Putting it all together Roberto Saban Review of Hardware Commissioning May 11 -13, 2005
Organization and Coordination of the Hardware Commissioning o o o 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 Roberto Saban TS/HDO HC Review 050513
Quality Assurance and Documentation of Results o o 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, nonconformities 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 ? Roberto Saban TS/HDO HC Review 050513
Controls and Communications o o o o World. FIP card: desynchronization & protocol problem No time allocation for World. FIP global test (individual system tests of controls infrastructure). Fieldbus must be tested with the final agents. LSS 8 L 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 Roberto Saban TS/HDO HC Review 050513
Infrastructure o o o 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 Roberto Saban TS/HDO HC Review 050513
Vacuum o o o 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. Roberto Saban TS/HDO HC Review 050513
Vacuum o o o 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. o o 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. Roberto Saban TS/HDO HC Review 050513
Cryogenics o o o 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 Roberto Saban TS/HDO HC Review 050513
Cryogenics o o o 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. postmortem). 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 Roberto Saban TS/HDO HC Review 050513
Cryogenics o o o 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. Roberto Saban TS/HDO HC Review 050513
Electrical Circuits and Magnets (warm and cold) o o o o No IP 2 X 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. Roberto Saban TS/HDO HC Review 050513
Electrical Circuits and Magnets (warm and cold) o o o To what extent is the QPS system affected by the World. FIP synchronization problem raised by MVE? In particular for the LSS 8 L commissioning? Manpower for additional tests: is an issue (e. g. El-QA) LSS 8 L is a milestone: most of the procedures can be tested there Threshold for detection of bad splices (1 m. V 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. Roberto Saban TS/HDO HC Review 050513
Electrical Circuits and Magnets (warm and cold) o o o o 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? Roberto Saban TS/HDO HC Review 050513
Electrical Circuits and Magnets (warm and cold) o o o o 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 Roberto Saban TS/HDO HC Review 050513
Electrical Circuits and Magnets (warm and cold) o o o 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! Roberto Saban TS/HDO HC Review 050513
Beam Systems o Collimators n n n o 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 n MKQA (MKI? ) kicker installation will be done in a rush Roberto Saban TS/HDO HC Review 050513
Beam Systems o RF n n n o BDI n n n o 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 ? interference with HC because of late delivery (BLMs) co-activities with RF must be carefully planned BLM installation must be prepared Beam Interlock n n n 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 Roberto Saban TS/HDO HC Review 050513
Compatibility of Hardware Commissioning with Installation o installation of the machine n n o UJ 22, 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 n n n 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 Roberto Saban TS/HDO HC Review 050513
From Hardware Commissioning to Cold Checkout o o o 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 Roberto Saban TS/HDO HC Review 050513
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 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 Roberto Saban TS/HDO HC Review 050513
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