Hardware Commissioning

Roberto Sabanon behalf of the Hardware Commissioning Working Group

Chamonix XIV 050119

Hardware CommissioningHardware Commissioning

the resourcesthe programme for 2005

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 programme has not been prepared yet: it strongly depends on the installation schedule which has lately been very uncertain.

Chamonix XIV 050119 R.Saban/TS

0

12

24

36

48

J an 03 Apr 03 J ul 03 Oct 03 Feb 04 May 04 Aug 04 Dec 04 Mar 05 J un 05 Sep 05 J an 06 Apr 06 J ul 06 Nov 06 Feb 07 May 07 Aug 07

[mon

ths]

why we started getting worried ...why we started getting worried ...

Dec 2003

July 2004Dec 2004

Mar 2003

establish a commissioning programme

define team compositionsdefine team numbersdefine the commissioning times

with a number of boundary conditions

Time allocated for Hardware Commissioning

if the boundary conditions change, we now can predict the impact on the three


Resources for Hardware CommissioningResources for Hardware Commissioning

basic assumptions programme of the tests

sequencesequence of the tests time neededtime needed for each

test inventory of the test test

teamsteams and their compositioncomposition

… 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.







1. Two sectors at a time around an even point

2. Five-day working weeks3. Two shifts during powering tests4. Two commissioning fronts per

sector5. The magnets are left floating in

temperature after the commissioning

6. The RF system is commissioned just before commissioning with beam

7. The PS and SPS complex run in 2006






1. 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

2. Cool down calibration at cold and cryo loop

tuning electrical quality assurance

3. Tests at cold electrical quality assurance quench protection

4. Powering Tests validation of the interlocks validation at low, nominal current

and all circuits in unison



The resulting scheduleThe resulting schedule

right of the even point

left of the even point


a closer look ...a closer look ...

warm tests 23 weeks

cool down 8 weeks

powering tests 11-16 weeks

tests at cold


Interlock tests of a powering subsector prior and after connection of the power cables to the DFB leads

Pow

er

Convert

ers

co

nnect

ed

to

Magnets

Pow

er

Convert

ers

co

nnect

ed

to

Magnets

Pow

er

Convert

ers

not

conn

ect

ed

to

Magnets

Pow

er

Convert

ers

not

conn

ect

ed

to

Magnets

300 K

1.9 K

90 K

Test of power converters connected to the DC cables in short circuit, including controls for powering, ramp, monitoring

connexion of power cablesto the current leads

Electrical Quality Assurance

superconducting electrical circuitssuperconducting electrical circuits

Individual System Tests of the Quench Protection and Energy Extraction Systems

Post-Mortem System tests

Commissioning of the electrical circuits one by one or in groups at low, intermediate and nominal currents

Commissioning of all the electrical circuits of the sector powered in unison to nominal current with nominal ramp rates

Individual System Tests of Powering Interlock Control

Powering Tests


circuit count and individual commissioning timescircuit count and individual commissioning times

Main circuits and IT quadrupolesSeparately powered quadrupoles600 A circuits, separation and recombination dipoles80-120 A orbit correctors, IT correctorsTotal

4078

436274828

Num

ber

of

circ

uit

s

Quench

Pro

tect

ion

6078

1310

269

Inte

rlock

test

s

4039

21869

366

Pow

eri

ng t

est

s

120181616

170

22013536585

805

Tota

l

unit is one 15 hour day of one commissioning front

MBMQ, MQXSeparately powered quadrupoles600 A circuits, separation and recombination dipoles80-120 A orbit correctors, IT correctors

11.05.51.70.80.3

Powering Tests


resources deployed for the powering testsresources deployed for the powering tests

Powering Tests

Front 1Front 2 Front 1 Front 2

Left Right

6.6 km

in the field on call2t + 2o 1e+1o cryogenics operation1e+1t cryogenics

instrumentation1x+2e+2t quench protection2x+2t 1x+1t+ ... machine interlocks1x+2t 2e+1t+ ... power converters2e+2t coordination1t 1e controls1o operation

4x+5e+10t+3o 1x+4e+2t+1o

o operatorx experte engineert technician

22 present in the field

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

two shifts = 15 hour days


the sequence of tests around an even pointthe sequence of tests around an even point

Powering Tests


power tests of MB circuit power tests of MB circuit 1 of 21 of 2

1. to commission the protection functionalities of the powering interlock controllers and all its connected systems with current through the circuits

2. to verify the compatibility of the switch-on and switch-off processes of the converters with the sensitivity of the protection systems

1. to set up the power converter current loops2. to validate the protection mechanisms under real powering

conditions and with limited energy stored in the circuits3. to validate quench-related procedures, e.g. cryogenic recovery

procedures4. to validate the sensitivity and compatibility during ramps of the

systems susceptible to noise pick-up, couplings, etc5. 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

Powering Tests

HCA:PIC2

HCA:PLI1

33% nominal 66% nominal80% nominal nominalinjectionstandby

HCA:PLI2HCA:PLI3HCA:PLI4

LHC-D-HCP-0003


power tests of MB circuit power tests of MB circuit 2 of 22 of 2

1. to verify the power converters during the ramp2. to calibrate the DCCTs for the main and the Inner Triplet power

converters and to verify the calibration systems3. to validate the protection mechanisms with nominal energy in the

circuits4. to verify the quench current of each circuit5. to validate quench-related procedures, e.g. cryogenic recovery

procedures

1. to verify the tracking of the circuits2. to verify thermal performance of the ventilation and water cooling

systems in underground areas3. to carry-out a 24-h reliability run in order to detect premature

failures due to wrong settings or possible assembly errors

33% nominal 66% nominal80% nominal nominalinjectionminumumstandy-by

HCA:PNO

HCA:PAC

Powering TestsLHC-D-HCP-0003


essential time saversessential 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







… 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.


Missing Possible Source

Cryogenic Instrumentation & Process Control

Technical Engineer 8 Staff, NI

Engineer 2 Staff, NI

Database Expert 1 Staff

Quench Protection

Technician 7 Staff, NI


Machine Interlocks

Technician 5 Staff, NI

Electrical Engineering (Power Converters)

Technician 3 Staff

Engineer 2 Staff

Commissioning Coordination

Technician 6 Staff


Controls

Technician 1 Staff

Engineer 2 Staff, NI, IS

The personnel involved in the individual system tests and the hardware commissioning 142142 of which 4646 are missingare missing.

Additional budget for IS and FSU is 1.335 1.335 MCHFMCHF.

The resulting need for resourcesThe resulting need for resources

with the basic assumption


Report SummaryReport Summary

~20 months 142 people involved 46 missing in some cases experience

is a mustmust engineers and technicians

cryogenics quench protection interlocks coordination & operation controls

possible sources national institutes but also recruitment

staff for supervision is staff for supervision is already criticalalready critical

training of new resources training of new resources for commissioning is for commissioning is criticalcritical



Report Summary : ParallelismReport Summary : Parallelism 1 of 31 of 3

powering testscool down

warm tests


warm tests


warm tests


warm tests

28 months



15.5 months


warm tests



warm tests


warm tests

warm testsOverload of Overload of CIWSU, CIWC, CIWSU, CIWC, CIWCS, CIWS, MI-CIWCS, CIWS, MI-PCIST, PCIST, PCIST, PCIST, COCD, HCC, COCD, HCC, ABOPABOP

20 months


warm tests



warm tests


warm tests

warm tests

Overload of only Overload of only the Operator, HC the Operator, HC Coordination and Coordination and Cryo Operation Cryo Operation TeamsTeams

2.5 months




CIW

SU

CIW

CS

CIW

SM

I-PC

IST

PC

IST

CO

CD

HC

CA

BO

P

20 months for thecommissioning activity

CIW

SU

CIW

CS

CIW

SM

I-PC

IST

PC

IST

CO

CD

HC

CA

BO

P

12 months for thecommissioning activity

142 people (46 missing)

?

• where do we find them?• how long do we have to train them?• who is going to supervise them?


what do we do with the Report ?what do we do with the Report ?

find the additional resourcesresources study alternatives

strategies alternative to personnel strategies alternative to personnel directly under the supervision of directly under the supervision of the Groupsthe Groups

partial commissioning of the partial commissioning of the sectorssectors

review the commissioning review the commissioning proceduresprocedures


programme for 2005: the latest schedule ...programme for 2005: the latest schedule ...

Sylvain Weisz on November 26, 2004 at TCC

a lot is happening before ...

installationcabling

IST


programme for 2005: installation sequence for Sector 78programme for 2005: installation sequence for Sector 78

Point 8

Point 7

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

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


programme for 2005: the equipment concernedprogramme for 2005: the equipment concerned

Part of the Matching Section L8 with a Separation Dipole

Inner Triplet L8 with a Separation Dipole


key dateskey 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

3 October 2005

31 October 2005

3 March 2006

30 June 2005


the sector test in ... 2006the sector test in ... 2006


... in summary : ... 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


Documents

Hardware Commissioning