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LS1 Cabling Progress LS1 Committee (LSC) – 21 June 2013

EDMS 1293605. LS1 Cabling Progress LS1 Committee (LSC) – 21 June 2013. Daniel RICCI on behalf of the Cabling and Optical Fibre Section (EN-EL-CF). Outline. The LS1 challenge for cabling Monitoring of cabling activities & current performance Facing the challenges: where do we stand?

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LS1 Cabling Progress LS1 Committee (LSC) – 21 June 2013

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  1. EDMS 1293605 LS1 Cabling ProgressLS1 Committee (LSC) – 21 June 2013 Daniel RICCI on behalf of the Cabling and Optical Fibre Section (EN-EL-CF)

  2. Outline • The LS1 challenge for cabling • Monitoring of cabling activities & current performance • Facing the challenges: where do we stand? • Conclusions Cabling = copper(ctrl & DC) cables AND optical fibres D. RICCI – CERN, LSC meeting – EDMS 1293605

  3. The LS1 challenge:the important numbers • 37 main projects to carry on + day-by-day installation works (Someexamples: R2E, LHC cabling campaigns, WCC hose consolidation, SPS campaigns & irradiated cables TS1+, new SPS fibre infrastructure (BI & others), PSS, LINAC4 & Meyrin campaigns, Computer Centre extension B513, LHC-Experiments fibreupgrade) • Overallestimated budget ~12 MCHF • ~1000 km of copper and opticalcablesbeinginstalledduring LS1 Moreover, activitiesalsoinclude • Managing CERN-wide optical fibreinfrastructure (3,000 km installed optical cables) • Qualification, procurement and standardisation of cabling and optical fibre components (3.5 MCHF/year) • Managing cable park (4200 drums) and cable tray infrastructure (350 km) • Monitor cable aging and put in action the replacement campaigns (~1MCHF/machine point) D. RICCI – CERN, LSC meeting – EDMS 1293605

  4. LS1 challenge:planning and resources Example CF planning (LHC only) • Very « dense » planning • Must copewith machine constraints/priorities • Delay on one activitycanprovoke « domino » effect • ~35 people in CF plus ~100 contractor people • Challenging supervision, training and knowledgetransfer of new workingmethod LS1 New cabling R2E Consolid. D. RICCI – CERN, LSC meeting – EDMS 1293605

  5. The cablingstrategy(in a snapshot)see LSC presentation 15/3/2013 • 1) Enhanced section structure • 2) Anticipatequalification and procurement of material PROJ 1 Variousworks TE/ABT Campaign Booster PROJ 2 LIU Campaign SPS-BA1 PROJ n Variousworks BE/BI + fibres… CampaignLHC-Point1 • 3) Optimizework organisation and resource distribution by working by geographicalcampaigns • 4) Boost training & projectpreparationwithcontractors • 5) Project progress and schedule monitoring Simulation D. RICCI – CERN, LSC meeting – EDMS 1293605

  6. LS1 progress monitoring • Methoddeveloped in agreement with the management requestto be able to follow activity progress in ‘real-time’ • Objectives • Help Project Managers to manage parallel projects and workload • Warn timely on activity delay or anticipation • Prevent resource bottlenecks • Be able to provide detailed status reporting (e.g. for each geographical campaign) • Be a test-bench for LS2 • Costs • Dedicated FTEs to implement/following (1.5 FTEs for 2013) • Enforce new work style with contractors • More commitment (mainly time) requested from the Project Managers D. RICCI – CERN, LSC meeting – EDMS 1293605

  7. Monitoring method • Challenge: CF field-activities are composite and of different nature, depending on the project • Project preparation, ordering of material, documentation and other administrative activitiesdone by CF are not included Example of field-activities for coppercables De-cabling Mechanics cabletrays/racks Reworks Cablingcampaign (core) Cablepulling (60%) Connectors (30%) Test (10%) • variable • variable • variable • variable De-cabling Cablingcampaign (core) Reworks Reworks Cablepulling (60%) Connectors (30%) Test (10%) De-cabling Mechanics cabletrays/racks Cablingcampaign (core) Cablepulling (50%) Connectors (40%) Test (10%) • t3 • t1 • time • t2 D. RICCI – CERN, LSC meeting – EDMS 1293605

  8. Monitoring method • Heterogeneous monitoring toolsapply • Quick implementation to bereadyat the beginning of LS1 campaigns De-cabling (variable) Mechanics cabletrays/racks (variable) Reworks Cablingcampaign (core) Cablepulling (60%) Connectors (30%) Test (10%) • Cabledatabase (Cablothèque) • Fillingdata is part of the contractor’sobligations • Sotware data extraction (EDMS 1245912) • Weekly check fromeachconcerned Project Managers • Very important to get as accurate feedback as possible • Weeklyfeedback fromContractors • Fillingfollow-up sheets (for detailed cross checking) • Drawback: contractorsclaimingthisis not included in the contract and produce more work D. RICCI – CERN, LSC meeting – EDMS 1293605

  9. Monitoring: forecast • Forecastcurveisextractedfromscheduledactivities (MS-project planning) • Detailed summary of all activities of CF section • Updated weekly End of LS1 50% LS1 Beginning of LS1 D. RICCI – CERN, LSC meeting – EDMS 1293605

  10. Monitoring: forecast Simple rules • Each activity • Starting date  0% • Ending date  100% • Linear interpolation • Activity plans weekly updated • with the exception of the campaign already started D. RICCI – CERN, LSC meeting – EDMS 1293605

  11. Monitoring: forecast Simple rules • Each activity • Starting date  0% • Ending date  100% • Linear interpolation • Activity plans weekly updated • with the exception of the campaign already started D. RICCI – CERN, LSC meeting – EDMS 1293605

  12. Monitoring: progress • Progress curveisextractedfromheterogeneous monitoring tools • Very large stream of information to process Computed % of completion Input from contractors Phase 2 Phase 1 Phase N Phase 5 Phase 4 Phase 3 De-cabling Mechanics cabletrays/racks Reworks Cablingcampaign (core) D. RICCI – CERN, LSC meeting – EDMS 1293605 Cablepulling (60%) Connectors (30%) Test (10%)

  13. Monitoring plots D. RICCI – CERN, LSC meeting – EDMS 1293605

  14. Monitoring plots D. RICCI – CERN, LSC meeting – EDMS 1293605

  15. Monitoring plots D. RICCI – CERN, LSC meeting – EDMS 1293605

  16. Current performance Dashboard: http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/ D. RICCI – CERN, LSC meeting – EDMS 1293605

  17. Monitoring methodimprovement Development of a new monitoring procedure based directly on GESMAR • All the information concerning the progress of the work is directly filled by contractors • Data extraction from GESMAR + elaboration/plotting by CF (to be included in GESMAR in the future) • First software implementation released to be taken over now by our contractors De-cabling (variable) Mechanics cabletrays/racks (variable) Reworks Cablingcampaign (core) Cablepulling (60%) Connectors (30%) Test (10%) Cablothèque (module of GESMAR) Integrationinto GESMAR Manythanks to Serge Oliger! (EN-EL-CD) D. RICCI – CERN, LSC meeting – EDMS 1293605

  18. Facing the challenges: where do we stand? • The technical challenges • CF working method is solid concerning cabling installations • Procurement of material: process well known, largely anticipated  not particular issues so far. • Recrudescence of theftsis worrisome. Consider securing more the sites! • Preparation/execution of projects and cabling campaigns is optimised • However, still very dependent on users timely feedback on final cabling requests! • Contract orders are issued timely and budget is in line with expectations • Coping with more resource needs than initially foreseen for safety and administrative tasks • Procurement and logistics for RP-related material (personal protection equipment, baskets, waste bags/bins, etc.) • Thousands of pieces • Find budget (~500 kCHF), manage purchases, deliveries, storage places, consumption levels, etc. • ALARA preparation and follow up • Lot of preparation: multiple iterations required with RP+contractors to achieve acceptable analysis • Workload on RSSOs is much more than estimated D. RICCI – CERN, LSC meeting – EDMS 1293605

  19. Facing the challenges: where do we stand? • The additional staff • As foreseen, the section management/coordination levels are extremely loaded (even overloaded) • Huge efforts to transfer the know-how to the newcomers • Huge efforts to train the project managers (aim is “autonomy”) • Workload for support functions is demanding taking into account the available manpower and skills  support priority being given to installation activities (e.g. planning, QA, access & safety) • Little and time-limited contingency to recover from (unforeseen) resource loss Manythanks to Fabio Formenti! (TE-HDO) Structure by project cells Support Function Unit with Support Manager D. RICCI – CERN, LSC meeting – EDMS 1293605

  20. Facing the challenges: where do we stand? • Challenge for contractors • Four installation contracts currently operational: • C209 (electrical), C210 (electrical), C202 (fibres), B1213 (WCC) • Contractors are increasing their staff. However, they need to: • be able to constantly find qualified personnel and to train them • cope with CERN planning (peaks and valleys) • cope with radiation rules: no temporary contracts + replace/rotate the personnel achieving the max. allowed dose in radiation areas D. RICCI – CERN, LSC meeting – EDMS 1293605

  21. Facing the challenges: where do we stand? • Challenge from contractors • One of the main electrical contractor is still struggling with their internal organisation and expertise level of their personnel • CERN has limited control on this (“delit de marchandage” always behind the corner!) • CF is currently working on contingency actions • Increasing at maximum the work supervision • Organizing more connector trainings/tests for the contractors • Working on a plan of actions in case of one contractor resigns (this will not be cost free…) • Strongly limited in “contract managers” • Even more overload on section coordination! D. RICCI – CERN, LSC meeting – EDMS 1293605

  22. Facing the challenges: where do we stand? • Planning challenge • Going well so far. Thanks also to joint effort with planning coordinators • Managed so far to have certain “agility” to smooth the curve peaks • Keep high level of attention to avoid “domino” effects • Attention on how to cope with new (unforeseen) projects • Last contingency slot in April 2014 was already filled by R2E-cryo • In case of more new projects, set new activity list with priorities! Manythanksto Katy Foraz’s team! D. RICCI – CERN, LSC meeting – EDMS 1293605

  23. An eyeon the field Flexwell (coax) cables in LHC P4 Replacement of WCC hoses in LHC P8-left D. RICCI – CERN, LSC meeting – EDMS 1293605

  24. An eye on the field Optical fibre cabling SPS & LHC CTRL cabling in the PSB D. RICCI – CERN, LSC meeting – EDMS 1293605

  25. Conclusion • 27 CF worksites currently ongoing CERN-wide with 4 main installation contractors • A tool for monitoringthe LS1 progress for CF isworking and availableonline • now developing a new version fully integrated in GESMAR • The working method is proved and work organisation is optimised around geographical campaigns.The forecast schedule is being kept so far • requires a lot of efforts and commitment from CF people! • Main challenges are: the overload of the section work-coordinators, the risks associated to the quality and (especially) the stability of the contractors • cabling activities are under control but still very sensitive to work plan perturbations • It is important to build-up contingency reserve (to cope with unforeseen circumstances) when activities are performed better than in the plan • attention to the new coming projects! Prioritize and schedule wisely… • The success of the LS1 cabling project is a real team effort! • Many thanks to all the CF colleagues which are making possible a smooth LS1! …and thanksfor everyone’s support! D. RICCI – CERN, LSC meeting – EDMS 1293605

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