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Automation of Hardware Commissioning - Offline Analysis of 60A circuits

Automation of Hardware Commissioning - Offline Analysis of 60A circuits. by Zinour Charifoulline , Scott Rowan. Outline. Test Procedures/Offline Analysis Automated Analysis Walkthrough Automated Analysis Results PCC.1 PNO.d1 Inconsistencies EPC Feedback Summary/What Next?.

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Automation of Hardware Commissioning - Offline Analysis of 60A circuits

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  1. Automation of Hardware Commissioning - Offline Analysis of 60A circuits by ZinourCharifoulline, Scott Rowan

  2. Outline Test Procedures/Offline Analysis Automated Analysis Walkthrough Automated Analysis Results PCC.1 PNO.d1 Inconsistencies EPC Feedback Summary/What Next? S. Rowan - MPE-TM - 27/02/2013

  3. Test Procedures/Offline Analysis S. Rowan - MPE-TM - 27/02/2013

  4. Test Procedures Tests Procedures exist for all circuit types by current level Defines all powering cycles to fully commission circuits Defines offline analysis criteria to be checked and signed by experts Pass Criteria is seemingly simple enough to automate S. Rowan - MPE-TM - 27/02/2013

  5. Offline Analysis ±PCC.1 //Verify converter current to be +3.7A/+-0.6A 60seconds after the 1st crowbar activation (2nd PM) assertThat(I_MEAS).isEqualTo(+3.7, AMPERE).withinAbs(0.6, AMPERE) .at(60, SECOND).after(Occurrence.SECOND, PM_EVENT_TRIGGER); //Verify converter current & voltage decay is an exponential function with an absolute tolerance of 0.1A/0.05V starting 20ms after the 1st crowbar activation (2ndPM) assertThat(I_MEAS).isEqualTo(EXP).withinAbs(0.1, AMPERE) .starting(20, MILLI(SECOND)).after(Occurrence.SECOND, PM_EVENT_TRIGGER) .ending(150, SECOND).after(Occurrence.SECOND, PM_EVENT_TRIGGER); assertThat(V_MEAS).isEqualTo(EXP).withinAbs(0.1, VOLT)… … Using the eDSL Java Interfacepass criteria can be written in an easy to read/understand sentence form S. Rowan - MPE-TM - 27/02/2013

  6. Offline Analysis ±PCC.1 • Question! • Can this be used by a non-java expert?? //Verify 1st PM-trigger exist and offset is zero assertThat(I_MEAS).isEqualTo(0.0, AMPERE).withinAbs(0.1, AMPERE) .at(0, MILLI(SECOND)).after(Occurrence.FIRST, PM_EVENT_TRIGGER); //Verify start point at I_PCC=10A assertThat(I_MEAS).isEqualTo(10.0, AMPERE).withinRel(1.0, PERCENT) .at(1, SECOND).before(Occurrence.SECOND, PM_EVENT_TRIGGER); Using the eDSL Java Interface pass criteria can be written in an easy to read/understand sentence form Several additional checks are added to improve robustness S. Rowan - MPE-TM - 27/02/2013

  7. Automated Analysis Walkthrough S. Rowan - MPE-TM - 27/02/2013

  8. Offline Analysis ±PCC.1 Verify 1st PM-trigger exists and offset is zero PCC.1 Automated Analysis Walkthrough S. Rowan - MPE-TM - 27/02/2013

  9. Offline Analysis ±PCC.1 Verify plateau current I_PCC=10A PCC.1 Automated Analysis Walkthrough S. Rowan - MPE-TM - 27/02/2013

  10. Offline Analysis ±PCC.1 Verify converter current to be +3.7A/+-0.6A 60sec after the 1st crowbar activation PCC.1 Automated Analysis Walkthrough S. Rowan - TE-MPE-PE - 27/12/2013

  11. Offline Analysis ±PCC.1 Verify current decay is an exponential function with an absolute tolerance of 0.1A after the 1st crowbar activation PCC.1 Automated Analysis Walkthrough S. Rowan - MPE-TM - 27/02/2013

  12. Offline Analysis ±PCC.1 Verify voltage decay is an exponential function with an absolute tolerance of 0.05V after the 1st crowbar activation Then simply repeat for tests for negative cycle!!! PCC.1 Automated Analysis Walkthrough S. Rowan - MPE-TM - 27/02/2013

  13. Automated Analysis Results S. Rowan - MPE-TM - 27/02/2013

  14. Automated Analysis Results ±PCC.1 • 2011 HWC campaign • 233 PCC.1 tests on 225 60A-circuits • 17 consistency fails • 10 failed due to I_ERR_PCC which is not in offline analysis • 3 cases due “just” failing decay criteria • 92.7% of consistency. PCC.1 Automated Analysis Results 2011 S. Rowan - MPE-TM - 27/02/2013

  15. Automated Analysis Results ±PCC.1 • 2012-2013 HWC campaign • 398 PCC.1 tests on 350 60A-circuits • 10 consistency fails • 1 was “successful” but “tuning to be done”? • 8 cases due to “just” failing decay criteria • 1 anomaly accepted manually??? • 97.5% of consistency! PCC.1 Automated Analysis Results 2012-2013 Should have failed! Circuit: RCBV19.L5B1 S. Rowan - MPE-TM - 27/02/2013

  16. Automated Analysis Results ±PNO.d1 • 2011 HWC campaign • 1022 PNO.d1 tests on 750 60A-circuits • 69 consistency fails • 58 cases due to “just” failing decay criteria • 8 of which due to crowbar voltage • 2 current plateau checks failed • 93.2% of consistency! PNO.d1 Automated Analysis Results 2011 S. Rowan - MPE-TM - 27/02/2013

  17. Automated Analysis Results ±PNO.d1 • 2012-2013 HWC campaign • 997 PNO.d1 tests on 750 60A-circuits • 97 consistency fails • 64 cases due to “just” failing decay criteria • 20 due to failing crowbar voltage check • 1 significantly bad circuit (same as PCC.1) • 12 based on data errors (passed manually) • 90.3% of consistency! Should have failed! Circuit: RCBV19.L5B1 PNO.d1 Automated Analysis Results 2012-2013 S. Rowan - MPE-TM - 27/02/2013

  18. Inconsistencies S. Rowan - MPE-TM - 27/02/2013

  19. Inconsistencies - Current decay Thanks to LabView+RADE! Layout Database values All should pass the criteria ~60% of inconsistencies (4% of all tests) due to high circuit resistance, resulting in decay being outwith the defined criteria 3.7±0.6A@60s 3.4±0.5A@60s Possible solutions: Refine thresholds: 3.7±0.6A => 3.4±0.5A Use Layout DB to compare decay constant 27 circuits shouldfail with current criteria R_TOTAL>0.0675Ω S. Rowan - MPE-TM - 27/02/2013

  20. Inconsistencies – Crowbar Voltage limits ~30% of inconsistencies (2% of all tests) due to voltage limits across crowbar Most failures due to strict criteria and/or noise in signal. Possible solutions: Relax thresholds: 1.1±0.1A => 1.1±0.2A Check average of plateau lies within limits S. Rowan - MPE-TM - 27/02/2013

  21. EPC Feedback S. Rowan - MPE-TM – 27/02/2013

  22. EPC Feedback Consistencychecks «correspondent vraiment» to whatisexpected Consistency check over previous campaigns resulted in discovering a faulty module(RCBV19.L5B1)that EPC were unaware of! Regarding pass criteria - EPC accept all proposed solutions With existing pass criteriathe automated analysis has >90% consistency With relaxed pass criteria60 A circuit analysis has >99% consistency Regarding possibly more robust assertions Comparison to a modelled reference curve? – difficult to implement Plateau averages? – possibility, though accuracy/necessity questionable Time constant check on decay? – to be discussed, will require Layout DB Ability to use parameters from Layout Database? – “soon™” S. Rowan - MPE-TM - 27/02/2013

  23. EPC Feedback A simple qualification check wasrequested for 3 knownfaults. Note: All hadalready been flagged by consistency check. Fails, even with relaxed criteria RCBH13.L6B1:PNO.d1 S. Rowan - MPE-TM - 27/02/2013

  24. EPC Feedback RCBV30.L4B1:PCC.1 A simple qualification check wasrequested for 3 knownfaults. Note: All hadalready been flagged by consistency check. Fails, even with relaxed criteria S. Rowan - MPE-TM - 27/02/2013

  25. EPC Feedback RCBV24.L4B1:PNO.d1 A simple qualification check wasrequested for 3 knownfaults. Note: All hadalready been flagged by consistency check. • Interesting curve • Passes 25A check point but fails 8A • Must be taken into account when defining new criteria S. Rowan - MPE-TM - 27/02/2013

  26. Summary/What Next? S. Rowan - MPE-TM - 27/02/2013

  27. Summary Framework and language clearlyusable by non-java experts! 60 A circuit offline analysis can now be fully automated (PCC1, PNO.d1) Will be ready for upcoming HWC campaign With relaxed pass criteria 60 A circuit analysis has >99% consistency Pass criteriato be finalised/documented in test procedures All test procedures currently being updated by MP3 Due to the discovery of an unknown fault, we propose to continue and carry out consistency checks for all remaining numerous circuit types (80-120 A & 600 A). May find further unknown system faults Will assist in refining pass criteria, useful for manual analysis Analysis not likely to be automated during coming HWC, but if the algorithms are written and qualified, future implementation is a possibility. S. Rowan - TE-MPE-PE - 11/12/2013

  28. Thanks for listening! S. Rowan - MPE-TM - 27/02/2013

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