Nikolaos TRIKOUPIS, TE-CRG-CI LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico Beam screen circuit 3TRIKOUPIS Nikolaos, TE-CRG-CI DC: 0-30W, AC: 0-200W 271 cards (485 channels) Step-down transformers Independent AC supply LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico Project key points 4 Tight deadlines. Must be ready for CSCM tests: JUN/2014. Production launch was delayed for better design validation Just on time. Design development & validation FESA dev. & val. for technical specifications - EN/ICE UNICOS tests according to requirements Tests by the operation (after commissioning). Functionality tests at P8 warm) crates with long cables external load (100m) FEB/2014 LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI Production key dates & Issues 5 TE-CRG-CI: Design & component procurement. TE-MPE: Management of PCB production & assembly. 1 st deadline: 23/06/ /01/2014: Green light for production. Delay strategy was beneficial due to design changes. 21/03: Bare PCB receptions (Foreseen 01/03; +20 days of delay). 28/03: Shipment of all material to company: Delay: +10 wks (TT) + 4 wks (EHBS/FPGA) +7 wks (EHBS) 09/04: Status of company: 16/04: Planned end of QA for components. 03/05: Reception (50pcs). However, +17 days (20 pcs), + 27 days (30 pcs). 23/06: Deadline for 2 wks (reception) and 1 wk (installation). Issues 1.TE-MPE: Both TT-ins and EHBS to same company. Jobs could not be assembled in parallel. LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI 2.Recurrent broken SMD parts during assembly due to inappropriate tool use. 3.1 humidity controlled part was not treated according to specs. All parts (except 50pcs) replaced. Humidity control storage for LAB36. Reception/Installation/Quality assurance 6 PVSS testbench development (acceptance tests), calibration parameters, MTF, layout. All thermocouples verified at cold. Rechecking after technical stops/interventions. Data in timber; data analysis (e.g. installation and performance analysis with the Run 1). Commissioning S67Data analysis in timber Acceptance tests with PVSS scripts MTF LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI FESA code & integration in the control system 7 FEC/FESA EN/ICE developed the EHBS FESA software based on previous EH code structure. New design was completely different than before. FESA code turned complex. Specs updates were difficult to implement. After FPGA code release, 3 minor bugs were identified and handled in FESA. Activation EHBS foresees: 1) Connect/disconnect load, 2) Enable/disable command. Operation wanted to use both commands but the AnaDO UNICOS object was not compatible with timing requirements needed by CI (due to a single DO). Connect/disconnect load feature was removed from UNICOS object at the end. LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI Operation issues 8 Electrical heaters powering TE-CRG-CI was following a rule No AC voltages with beam. Well discussed during the TE technical review (4 th Feb 2013). Power requests around 25W resulted in constant AC/DC relay movements (OA: No reason to not use AC). FESA software had to be modified to include AC/DC hysteresis. Communication loss EHBS according to specs: Stops power, operator action required. However, situations like background EN/ICE updates triggered sector-wide protections. FESA code modified for automatic recovery; TE/CRG-OA responsibility to limit power. Over-temperature EHBS according to specs: Interlock on triggered thermocouple. PLC code adapted to reduce monitoring by operators. Implementation of rule: 3 TS in 2 hours 1 FS. Multiple technical meetings during JUN/2014 to resolve all issues/define all interlocks. Missing test station for use by operation team in real conditions was a minus. Currently, transparent integration in the cryogenics instrumentation infrastructure. EHBS fulfilled and exceeded all specifications as distributed on 13 Nov LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI R2E strategy 9 Radiation strategy adapted (A) Identification and selection of radiation tolerant electronic components. (B) Validation of an early prototype using a % of available production components. (C) Post-production validation. 5 radiation test campaigns. The strategy turned out to be excellent for this project. 3 presentations given at the RADWG. The EHBS project was presented at the LMC as one of the best R2E-related developments for the A&T sector during the LS1. (C) CHARM NOV/2014 JAN/2015 (B) PSI NOV/2013 (A) CNRAD/CNGS JUN-DEC/2012 (A) PSI JUL/2013 (A) PSI FEB/2013 LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI Summary of lessons learned 10 More effort/time from all parties when defining requirements will pay off later. Operational experience would have been beneficial. R2E internal experience and strategy was a plus. Delaying the production as long as possible to recognize drawbacks. Anti-fuse FPGA has the draw-back that code is limited in size and cannot be changed. Tight schedule requires a lot of effort to track TE-MPEs work flow. Environment controlled conditions for long-term storage of TE/CRG-CI components. Extra functionalities may be used to solve design problems/bugs. Questions? LS1 projects review: feedback on projects and lessons learnt 01/JUN/2015, Indico TRIKOUPIS Nikolaos, TE-CRG-CI