03 § May flag certain spools pending verification tests Strand Production Readiness Review - 22 Aug 2019 13

Workflow: Supplier to Strand WBS § Control point: Authorization to deliver § Control point: Discrepancy resolution § QA Package: § All traceable certs § Mechanical QC § Electrical QC § Cert. of Conformance § Delivery notification 302. 2. 02 302. 2. 03 § May flag certain spools pending verification tests Strand Production Readiness Review - 22 Aug 2019 14

Workflow: Supplier to Strand WBS § Control point: Authorization to deliver § Control point: Discrepancy resolution § QA Package: § All traceable certs § Mechanical QC § Electrical QC § Cert. of Conformance § Delivery notification 302. 2. 02 302. 2. 03 § May flag certain spools pending verification tests Strand Production Readiness Review - 22 Aug 2019 15

Workflow: Strand WBS to Cable WBS § Delivery arrival at LBNL and return of delivery verification to strand WBS § Control points: § Cable work order § ATPPs § Auth. to ship cable § Cable release approval § Cable MIP has been reviewed separately § Strand MIP is in the Cable MIP Strand Production Readiness Review - 22 Aug 2019 16

Workflow: Strand WBS to Cable WBS § Delivery arrival at LBNL and return of delivery verification to strand WBS § Control points: § Cable work order § ATPPs § Auth. to ship cable § Cable release approval § Cable MIP has been reviewed separately § Strand MIP is in the Cable MIP Extracted Strands to FNAL for Ic, nvalue test Strand Production Readiness Review - 22 Aug 2019 17

Summary of Procurements PO Length Avg. Spool Del. Date #DR QXFS QXFA/P LARP QXFA/P AUP CERN LARP 624035 208 km 2. 6 km 01/16 – 03/17 1 376 UL 12 UL LARP 632982 400 km 2. 3 km 09/17 – 06/18 0 144 UL 586 UL 40 UL AUP 646116 300 km 2. 7 km 12/18 – 02/19 1 553 UL 28 UL 7428700 100 km 3. 7 km 02/19 – 03/19 0 187 UL 8 UL AUP (LBNL) 40 UL AUP 646116 SA 1 580 km 04/19 – AUP 655175 400 km 04/20 Sched. (All) AUP TBD 420 km 2021 (All) Ongoing UL = 200 m 500 m 840 m Strand Production Readiness Review - 22 Aug 2019 18

Strand Procurement & Schedule Detail Cumulative Strand ULs Delivered, Cables Completed, and Coils Started (Rejected Cables and associated strand not included) 100 Strand Delivered Cable Completed Coil Start 90 ra n d 70 60 st bl es Scheduled 50 ca ils 40 co Number of Units 80 Actual strand 30 20 10 0 1 -Oct-16 1 -Oct-17 1 -Oct-18 1 -Oct-19 30 -Sep-20 30 -Sep-21 30 -Sep-22 30 -Sep-23 29 -Sep-24 29 -Sep-25 Date CD-3 a granted Strand Production Readiness Review - 22 Aug 2019 19

Actual deliveries vs schedule Scheduled Apr-19 Actual Jun-19 44 km 61 km Issues: 1) Liquid helium cap imposed by He supplier has required supplemental delivery from Fermilab to complete QC testing 2) Extrusion press breakdown transferred work to backup provider Strand Production Readiness Review - 22 Aug 2019 20

Publications of the QA/QC processes Strand Production Readiness Review - 22 Aug 2019 21

Charge Questions 1. Scope and interfaces: Is the L 3 task scope clearly defined and are interfaces with other tasks sufficiently well-defined for execution during QC validation, and preparation and test of extracted strands and witness samples? § Recent BCR after Cable PRR produced a change in scope to reposition testing of XS prior to coil reaction § Mitigates risk that an unknown will be discovered when many cables have been produced ahead of coil reactions § Remainder of scope is same as that approved at CD-3 b Strand Production Readiness Review - 22 Aug 2019 22

Charge Questions 2. Procurement and Manufacturing: are the procurement and manufacturing work flow documents and travelers —including scheduling, personnel needs, floor space, and facilities requirement— appropriate to execute these activities during series production? § Next talk will discuss the strand supplier; however that has been approved under CD-3 a and is only a reference point for this PRR § Procurement of verification testing at NHMFL and manufacturing of components needed for testing will be covered in upcoming presentations Strand Production Readiness Review - 22 Aug 2019 23

Charge Questions 3. QA/QC: Is the QA/QC plan adequate? Is there appropriate documentation for quality control procedures, manufacturing and inspection plan, and data reporting? § A Quality Plan has been reviewed and approved by CERN § The QP has been updated after the Cable PRR § Strand MIP elements are incorporated into the Cable MIP approved by CERN § Upcoming talk will describe QA/QC from the QP and data recording in VECTOR § The vendor’s QP is part of the documents submitted for contract negotiation prior to the authorization to begin work; this process has been at CD-3 a approval. Strand Production Readiness Review - 22 Aug 2019 24

Charge Questions 4. Cost and Schedule: Are the cost and schedule estimates sufficiently well-defined and of adequate maturity to support these activated during series production? § Upcoming presentations will describe cost and schedule for verification, XS, and witness sample testing § The cost and schedule of strand procurement under CD-3 a approval is the subject of ongoing monitoring and monthly management discussions. Strand Production Readiness Review - 22 Aug 2019 25

Charge Questions 5. ES&H: Have all hazards been identified and addressed? Are ES&H policy and documentation sufficient for the series production? § ES&H requirements are incorporated within test procedures, which will be described in upcoming presentations. 6. Risk: Are risks understood and appropriately managed for the series production? § Most risks are related to procurement details under CD-3 a approval. § Successful Strand PRR could close opportunities 001 and 003, and close threat 005. Strand Production Readiness Review - 22 Aug 2019 26

Charge Questions 7. Reviews: Are all closeout recommendations for this L 3 task from Final Design Review addressed? § No recommendations were made. § Cable PRR is the most recent review affecting this L 3 task. Scope, interfaces, QP, and other documents were modified in response to Cable PRR recommendations. These changes affected the strand L 3 task. Modifications are complete. 8. Is this L 3 task ready for series production? § Upcoming presentations will argue that this task is ready for series production Strand Production Readiness Review - 22 Aug 2019 27