Cabling activities in the lhc injectors during ls1
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Cabling activities in the LHC-injectors during LS1. Daniel RICCI, on behalf of EN-EL-CF. LS1 : Cabling activities. The consolidation and maintenance of the accelerator infrastructure (cabling and fibres ) A large amount of requests from equipment groups.

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Cabling activities in the lhc injectors during ls1

Cabling activities in the LHC-injectors during LS1

Daniel RICCI, on behalf of EN-EL-CF


Ls1 cabling activities

LS1 : Cabling activities

  • The consolidation and maintenance of the accelerator infrastructure (cabling and fibres)

  • A large amount of requests from equipment groups

The goal of LS1 is to implement everything needed for a safe and a reliable operation of LHC @ 7 TeV/beam

Priority 2

Operation of LHC @ 7 TeV

Reliable Operation of LHC

Priority 1& Priority 2

but also Priority 3 & 4

D. Ricci – Cablingactivitiesduring LS1 – IEFC workshop


Outline

Outline

  • Part1: status of the accelerator infrastructure (why we need to consolidate)

    • Overloaded cabling areas

    • Irradiated cabling areas

  • Part 2: activities foreseen for LS1

    • Consolidation projects

    • Requests from equipment groups

  • Part 3: resources and priorities

  • Summary and conclusions

    Cabling activities:

    • Installation of copper cables

    • Installation of optical fibres

    • procurement of cables/connectors

D. Ricci – Cabling activities during LS1 – IEFC workshop


Ls1 cabling activities1

LS1 : Cabling activities

  • Part1: status of the accelerator infrastructure (why we need to consolidate)

    • Overloaded cabling areas

    • Irradiated cabling areas

D. Ricci – Cabling activities during LS1 – IEFC workshop


Status of the accelerator infrastructure

Status of the accelerator infrastructure

  • SPS was put in service in 1976 (36 years old)

    • So far, cables for new systems were just “added”

    • Irradiated cable replacement campaigns carried on regularly since 20 years

  • PS was put in service in 1959 (53 years old)

    • Only one cleaning campaign carried on in 1995-2000

      • 600 km of cables removed in PS and PSB

      • No irradiated cable replacement

  • Rest of PS-complex and Meyrin technical galleries

    • Till now, cables were just “added” for new machine systems and general CERN infrastructure

    • All cables installed before ’80s are with halogens (risk in case of fire accidents)

D. Ricci – Cabling activities during LS1 – IEFC workshop


Overloaded areas sps

Overloaded areas: SPS

BA3 false floor

TS5 et ECX5


Overloaded areas sps1

Overloaded areas: SPS

  • Overloaded cable trays do not allow pulling cables in the proper technical way

  • This situation is general for SPS

  • In some cases, cables cannot be installed anymore

Shafts

Galleries

D. Ricci – Cabling activities during LS1 – IEFC workshop


Overloaded areas ps complex and meyrin site

Overloaded areas: PS-complex and Meyrin site

PS ring centre

Tunnel TT2

Gallery TP9

Intersection Linac2-Linac4-PSB

D. Ricci – Cabling activities during LS1 – IEFC workshop


Overloaded areas ps complex and meyrin site1

Overloaded areas: PS-complex and Meyrin site

Bld.361 (under the Booster), room BCER

D. Ricci – Cabling activities during LS1 – IEFC workshop


Overloaded cable areas ordered by critical state

Overloaded cable areas (ordered by critical state)

Critical state: severity of overload (1=highest)

SPS machine

Critical state 1:

  • Point 5 surface, shafts and underground

  • Point 4 surface, shafts and underground

  • Point 3 surface, shafts and underground

    Critical state 3:

  • Point 6 surface, shafts and underground

  • Point 1 surface, shafts and underground

  • Point 2 surface, shafts and underground

  • Point 7 surface, shafts and underground

    Critical state 5:

  • TT60, TT70

    Shafts are the most critical areas for all points.

  • PS-Complex and Meyrin site

  • Critical state 2:

  • Bld.360-361 (under the Booster), rooms BCER, BOR, BAT

  • Bld.354, room CCR et MNR, gallery 815

  • Gallery TP9 between Bld.354 and Bld.361

  • Bld.353 (ring centre) and tunnel of PS Bld.350 accelerator

  • TT2 entire tunnel (from Build. 269 to TT2A towards nTOF)

  • Critical state 4:

  • Bld.2001 (upstairs), cable connections from Build.2008

D. Ricci – Cabling activities during LS1 – IEFC workshop


Overloaded areas ps complex and meyrin site2

Overloaded areas: PS-complex and Meyrin site

B361

Bld. 2001

Tunnel TT2

Gallery TP9

B354

D. Ricci – Cabling activities during LS1 – IEFC workshop


Maintenance of the accelerator infrastructure

Maintenance of the accelerator infrastructure

  • Consolidation (clean-up) activities:

  • With the help of users’ groups:

    • List of unused cables

    • Identify unused cables on site

    • Disconnect unused cables from their equipment

  • Remove unused cables

D. Ricci – Cabling activities during LS1 – IEFC workshop


Maintenance of the accelerator infrastructure replacement of sps irradiated cables

Maintenance of the accelerator infrastructure: replacement of SPS irradiated cables

Total cables concerned: 6300

Total length: 630 km

(~12% of the total)

TS2: 1400

TS1: 1200

BA6: 2100

TDC2-TCC2: 800

TS4: 800

North Area: TCC2, TDC2

BA2: TS2

BA4: TS4

BA1: TS1

BA6: TS6, TCC6, TT60, TT61, TNC

D. Ricci – Cabling activities during LS1 – IEFC workshop


Maintenance of the accelerator infrastructure replacement of irradiated cables

Maintenance of the accelerator infrastructure: replacement of irradiated cables

  • SPS: regular replacement carried on until 2009

TCT: Top cable tray, AA: Almost All, R: Rest, Part: Partial.

1 complete SPS point every shutdown

Replacement foreseen every 5/6 years is today every ~10 years

D. Ricci – Cabling activities during LS1 – IEFC workshop


Maintenance of the accelerator infrastructure replacement of sps irradiated cables1

Maintenance of the accelerator infrastructure: replacement of SPS irradiated cables

SPS TS1, TS6


Maintenance of the accelerator infrastructure replacement of sps irradiated cables2

Maintenance of the accelerator infrastructure: replacement of SPS irradiated cables

  • Cable ageing + radiation can cause failure of SPS equipment and could stop the machine

    • Replacement is organized by campaigns. Not possible selective replacement of one/few cables:

    • Cables entangled

    • Risk of damaging the other cables

    • High dose level taken by workers

  • Irradiated cable areas are also overloaded  the consolidation (clean-up) benefits also the irradiated areas and viceversa

D. Ricci – Cabling activities during LS1 – IEFC workshop


Maintenance of the accelerator infrastructure replacement of radiation sensitive fibres

Maintenance of the accelerator infrastructure: replacement of radiation-sensitive fibres

  • July 2011 @ LHC-P7

  • found rad-sensitive optical cable

  • contingent problem solved (new cable installation)

  • started measurement campaign in all LHC & SPS radiation areas

Affected area: ~200 m

  • Measurement and replacement campaigns

  • Rad-sensitive fibres found so far in P1, P5, P7

  • Strategy:

    • install new spare cables (in Xmas break + LS1)

    • replace rad-sensitive cables (LSI)

    • continue monitoring + fiber database (2012 + LS1)

 New procedure = Quality Control

D. Ricci – Cabling activities during LS1 – IEFC workshop


Ls1 cabling activities2

LS1 : Cabling activities

  • Part 2: activities foreseen for LS1

    • Consolidation projects

    • Requests from equipment groups

D. Ricci – Cabling activities during LS1 – IEFC workshop


Consolidation replacement of irradiated cables ts1 tcc2 tdc2 ral

Consolidation: replacement of irradiated cables: TS1+, TCC2-TDC2, RAL

  • 2000 cables concerned incl. replacement of kickers cables in TS1+ (requested by TE-ABT)

  • 2.8 MCHF

  • 6 FTE

  • 2013-2014

* Not including zone preparation (only cabling)

SPS racks RAL

D. Ricci – Cabling activities during LS1 – IEFC workshop


Consolidation replacement of irradiated cables radio protection

Consolidation: replacement of irradiated cables: Radio Protection

  • Very high dose levels foreseen for EL activities during LS1

    • Increasing efforts in preparatory activities (dose estimation, ALARA, etc.) and in contract management (training, rotation of personnel, etc.)

  • We will need help from our RP colleagues:

    • Estimated doses available well before the end of 2012

    • “Hot” equipment shall be removed in the areas of intervention

    • Place the shielding in a way to not obstruct the access to the cable trays

    • Identify clearly for which areas the waste shall be treated as radioactive

    • RP operator field support during contractor working hours

D. Ricci – Cabling activities during LS1 – IEFC workshop


Consolidation clean up unused cables in sps p5

Consolidation: clean-up unused cables in SPS-P5

  • Concerned areas: BA5, BB5, TS5, ECA5,…

  • Number of cables currently installed: ~6000

  • Total estimated cable length: 600 km

  • 3.2 MCHF (to be confirmed)

  • 2 FTE

  • 2013

    With the help of users’ groups:

  • Started to establish cleaning list of unused cables

  • Identify and disconnect (all) unused cables on-site during 2012

https://edms.cern.ch/document/1149428/3

D. Ricci – Cabling activities during LS1 – IEFC workshop


Clean up unused cables in sps p5 status of feedback from users 05 3 12

Clean-up unused cables in SPS-P5: status of feedback from users (05/3/12)

D. Ricci – Cabling activities during LS1 – IEFC workshop


Clean up unused cables in sps p5 summary

Clean-up unused cables in SPS-P5: summary

Results of activities during the last Xbreak(feedback from users + EN-EL inspection):

  • Found 1515 cables registered in the cable DB; total length 220 km

    • This includes:

      • Abandoned cables (oxidated connectors, old patches, etc…): identified by EN-EL

      • Unused cables: identified by the users

      • Unused cables in the racks: identified by the users in collaboration with EN-EL

  • Found 1400 cables not registered in the cable DB; total length 50 km

    • This are abandoned (cut, etc.) cables to be removed by default (in agreement with technical coordination)

      Total amount of cables to remove: ~2900; total length ~270 km

      ~40% of total installed cables  enoughto organize a cleaning campaign!

      …however we still need the users to complete their actions (thanks!)

D. Ricci – Cabling activities during LS1 – IEFC workshop


Clean up unused cables in sps p5 follow up

Clean-up unused cables in SPS-P5: follow-up

Upon the receipt of the list of the unused cables

established by the users. (See EDMS 1149428)

Volume estimation

of the unusedcables

Volume estimation

0

Identification of the cable

ladders or passages concerned

Accessibilities to the cable ladders - schaffoldings, lifting equipment, etc…

Study of technical constrains

Estimation of the

total length

Estimation of the waste of

irradiated cables.

Price estimation

March 2012

Storage of the

irradiated cable

waste: containers and storage area.

Identification of the

starting points

Preparation

of the campaign

Schedule

proposal

Ressources definition

Work Supervisor, transport, RP, safety process, etc…

Study of access conditions

6-9 months

Dose level estimation:

ALARA comitee

Process definition to reduce the

dose level taken by the workers.

Technical and adm.

preparation

See IEFC presentation of 21/10/11 for more details on the challenges related to organize cabling campaigns

t

D. Ricci – Cabling activities during LS1 – IEFC workshop


Consolidation replacement of radiation sensitive fibres

Consolidation: replacement of radiation-sensitive fibres

  • Monitoring activities to be continued in 2012

  • New contract for rad-resistant fibres

  • 1.2 MCHF (to be confirmed)

  • 5.5 FTE

  • 2013-2014

D. Ricci – Cabling activities during LS1 – IEFC workshop


Consolidation replacement of wcc hoses in 3 lhc sectors

Consolidation: replacement of WCC hoses in 3 LHC sectors

  • Risk of “leakage” due to hoses not conforming to the technical specifications (presence of chlorine and cracks)

  • Hose of WCC to be replaced in 3 LHC points (4 right, 6 and 8)

  • Length: 3120 m

  • Commissioning and tests

  • 2 MCHF

  • 5 FTE

  • 2013-2014

D. Ricci – Cabling activities during LS1 – IEFC workshop


Requests from equipment groups

Requests from equipment groups

A large amount of user requests have already been made filling much more than 100% of our capacity during LS1. Moreover based on the last shutdown, we estimate that only 50% of the requests for LS1 are currently known.

Some examples:

  • R2E; relocation of EL equipment and re-cabling in 4 LHC points

  • PS Access system (PSS)

  • Linac4 and Transfer line to Linac2

  • RF upgrade project in SPS BA3

  • the BE/BI upgrade projects, IT upgrade projects, HIE Isolde, Elena, Video SPS, RF fire brigade, GSM-BTS, DAQ system for CMS and LHCb, etc.

D. Ricci – Cabling activities during LS1 – IEFC workshop


Requests from equipment groups relocation of el equipment and re cabling in 4 lhc points

Requests from equipment groups: relocation of EL equipment and re-cabling in 4 LHC points.

R2E

  • Huge amount of cabling relocation activities

  • Work in 2 shifts

  • New WCC for P5 and P1

  • 5 MCHF

  • 10 FTE

  • 2013-2014

D. Ricci – Cabling activities during LS1 – IEFC workshop


Requests from equipment groups ps pss personnel safety system

Requests from equipment groups: PS-PSS (Personnel Safety System)

  • GS/ASE project (P. Ninin)

  • 3,2 MCHF

  • Cables & Fibres

  • 3.5 FTE

  • 2012-2013

  • Includes a portion of consolidation in Meyrin

ISOLDE

NTOF

AD

HALL EST

PS

PSB

TT2

CTF

LINAC’s

CABLE DISTRIBUTION ON SITE

Sas Material

Sas Personnel

28 new access points to integrate and equip


The day to day business

The day-to-day business

  • Roughly 2200 cables/year are installed on the three main sites: LHC, SPS, PS (~80 cabling requests per site)

  • This includes:

    • Treatment of DIC and DIF (Demandes Installation Cables et Fibres)

    • Technical study (cable trays, routing, termination, planning, cost, etc.)

    • Material procurement (price enquiries, invitation to tenders, etc.)

    • Installation works (managing contractors, etc.)

    • Work surveillance

    • Acceptance and quantity check

  • Day-to-day business includes also:

    • Section and coordination

    • Contract management

    • People training

    • Etc.

D. Ricci – Cabling activities during LS1 – IEFC workshop


Ls1 cabling activities3

LS1 : Cabling activities

  • Part 3: resources and priorities

D. Ricci – Cabling activities during LS1 – IEFC workshop


Strategy workload

Strategy & workload

  • In order to cope with the huge program of work during LS1, all CF projects have been organised so that

    • they could start during the technical stops in 2011/2012 and

    • ideally, only those activities which must take place during a full shutdown are carried out during LS1.

  • Therefore the CF program for the shutdown has already commenced (2011)

  • EL-CF had already doubled its staff in the last 3 years. This substantial increase of has now reached the limit of the training and supervision capacity of the CF core staff  Projects have to be prioritized

D. Ricci – Cabling activities during LS1 – IEFC workshop


Projects priorities

Projects & Priorities

D. Ricci – Cabling activities during LS1 – IEFC workshop


Summary conclusions

Summary & conclusions

  • Huge amount of work for CF before and during LS1

  • Project preparation started already (works are anticipated during TSs)

  • Cabling and fibre activities are strongly dependent from other groups

  • We need your help to cope with everything:

    • Users:

      • continue helping with the identification of unused cables

      • present your cabling/fibres requests now (for organizing the activity: resources, plannning, purchase of material)

    • Planning coordination:

      • SPS, PS: anticipate as much as possible the communication of the access constraints, drive and organize activities with other services/groups

    • Machine coordination:

      • what do we do with old systems (e.g. Intercom Public Access in SPS)?

    • RP:

      • estimate doses, remove “hot” equipment, etc. (see slide 21)

    • Management:

      • help us to set priorities (now…)

    • Project leaders:

      • start to take into account the cable removal in the new projects in order to avoid these situation to repeat in the future

D. Ricci – Cabling activities during LS1 – IEFC workshop


Cabling activities in the lhc injectors during ls1

Thank you for your attention

…and have a nice weekend!

D. Ricci – Cabling activities during LS1 – IEFC workshop


Ls1 cabling activities4

LS1 Cabling activities

Extra slides

D. Ricci – Cabling activities during LS1 – IEFC workshop


Requests received for ls1 nov 2011

Requests received for LS1(Nov. 2011)

From IEFC meeting 27th Jan 2012

SPS machine

Critical state 1:

  • Point 5 : clean-up campaign (EN-EL)

  • Point 4 : -

  • Point 3 : BE-RF cavities/new bld.

    Critical state 3:

  • Point 6 : -

  • Point 1 : repl. irr. cables + cons. RAL (EN-EL)

  • Point 2 : cons. RAL (EN-EL)

  • Point 7 : -

    Critical state 5:

  • TT60, TT70 : -

    All SPS: BE-BI instr. (BCT, BTV, BPM, BLM, etc.)

    + other cabling requests of various types

  • PS-Complex and Meyrin site

  • Critical state 2:

  • Bld.361 (Booster) : BE-BI instr. (BCT, BPM, BLM, etc.) + PSS (GS-ASE) + cons. Multipole (TE-EPC) + Interlock (TE-MPE) + L4-PSB connection

  • Bld.354 : -

  • Gallery TP9 : -

  • Bld.353, PS tunnel Bld.350 : BE-BI instr. (BCT, BWS, BBQ, BLM, etc.) + PSS (GS-ASE)

  • TT2 tunnel : BE-BI instr. (SEM) + PSS (GS-ASE)

  • Critical state 4:

  • Bld.2001-2008 : -

  • + other cabling requests of various types

D. Ricci – Cabling activities during LS1 – IEFC workshop


Cleaning up sps p5

Cleaning up SPS-P5

How is it possible to arrive to this situation in pt5?

1: No huge campaign for removal of old cables since the SPS’ installation in the BA5 and in the tunnel.

2: The installation of a new system doesn’t includes the removing of the previous one.

3: The duration of the Shutdowns

doesn’t preview the huge removal of the old system.

  • Now is not possible to pull (install) new cables in the tunnel of Point 5.

  • Now is the time to foreseen a cleaning cable campaign !

D. Ricci – Cabling activities during LS1 – IEFC workshop


Cleaning up sps p51

Cleaning up SPS-P5

Summary:

  • For some users we are still missing a reply

  • For other important users we strongly recommend a research in the field

  • It seems many cables are very old and not known by the users. However, it is clear to which system they belongs  requires system owners to understand “what it is”

  • In the great majority of cases the users think “What are the cables which I do not need anymore in the existing system?”, they should instead think “I have a system with a lot of cables. How could I improve my system in order to reduce the number of cables? Which cables can I remove then considering these improvements?”

    • Example: a lot of cables affected to “Intercom Public Address” (Intercom station only). Do we need to keep it in use like it is? Can it be replaced by portable telephones like in LHC?

From IEFC meeting 27th Jan 2012

D. Ricci – Cabling activities during LS1 – IEFC workshop


Cas pratique plan de travail

EDMS n°1154423

Cas pratique : Plan de travail

  • Fournir les listes de câblages aux utilisateurs:

  • Réponse des utilisateurs :

  • Relevé des câbles abandonnés:

  • Evaluation du volume et de la stratégie (manpower + coûts):

  • Mise en œuvre (préparation):

  • TRAVAUX (durée de 6-9mois):

Octobre 2011

Janvier 2012

Janvier 2012

Juin 2012

Octobre 2012

Janvier 2013 (LS1)

Action EN/EL

Action utilisateurs

+

Action EN/EL

Action utilisateurs

Action EN/EL

+

Action EN/EL

Action coordination

+

Action EN/EL

Action coordination


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