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Hardware Commissioning

Hardware Commissioning. Preparation Documentation MTF Programme Status The Review The commissioning activity in 2005-2006 Resources Outlook The new schedule. Roberto Saban on behalf of the Hardware Commissioning Team. MAC19 060616. The method. Sytem owners define and carry-out. .

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Hardware Commissioning

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  1. Hardware Commissioning Preparation Documentation MTF Programme Status The Review The commissioning activity in 2005-2006 Resources Outlook The new schedule Roberto Saban on behalf of the Hardware Commissioning Team MAC19 060616

  2. The method Sytem owners define and carry-out  • What tests • the procedures and the sequence • How • what conditions are required to start • what conditions determine it is finished • what conditions are required during the tests After the qualification for operation of the individual systems of a sector (vacuum, cryogenics, quench protection, interlocks, powering, etc.), individual system tests Hardware Commissioning Coordination with System Owners define and carry-out  each sector will be commissioned as a whole up to the powering to nominal current of all the circuits. • What tests • the procedures and the sequence • How • what conditions are required to start • what conditions determine it is finished • what conditions are required during the tests hardware commissioning  Validation and specific studies will be carried-out on the first commissioned sector. Hardware Commissioning Coordination ensures that the conditions required exist Preparation and ensures that the conditions required exist

  3. The logic individual system tests hardware commissioning subsystems ready • impact on equipment safety • impact on equipment/system performance • impact on machine performance all systems ready for machine check out Preparation • two types of documents : • as designed • as tested

  4. Commissioning Procedures & Failure Scenarios • Progress has been made in convincing our colleagues from the equipment groups of the usefulness of the documentation • Documentation describing the Individual System Test and Hardware Commissioning Procedures now exist for most of the systems • Only a few documents describing Failure Scenarios have been prepared • A standard chapter on Safety was introduced in all of them following the guidelines of the Safety Coordinators • These documents are used as a hard reference by those who carry out the tests in the field; these documents are alive: in fact, the have undergone updates following experience when carrying them out Preparation

  5. The Manufacturing & Test Folder IST Sector Region Equipment group Equipment Components  SECTOR 7-8  Superconducting Circuits RQS.A78B2.RR77 Arc 78  Power Converter  Preparation

  6. The Manufacturing & Test Folder EDMS – MTF for Circuit Related Components: AC Distribution Powering Interlock for warm and cold circuits Quench Protection System Energy Extraction Control Cooling & Ventilation Cooling Power Cables Electrical Quality Assurance Power Converter Short Circuit Tests DFBs Cryogenics Vacuum Access & Safety EDMS – MTF for Beam Related Components: Beam Instrumentation Controls + Beam Energy Meter Collimators Kicker System Diluters Beam Interlock System Beam Dumping System Beam Injection System RF Preparation

  7. The Manufacturing & Test Folder Preparation Data already uploaded for Sectors 78, 45 and 81 ! (~1000 slots filled in)

  8. The commissioning programme Left Right Front 2 Front 1 Front 1 Front 2 6.6 km Front 1arc and the matching section on the even side Front 2arc, the matching section on the odd side and the inner triplets on both sides two shifts = 15 hour days Preparation

  9. The day to day coordination : the human resources Project Management Progress Tracking Planning Re-scheduling Meetings Crisis Management MTF Database Analysis Information processing Publications 1 Project Leader 1 Mr.Circuit & DPL 1 Database/Web Expert 1 Administrative Assistant Field Preparation hardware oriented small repair missing details access/balisage LHC Safety Coordination advise on safety matters enforce safety in the field Field Control Room or CCC 1 AB Operator operation support to operation data recording reporting • Sector A • 1 Engineer • 1 Technician • Sector B • 1 Engineer • 1 Technician Preparation

  10. The review & its recommendations • Some organisational matters were judged worth further attention. • It was noted that Hardware Commissioning will be the first occasion where the safety measures (responsibility, training, access conditions, signalling, etc.) put in place for LHC will be evaluated for the first time. Furthermore, Hardware Commissioning will be a test of the new organisation of Safety at CERN; its impact must be monitored. • A number of issues related to controls & informatics were noted. • Important technical issues related to either the conditions under which the tests are carried-out (e.g. the ventilation of the tunnel during the tests) or the tests themselves were considered; some of them must be reconsidered in the light of the present installation and commissioning scenario. Status

  11. The commissioning activity in 2005-2006 Three underground powering areas around even points were tested with the power converters connected to the cables (water and air cooled) DFBs field control room Energy Extraction Systems Power Converters One smaller underground powering area close to Point 7 is being tested now. Status

  12. The commissioning activity in 2005-2006 Status

  13. The commissioning activity in 2005-2006 Data provided by ST-CV The supply air temperature of the HVAC units is regulated at 17.5 ± 1.5 ˚C except ESCL 7,9,10,11 and 12. ESCL1 PID is optimized for hi-speed fan . ESCL7 showed a regulation problem since a manual valve had remained closed. ESCL9 to 12 inefficiency problem. Status

  14. The commissioning activity in 2005-2006 The temperature at the ducts showed maximum values of 74 ˚C 10h after start up PC. At 03:15 cables 1808470 showed 154 ˚C at their end. Tightening problem solved at 04:30. Status

  15. Resources Status

  16. The new schedule A piece of cake The nightmare Outlook

  17. The new schedule • It looks it can be done with a few reserves like the activation of the tunnel during this first run, the commissioning of the access safety and access control system, the approval of the as-built access safety and access control system by the INB authorities, the fact that we would start with a machine which is not so well aligned (no smoothing) • Careful tuning of co-activities is needed • Some additional resources will be needed in 2007 (man power and hardware) • Resources not originally planned for will be needed in 2008 • The program for 2008 must be closely watched to ensure that the remaining commissioning can really be done in the three months allocated Outlook

  18. Conclusions • Preparation “finished” • Awareness of safety and equipment integrity must be continuously stimulated • First experience in the field positive but the real heat is not yet on • The resources were found but must be monitored in the light of the changing scenario • Delicate scheduling of the activities to match the available resources and the requirements of the schedule Hardware Commissioning

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