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HL – LHC WBS & more . Project Coordination Office supporting the HL Project Isabel Bejar Alonso, Joao Carlos Batista Lopes, Claudia Parente. Why we are having this presentation?. Three main messages. - PowerPoint PPT Presentation
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The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.
HL – LHC WBS & more
Project Coordination Office supporting the HL Project
Isabel Bejar Alonso, Joao Carlos Batista Lopes, Claudia Parente
2
Why we are having this presentation?
3
Three main messages•WBS why it is so important and why will be
used as starting point for most project processes• Standards – what tools we will have to ensure
that we use the “right” ones while preparing the design files• Safety – how to integrate it from the beginning
4
Modifying at least 1.2 Km of an existing machine
3000 fb-1 in 10 yearsLimited pile up : 140 5 1035 levelled
5
Modifying at least 1.2 Km of an existing machine
Cryogenics
Collimation
IR Magnets
6
And modifying means …• New systems • New equipment for existing systems•Modifications to the present systems to adapt
to the new equipment/system• “Consolidation” (even if handled outside HL)• Dismantling and elimination of equipment
replaced
7
WBS some conceptsDefinition“The Work breakdown structure is a deliverable-oriented hierarchical decomposition of the work to be executed by the project team to accomplish the project objectives and create the required deliverables. The WBS organizes and defines the total scope of the project” (PMBOK)
Why- To ensure a clear definition and communication of project scope
- To have a baseline for planning, costing, scheduling, …ing.
8
WBS some concepts - DeliverableDefinition“Any unique and verifiable product, result, or capability to perform a service that must be produced to complete a process, phase or project. ” (PMBOK)
ImportantA deliverable is not a task or an activity. You will need those to obtain the deliverable.
What at CERN we call Work packages is not what the PMBOK calls Work Packages as they are not the lowest level in the WBS.
9
Starting pointLS2 - 1 y (14 months access) LS3 - 2 y (26 months access)
US1 US2 Cost (MCHF) In kind LS2 LS3 LS3 LS3 in part
P4 new cryoplant Y 15H SC link P7 Y 5IR (IT,D1, TAS) % Y 210 YESP1-P5 cryoplant % Y 75SC link (EPC&DFBX on surface) % Y 40Collimators IR Y 10Collimators MoGr % Y 15Collimators for INJ &TCLA Q4/Q5) Y 5DS cryocoll.(11T) P2 Y 20 395LRBB comp.wires Y 10DS cryocoll.(11T) P7 Y 25DS cryocoll (11 T) P1-P5 Y 40SC link (EPC&DFB on surface) for MS Y 20 95MS new layout (P1-P5) and Q5 in P6 Y 30 YESMachine & Magnet QPS (Availability) Y 25CC cavity P1-P5 Y 95 YESSCRF 2nd Harmonic YCrystal Coll Y ? YES ?Halo control (e-lens) Y ? YESHigh Band Feedback System Y ? 150Studies 10Other systems (Studies, Vacuum, Diagnostics, Remote handling 30Infrastructure, Logistics, Integration,Installation HWC 130 170
And not only
10
To be done for every existing system installedIdentify the changes included in the HL scope and prepare a list of deliverables
11
To be done for every deliverableEvery deliverable shall be linked to an LHC system or declared as a new LHC system /subsystem (ex. Halo control)
Every deliverable is assigned to a HL WP.
New HL WPs will be created if required
12
As a collaborative process
13
As a structured process
14
Supported by guides and templates
15
WBS as the starting point for the …ing
DELIVERABLES TASKS & ACTIVITIES
SCHEDULE
RESOURCESBUDGET
MILESTONES
EVM
RISK RISK REGISTER …
16
Supporting the Technical processes
performance and interface requirements … but not only
17
From Concept to Design
Once finalized the Conceptual phase we will enter the Implementation phase where the functional specifications will become design files for components that will be fabricated.
To the existing performance, and interface requirements we will have to add “design constraints”
“Design constrains” hierarchyRules
&Regulations
Codes and standards
Specific technologies and methods
Safety Quality Technical
Called sometimes “constrains”; Safety, Quality and Technical requirements have to be added to the performance and interface requirements identified during the conceptual phase
Rules&
Regulation
s
Codes and standards
Codes & StandardsAdvantages• Increased confidence on the
Quality of equipment• Increase of equipment’s reliability
and availability• Minimization of risks and costs
• Ensures Compliance with CERN Safety rules/EU regulations • Presumption of conformity with the
Essential Safety Requirements of EU directives (whenever applicable) by using Harmonized Standards
DisadvantagesCodes and standards are not (yet, or completely) cost free or Global market oriented• 55% and 70% of all European
standards adopted by CEN and CENELEC are technically equivalent or identical to ISO and IEC standards, respectively
• Unified approach still to be extended to other standards development organizations namely in the US.
Rules&
Regulations
Codes and standards
Codes & StandardsReliability and Availability
Working in a Radioactive environment
Minimization of risks and costs
Components Designed and built around the globe
But how to identify the applicable ones
Standards evolution since the LHC
Two examples:• Cold masses (dipoles)• Vacuum vessels
Do not reuse your old specs ….
IT-2544 / Vacuum vessels
IT-2799 / CM dipoles
LHC PRESENTLY
Standards architecture ICSManufacturing
engineering
Welding processes
Welded joints
* based on the International Classification of Standards (ICS)
Brazing and soldering
A non-exhaustive overview of some fields and their corresponding groups and sub-groups*
Welding, brazing and soldering
Metallurgy
Iron and steel products
Iron and steel castings
Iron and steel forgings
Steels for pressure purposes
Testing of metals
Mechanical testing of metals
Non-destructive testing of metals
Electrical engineering
Superconductivity and conducting
materials
Insulating materials
Magnetic materials
FIELDS
GROUPS
SUB-GROUPS
The complete map contains the groups that were used in old specs + what we think you could need
Standards – Present scenarioManufacturing
engineering
Welding processes
Welding joints
Iron and steel products
Mechanical testing of metals
Non-destructive testing of metals
Iron and steel castings
Metallurgy
Fusion welding
Examples
Identification with the WPE the interesting subgroups
Welding and allied processes - Fusion weldingSpecified in its superseded /replaced versionSpecified in its valid version
Approval testing of welders
Iron and steel castings
Specified in its superseded/replaced versionSpecified in its valid version
Harmonized standards 89/106/EEC - Construction products (CPD/CPR)
Mechanical testing of metals
28
Codes & Standards maps• A guide to identify if there is an standard that
guides you to fulfill your quality/technical/ safety requirements• A basis for benchmarking and best practices • ICS makes easier to find the equivalence in
other countries
Safety requirements
Rules&
Regulations
But how to identify the applicable ones
30
Guided processWPE tasks to identify Safety requirements
Step
1 -
Iden
tifica
tion
of C
ERN
Saf
ety
rule
s &
Host
stat
e re
gula
tions
Step
2 -
Iden
tifica
tion
of th
e sy
stem
/pro
cess
Saf
ety
requ
irem
ents
Step
3- R
isk a
sses
smen
tSt
ep 4
– c
onso
lidati
on o
f Saf
ety
requ
irem
ents
PhaseInput Tasks Output
Safety form(EDMS 1095136) WPE meets PSO
DOCUMENT 1:Description the system/process identification of related hazards
WPE meets HSE correspondent
DOCUMENT 2:CERN Safety rules &
Host State regulations applicable to the system/process
WPE selects Safety requirements
Safety form(EDMS 1313236)
DOCUMENT 3 (V1):List of requirements and related Safety
checks
DOCUMENT 1
DOCUMENT 2
If required, WPE organizes risk assessment
Safety form(EDMS 1114759)
Safety guideline(EDMS 1114042) DOCUMENT 4:
Action plan with control measures
WPE consolidates Safety
requirements
DOCUMENT 3 (V1)
DOCUMENT 4
DOCUMENT 3 (V2)
To verify document 3 (V2) with PSO and HSE
System Safety file
Safety file for the detection system
System
Auxiliary system – e.g. Power supply
Electricity
System – e.g. Superconducting magnet
Pressure
ChemicalElectricity
Mechanical Radiation
Auxiliary system – e.g. Control system
Software
Electrical Safety file
Chemical Safety file
Magnetic field Safety
file
Mechanical Safety file
Radioprotection Safety file
Pressure equipment Safety file
Electrical Safety file
Control system
Safety file
Magnetic
31
With roles and responsibilities identifiedHigh Luminosity Project Safety requirements
Bo
tto
m le
vel:
CER
N O
rgan
ic U
nit
,
ext
ern
al c
om
pan
ies
Inte
rmed
iate
leve
l: P
ers
on
in c
har
ge o
f
syst
em
s/p
roce
sse
s &
su
b-s
yste
ms/
pro
cess
es
Top
leve
l: P
roje
ct &
Wo
rk p
acka
ge
man
agem
en
t
Participants Responsibilities
Project Coordination
To provide system/process with compliance documents demonstrating compliance with S/PSR: S/PCD
To ensure that Project Safety requirements (PSR) are taken into account
PSO
Work package leader (WPL)
To ensure that WP Safety requirements (WPSR) are taken into account
Work Package engineer(WPE) – system/process
level
Work package engineer(WPE) – sub-system/
process level
To select from S/PSR the Safety requirements applicable to the sub-system/process: Sub-S/PSR
To provide sub-system/process with compliance documents demonstrating compliance with Sub-S/PSR:
Sub-S/PCD
Sub-S/PSR Sub-S/PCD
Service & product providers
Suppliers: e.g. raw materials
S/PSR S/PCD
To select from Sub-S/PSR the Safety requirements applicable to the Service/product: S/PSR
To provide Service/product with compliance documents demonstrating compliance with S/PSR: S/PCD
To select Safety requirements applicable to supplies
To provide supplies with compliance documents
Work package Safety file
To Identify system/process Safety requirements (S/PSR)
S/PCD
Work package phases & Safety – Roles of the Work package memebrs & HSE together
Dism
antli
ngO
pera
tion
Impl
emen
tatio
nCo
ncep
t
Work package life cycle HSE compulsory checks HSE advice & support Work Package members
Acquisition
WPL
– E
nsur
e th
at th
e Sa
fety
requ
irem
ents
are
iden
tified
and
impl
emen
ted
durin
g th
e w
ork
pack
age
life
cycl
e
Including Safety checks
Periodic inspection
Commissioning
Operation & Maintenance
Check conformity of tendering
specifications
Operation clearance
Advi
ce a
nd e
xper
t sup
port
on
Safe
ty ri
sk a
sses
smen
t, ris
k re
ducti
on a
nd ri
sk c
ontr
ol(P
rovi
ded
by a
mul
tidis
cipl
inar
y te
am o
f Saf
ety
spec
ialis
ts)
Design clearance
Functional specification
Installation
Advice on the identification of
Safety requirements
Decommissioning & dismantling
Purchasing & manufacturing
Initial inspection
WP requirements definition
Dismantling clearance
Commissioning inspection
Design
Transport & delivery
Acceptance of delivered items
WPE - Identification of the system/process Safety requirements
WPE
- Rev
iew
, im
plem
enta
tion
and
verifi
catio
n of
the
syst
em/p
roce
ss S
afet
y re
quire
men
ts
Expl
orat
ory
phas
eCo
ncep
t sta
geDe
velo
pmen
t sta
geRe
tirem
ent s
tage
ISO 15288
Prod
uctio
n st
age
Utiliz
ation
stag
e
Supp
ort s
tage
Proj
ect p
lann
ing
perio
d Pre-
proj
ect
DoE
Prec
once
ptu
al p
lann
ing
Conc
eptu
al
desig
n
Proj
ect e
xecu
tion
Prel
imin
ary
desig
nFi
nal d
esig
nCo
nstr
uctio
n
Miss
ion
Acce
ptan
ce
Ope
ratio
ns
32
Documentation
33
What, when, where, why, …Safety file
Ope
ratio
n &
m
aint
enan
ce fi
leCo
mm
issi
onin
g fil
eIn
stal
latio
n fil
ePu
rcha
se/m
anuf
actu
ring
file
Engi
neer
ing
desi
gn fi
le
Life cycle Electrical equipment Pressure equipment Installation Use of cryogenic fluids
Engineering
· Calculation report;· Drawings of
electrical installation;
Purchasing & manufacturing
Installation
Commissioning
Operation & Maintenance
· EC declaration of conformity;
· Cable certificates;
· Records of electrical inspection;
· Acceptance test of emergency stops;
· Records of periodic inspection;
· Calculation report;· Risk assessment;· Drawings;
· Material certificate;· Welders & welding
certificates;· Records of test &
inspections;· EC declaration of
conformity
· Records of pressure tests on vessel & relief devices
· Records of periodic pressure tests
· Installation procedures;
· Operating instructions;
· Acceptance test of oxygen deficiency detectors
· Cryogenic risk assessment;
Documents provide by the work package chain: from top level to bottom level entities
Documents provide by the HSE Unit
34
Conclusions & Next steps• WBS as an enabler that ensures clear definition and
communication of the project scope• Structured approach with well defined processes• Guidelines and training to ensure a common approach• Support to identify the design requirements with maps
identifying standards by applicable categories and international equivalences• Support to identify safety requirements by hazards with
forms • Lists of applicable documents for each phase with templates
and clear approval and distribution processes
The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.
EXAMPLE
Coils manufacturing
Nb3Sn strand Nb3Sn cablesElectrical insulation
(Nb3Sn cables)Coils winding
Ceramic-binderinjection
Reaction of Nb3Sn coils
Vacuumimpregnationof Nb3Sn coils
Curing
“Wind & React” process (simplified)
Instrumentation(Quench/spot heatersTemperature sensors
Voltage tapsStrain gauges)
Splices Final assembly(insulation films and
quench heaters)
Based on USPAS lectures (courtesy E. Todesco)
Conducting materials Insulating materials
Soldering
Magnetic materials
Cold Mass assembly
CollarsIron yoke Shell End plates
Cold bore tube and beam screen
Note: shell + end plates + cold bore tube define the He II (atmospheric pressure) containment vessel
Based on USPAS lectures (courtesy E. Todesco) & LHC Design Report (Vol. I)
He II heat exchanger tube
Magnets system- Standards architecture
* based on the International Classification of Standards (ICS)
A non-exhaustive overview of some applicable fields and their corresponding groups and sub-groups*
Coils manufacturing
Electrical engineering
Conducting materials
Insulating materials
Magnetic materials
Rubber and plastic industries
Rubber and plastics products
Plastics
Metallurgy
Products of non-ferrous metals
Copper products
Testing of metals
Mechanical testing of metals
Non-destructive testing of metals
Manufacturing engineering
Welding, brazing and soldering
Brazing and soldering
Welding processes
Welded joints
Magnets system- Standards architecture
* based on the International Classification of Standards (ICS)
A non-exhaustive overview of some applicable fields and their corresponding groups and sub-groups*
Cold mass assembly
Metallurgy
Testing of metals
Mechanical testing of metals
Non-destructive testing of metals
Iron and steel products
General
Steels for pressure purposes
Electrical engineering
Magnetic materials
Testing
Non-destructive testing
EXAMPLESStandards Maps
Superconductivity and conducting materials
Magnetic materials
Brazing and soldering
Mechanical testing of metals
Recommended