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Hardware Commissioning

Hardware Commissioning. The talk is focussed on the superconducting electrical circuits . While we are aware it is not the only equipment that needs to be commissioned, the HC WG believes it will dominate the scene.

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Hardware Commissioning

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  1. Hardware Commissioning The talk is focussed on the superconducting electrical circuits. While we are aware it is not the only equipment that needs to be commissioned, the HC WG believes it will dominate the scene. The commissioning of almost all the other machine subsystems has been studied but an overall commissioning programmehas not been prepared yet: it strongly depends on the installation schedule which has lately been very uncertain. the resources the programme for 2005

  2. if the boundary conditions change, we now can predict the impact on the three why we started getting worried ... Time allocated for Hardware Commissioning Mar 2003 Dec 2003 July 2004 Dec 2004 • establish a commissioning programme • define team compositions • define team numbers • define the commissioning times • with a number of boundary conditions

  3. Resources for Hardware Commissioning • basic assumptions • programme of the tests … This document presents the resources identified for a commissioning scenario restricted by a number of assumptions: in particular, the parallel commissioning of two sectors around an even point -not more and not less- and the staggered commissioning of an additional set of two sectors where the cool down follows the powering tests of the first set. However from the data presented in this document, it is possible to derive the resources needed for a different scenario when some of the restrictions are lifted or relaxed. • sequence of the tests • time needed for each test • inventory of the test teams and their composition

  4. Resources for Hardware Commissioning • basic assumptions • programme of the tests • Two sectors at a time around an even point • Five-day working weeks • Two shifts during powering tests • Two commissioning fronts per sector • The magnets are left floating in temperature after the commissioning • The RF system is commissioned just before commissioning with beam • The PS and SPS complex run in 2006 • sequence of the tests • time needed for each test • inventory of the test teams and their composition

  5. Resources for Hardware Commissioning • basic assumptions • programme of the tests • Tests at warm • validation of subsystems, connectivity, computer networks and filed buses, timing, supervision, etc. • validation of the instrumentation and subsystem functional tests • electrical quality assurance • short circuit tests, interlocks • Cool down • calibration at cold and cryo loop tuning • electrical quality assurance • Tests at cold • electrical quality assurance • quench protection • Powering Tests • validation of the interlocks • validation at low, nominal current and all circuits in unison • sequence of the tests • time needed for each test • inventory of the test teams and their composition

  6. The resulting schedule right of the even point left of the even point

  7. tests at cold a closer look ... warm tests 23 weeks cool down 8 weeks powering tests 11-16 weeks

  8. 300 K 90 K 1.9 K superconducting electrical circuits Powering Tests Individual System Tests of Powering Interlock Control Test of power converters connected to the DC cables in short circuit, including controls for powering, ramp, monitoring Individual System Tests of the Quench Protection and Energy Extraction Systems Electrical Quality Assurance Power Converters not connected to Magnets Post-Mortem System tests Interlock tests of a powering subsector prior and after connection of the power cables to the DFB leads connexion of power cables to the current leads Commissioning of the electrical circuits one by one or in groups at low, intermediate and nominal currents Power Converters connected to Magnets Commissioning of all the electrical circuits of the sector powered in unison to nominal current with nominal ramp rates

  9. Quench Protection Number of circuits Powering tests Interlock tests Total 40 78 436 274 828 60 78 131 0 269 40 39 218 69 366 120 18 16 16 170 220 135 365 85 805 circuit count and individual commissioning times Powering Tests unit is one 15 hour day of one commissioning front Main circuits and IT quadrupoles Separately powered quadrupoles 600 A circuits, separation and recombination dipoles 80-120 A orbit correctors, IT correctors Total MB MQ, MQX Separately powered quadrupoles 600 A circuits, separation and recombination dipoles 80-120 A orbit correctors, IT correctors 11.0 5.5 1.7 0.8 0.3

  10. Left Right Front 2 Front 1 Front 1 Front 2 6.6 km resources deployed for the powering tests Powering Tests two shifts = 15 hour days Front 1 arc and the matching section on the even side Front 2 arc, the matching section on the odd side and the inner triplets on both sides in the field on call 2t + 2o 1e+1o cryogenics operation 1e+1t cryogenics instrumentation 1x+2e+2t quench protection 2x+2t 1x+1t+ ... machine interlocks 1x+2t 2e+1t+ ... power converters 2e+2t coordination 1t 1e controls 1o operation 4x+5e+10t+3o 1x+4e+2t+1o o operator x expert e engineer t technician 22 present in the field

  11. the sequence of tests around an even point Powering Tests

  12. power tests of MB circuit 1 of 2 Powering Tests LHC-D-HCP-0003 HCA:PIC2 • to commission the protection functionalities of the powering interlock controllers and all its connected systems with current through the circuits • to verify the compatibility of the switch-on and switch-off processes of the converters with the sensitivity of the protection systems HCA:PLI1 • to set up the power converter current loops • to validate the protection mechanisms under real powering conditions and with limited energy stored in the circuits • to validate quench-related procedures, e.g. cryogenic recovery procedures • to validate the sensitivity and compatibility during ramps of the systems susceptible to noise pick-up, couplings, etc • to perform a last check on the polarities of the circuits by verifying voltages across current leads during ramp at low current using QPS signals HCA:PLI2 HCA:PLI3 HCA:PLI4 standby injection 33% nominal 66% nominal 80% nominal nominal

  13. power tests of MB circuit 2 of 2 Powering Tests LHC-D-HCP-0003 HCA:PNO • to verify the power converters during the ramp • to calibrate the DCCTs for the main and the Inner Triplet power converters and to verify the calibration systems • to validate the protection mechanisms with nominal energy in the circuits • to verify the quench current of each circuit • to validate quench-related procedures, e.g. cryogenic recovery procedures HCA:PAC minumum standy-by injection 33% nominal 66% nominal 80% nominal nominal

  14. essential time savers • support from the controls group • user friendly application suite • tool to aid the interpretation of the test results • programmed procedures for battery tests • support from the MTF and database team • optimization of the MTF configuration for hardware commissioning • exchange of data between the central database and the specialist owned databases

  15. Resources for Hardware Commissioning • basic assumptions • programme of the tests … This document presents the resources identified for a commissioning scenario restricted by a number of assumptions: in particular, the parallel commissioning of two sectors around an even point -not more and not less- and the staggered commissioning of an additional set of two sectors where the cool down follows the powering tests of the first set. However from the data presented in this document, it is possible to derive the resources needed for a different scenario when some of the restrictions are lifted or relaxed. • sequence of the tests • time needed for each test • inventory of the test teams and their composition

  16. The resulting need for resources with the basic assumption • The personnel involved in the individual system tests and the hardware commissioning142 of which 46 are missing. • Additional budget for IS and FSU is 1.335 MCHF.

  17. ~20 months 142 people involved 46 missing in some cases experience is a must engineers and technicians cryogenics quench protection interlocks coordination & operation controls possible sources national institutes but also recruitment Report Summary with the basic assumption • staff for supervision is already critical • training of new resources for commissioning is critical

  18. warm tests warm tests warm tests warm tests cool down cool down cool down cool down powering tests powering tests powering tests powering tests 28 months Report Summary : Parallelism1 of 3 with the basic assumption

  19. Overload of only the Operator, HC Coordination and Cryo Operation Teams 2.5 months cool down powering tests 20 months warm tests warm tests cool down cool down powering tests powering tests Overload of CIWSU, CIWC, CIWCS, CIWS, MI-PCIST, PCIST, COCD, HCC, ABOP cool down cool down powering tests powering tests warm tests warm tests cool down cool down powering tests powering tests warm tests warm tests warm tests warm tests cool down powering tests 15.5 months Report Summary : Parallelism2 of 3

  20. Report Summary : Parallelism3 of 3 ? 142 people (46 missing) HCC HCC CIWS CIWS ABOP ABOP COCD COCD PCIST PCIST CIWCS CIWCS CIWSU CIWSU MI-PCIST MI-PCIST 20 months for the commissioning activity 12 months for the commissioning activity • where do we find them? • how long do we have to train them? • who is going to supervise them?

  21. what do we do with the Report ? • find the additional resources • study alternatives • strategies alternative to personnel directly under the supervision of the Groups • partial commissioning of the sectors • review the commissioning procedures

  22. programme for 2005: the latest schedule ... a lot is happening before ... installation cabling IST Sylvain Weisz on November 26, 2004 at TCC

  23. programme for 2005: installation sequence for Sector 78 1 install QRL subsectors A and B in sector 78 with a return module 2 leak and pressure test the QRL subsectors A and B in sector 78 with the return module 3 cold test the QRL subsectors without any magnet connected to it and warm it up 4 install the Q1Q2Q3D1, Q4D2 and the Q5 machine subsectors and connect them to the QRL subsectors A and B in parallel, install and interconnect the rest of the QRL in the sector in parallel, start the interconnection of all the magnets without jumper connection in the DS region L8 and first two arc cells 5 leak and pressure test the QRL and the Q1Q2Q3D1, Q4D2 and the Q5 machine subsectors 6 cold test the QRL and the Q1Q2Q3D1, Q4D2 and the Q5 machine subsectors Point 7 7 power test the Q1Q2Q3D1, Q4D2 and the Q5 machine subsectors in parallel, interconnect all the magnets without jumper connection 8 warm up the QRL and the Q1Q2Q3D1, Q4D2 and the Q5 machine subsectors 9 install and interconnect all the SSSs with jumper 10 leak and pressure test 11 open cryostat interconnect and final closure Point 8

  24. Inner Triplet L8 with a Separation Dipole Part of the Matching Section L8 with a Separation Dipole programme for 2005: the equipment concerned

  25. key dates • QRL subsector A & B cold test • LSS L8 short circuit tests • LSS L8 subsector cool down • partly in parallel with QRL whole sector test • power tests of LSS subsector • partly in parallel with QRL whole sector test • power tests of LSS subsector must end by 13 June 2005 30 June 2005 3 October 2005 31 October 2005 3 March 2006

  26. the sector test in ... 2006

  27. ... in summary : Effects of the compressed Schedule on the Hardware Commissioning • the situation with the resources for hardware commissioning is worrying • it cannot cope with continued reduction of the time available • it is undeniable that additional resources are needed • additional resources must be trained in advance • in some cases, additional resources cannot be integrated because of lack of supervisors • the programme, the scenario, the documentation, the tools and the infrastructure are well in hand • the readiness will be assessed by a review • the complete picture will emerge only after a close-to-final installation schedule becomes available • 2005 is certainly a crucial year: with the commissioning of the first machine subsectors left of Point 8, it could give an indication on how wrong the figures are

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