Putting it all together
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Putting it all together. Roberto Saban. Organization and Coordination of the Hardware Commissioning. Access Conditions clarify whom they concern & Safety Access Control: how is it implemented? Missing Documentation: specifications, individual system tests, failure scenarios

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Putting it all together

Putting it all together

Roberto Saban


Organization and coordination of the hardware commissioning

Organization and Coordination of the Hardware Commissioning

  • Access Conditions clarify whom they concern & Safety

  • Access Control: how is it implemented?

  • Missing Documentation: specifications, individual system tests, failure scenarios

  • Field Control Centre: yes, no, where?

  • Field Engineer: role and prerogatives

  • Decision making: HCC (Mr.Circuit) in agreement with equipment owners, Core Team for exceptional conditions in general

  • Ventilation modes according to the on-going tests should be defined

  • The leak test scenario must be revisited in the light of the new magnet installation scenario

  • Study of the effects and the recovery from a power cut, electrical faults, etc.

  • Go through all the planned tests and find out whether it can be automated, put in parallel and automatically analyzed

  • Automated procedures should be included in other systems


Quality assurance and documentation of results

Quality Assurance and Documentation of Results

  • e-logbook: for equipment groups and for HC Coordination

  • geographical regions: how do you handle systems which affects more than one such region. Functionality was added via MTF

  • Non conformity tracing: internal & external, non-conformities will be available for operation

  • Already known non-conformities: how are they handled? As-designed and the as-built database: we thought of this but who is doing it ?


Controls and communications

Controls and Communications

  • WorldFIP card: desynchronization & protocol problem

  • No time allocation for WorldFIP global test (individual system tests of controls infrastructure). Fieldbus must be tested with the final agents.

  • LSS8L tests for cryogenics still require additional gateways to be developed

  • Improve functionality based on a existing global design

  • Wi-Fi is connected to the GPNetwork and you then have to hop through an application server. How about proprietary software (siemens) running on a wi-fi connected pc ? Today will not run: a solution needs to be found.

  • Controls Middleware could become a show stopper

  • Accessing post-mortem data from outside the Technical Network: issue not yet addressed


Infrastructure

Infrastructure

  • Access Control (LACS) and Access Safety (LASS) remains an issue: looks like it is going to be late or is there a misunderstanding

  • Interfaces between the Access Safety System with machine equipment (EIS, interlock, etc) have now been defined.

  • SU: can we move the magnets? sure

  • Alignment/smoothing: when ? Once a year. Not too many at the same time. Need 8 weeks per sector and need two teams per sector. An adequate time slot compatible with installation, hardware commissioning and the metrology group remains to be found.

  • The performance of the Electrical Distribution System will have to be monitored during the 24-hour runs.

  • Annual tests (e.g. AUG, evacuation alarms) are not legally required once a year


Vacuum

Vacuum

  • Vacuum commissioning in the General Construction and Installation Schedule, is not placed at the right place; Katy is working on it.

  • Reduced ventilation in the tunnel helps with leak tests when two teams work in parallel. On the other hand high ventilation will flush the tunnel of residual He. So ?

  • Experience with the other leak tests will give a hint of the background for the UHV leak detection.

  • Safety: no powering of warm magnets during the leak detection.

  • Formal opening of the sector valves will be done during the machine check-out.


Vacuum1

Vacuum

  • The Individual System Tests (not leak tests) of vacuum are not documented.

  • CRI & ACR must be defined as owner of the pressure test.

  • The deviation from the baseline installation scenario for the leak tests for the first sector cannot give an early feed back on the quality of the welds; because it is not possible to weld any of the lines containing an electrical connection.

  • The compression of the planning has an impact on the ability to repair leaks in the background.

  • General parameters ES should be reviewed.

  • Evaluation of the failure numbers and their translation into time is required.

  • Localization of leaks with the MLI installed is impossible, based on String 2 experience.


Cryogenics

Cryogenics

  • Restricted access instead of no access during the first cool-down.

  • Additional week needed to better flush the QRL since the cold tests were cancelled. – Impact of a shortcut.

  • Additional resources deployed for HC will leave CERN after the HC … they become mentally absent before then. Extension of the AL contract is possible for two more years, just ask Lyn.

  • Less time devoted to tuning imply large number of resources for dedicated tuning when needed. 150 + 40 control loops reduce to 10 type loops. Tuning of the loops is not the end of the story; collective behavior also plays a role. Commissioning the loops of the current leads without current cannot be done.

  • Three staff recently left the operations team: need to be replaced


Cryogenics1

Cryogenics

  • Global Wi-Fi coverage of the tunnel

  • Naming inconsistencies between MTF and QRL/ACR result in the same component to be called differently. More problems may arise with other systems (e.g.post-mortem).

  • Access to the technical network from Wi-Fi.

  • No particular problems with the delivery of electronics

  • All signals going to logging or to the post-mortem system can be correlated


Cryogenics2

Cryogenics

  • No cold test or type test of DFB before HC.

  • Cool down of the DFB between 2 and 5 days! Minimum of 3 (nominal) + 1 (exceptional: e.g. stopping feed valves, heaters, etc.) weeks for the type tests of a DFB. The exceptional tests are challenged: general consensus is wait for the condition to occur by itself.

  • For the DFBX there is no expertise of the current leads.

  • DSL never tested at cold; again a type test is needed for the first one. Will require 3 weeks of cold tests. These tests are rporgrammed during the 10 weeks of the cool down.

  • There are no spare DFBs but spare components exist on site. Most serious damage is a short circuit caused by an arc in a pipe. Repair time 3-4 months. Most probable is an insulation weakness which can be repaired in situ but requires warm-up and opening.

  • Displacement of the beam pipes following cool-down: not likely, but Antonio wants to study it.


Electrical circuits and magnets warm and cold

Electrical Circuits and Magnets (warm and cold)

  • No IP2X covers on the warm magnets; you can access the terminals if you want by passing under the protection covers. The protections are there to protect the connections not the people.

  • Analysis of quench curves absolutely necessary to help with the decision to continue with higher current.

  • Danger of stored energy: watch out before you open any of the circuits.

  • People for quench analysis are in well identified places (MEL, MTM) and HCC.

  • Stressed the importance of the post-mortem system.

  • Analysis of each test must be carried-out: patience, experience, communication: all this takes time. For HC you need time.

  • Maintenance of QPS monthly; they take three hours. Why can’t this be made to run more frequently and faster? They need special conditions like no current in the magnets.

  • A missed quench on a corrector chain might also require the exchange of a magnet.


Electrical circuits and magnets warm and cold1

Electrical Circuits and Magnets (warm and cold)

  • To what extent is the QPS system affected by the WorldFIP synchronization problem raised by MVE? In particular for the LSS8L commissioning?

  • Manpower for additional tests: is an issue (e.g. El-QA)

  • LSS8L is a milestone: most of the procedures can be tested there

  • Threshold for detection of bad splices (1 mV may be necessary)

  • What is the probability that a beam loss causes the firing of a large number of magnets? High (RSc); therefore the tests must not be shorted.


Electrical circuits and magnets warm and cold2

Electrical Circuits and Magnets (warm and cold)

  • Can a power converter be a danger to itself? A failure of the extraction system is the main danger: it brings to the PC the energy stored in the magnets.

  • The synchronization of the eight sectors can only be done with the beam in the machine.

  • Short circuit tests also give a complete system test of the cooling and ventilation system.

  • Connection and disconnection issues being defined under FRM: not only during HC but also later during normal collider operation.

  • HC Coordination has the mandate for taking the circuits to nominal current not above.

  • The protection of the current leads for the 60 – 120 A circuits: the signals must be available to the control system.

  • Switch open failure: the thyristor will be damaged if only one opens and the heaters in the magnets are not fired.

  • Water cooled cables of warm magnets in point 3. Do they really need water?


Electrical circuits and magnets warm and cold3

Electrical Circuits and Magnets (warm and cold)

  • Supervision system for the WIC will be made available after the supervision for the PIC is done.

  • A local display gives the magnet which tripped

  • 2000 events can be recorded in the PLC memory.

  • Check the WIC signal against the timing of the PC trip.

  • Impressive demo of the sequencer for the interlock ISTs

  • PVSS-CMW interface critical

  • Automated procedures are going to be used in the future when coming out of a shutdown


Electrical circuits and magnets warm and cold4

Electrical Circuits and Magnets (warm and cold)

  • Polarity of superconducting circuits

  • Battery tests need renaming: automated and parallel

  • Resources for the analysis and automation in AB/CO

  • Specification of filters to isolate candidates for failures

  • Automated procedures are going to be used in the future when coming out of a shutdown

  • MTF: new requests or support ? Piquet service!


Beam systems

Beam Systems

  • Collimators

    • IST requirements, procedures and time required in preparation

    • Installation schedule very tight; it is planned to install everything by end 2006. As late as possible for IR 7.

    • their commissioning will take place after the HC of the sector

  • BT hardware

    • MKQA (MKI?) kicker installation will be done in a rush


Beam systems1

Beam Systems

  • RF

    • access system required for RF HC in December 2006

    • co-activities with BDI must be carefully planned

    • 6 months needed for commissioning and conditioning; if the schedule slips, can we let them float ?

  • BDI

    • interference with HC because of late delivery (BLMs)

    • co-activities with RF must be carefully planned

    • BLM installation must be prepared

  • Beam Interlock

    • UPS on BIC yes, but not for all the clients. Those who are not critical for the beam should not be on the BIC

    • repeat some of this after every shutdown -> automated procedures

    • HC coordination needed to schedule and organise the last phase of the commissioning with the users including the experiments


Compatibility of hardware commissioning with installation

Compatibility of Hardware Commissioning with Installation

  • installation of the machine

    • UJ22, otherwise no evident problem unless slippage of activities imply shifting

    • What if the magnet transport vehicle breaks down? Importance of preventive maintenance to reduce the probability of failure.

  • installation of the experiments

    • late installation and commissioning of Alice compensators

    • strong coordination with the experiments and the vacuum group is needed

    • late installation of the vacuum chamber for CMS; but not later than end of June 2007 !

    • replacement of Roman Pots by vacuum chambers in Point 5 is costly but if they arrive late it will have to be done

    • LHCf (not yet approved) to be installed either in Point 1 or 8 (inside the TAN or like a ZDC)

    • The installation of the beam dump lines is in parallel with the hardware commisisoning


From hardware commissioning to cold checkout

From Hardware Commissioning to Cold Checkout

  • commissioned sectors should be kept below 80 K to avoid some re-commissioning – impact on routine operation

  • coordination & configuration management to track “improvements” to already commissioned sectors

  • “main ring group (not OP)” to take over a sector after hardware commissioning is finished like for the end of a shutdown

  • the mandate of HC is to commission the sectors to run the magnets at nominal current (not above)

  • responsibility for safety will stay with TS until the end of the HC except during the sector test

  • in view of the time required to re-commission the warmed up sectors (78, 81, 34, 45), it might be wiser to keep them cold. A study is needed


Questions to speakers

questions to speakers

  • why is the test to be done, how will the results impact, how will the test be done technically

  • what happens if the test is not done

  • how can time be saved

  • how can time be saved by streamlining the tests after a certain number of results have been confirmed

  • what other systems are you dependent on

  • can you do it in time

  • are there any specific tests you wish to perform on the first sector

  • risk analysis of equipment damage (system point of view, impact on schedule, recovery plan, ..)

  • what can go wrong (technical, manpower, tools…)

  • personnel safety


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