Re-Commissioning (IST) of Electrical Systems: QPS, EE & PIC

1

Re-Commissioning (IST) of Electrical Systems: QPS, EE & PIC

Zinour Charifoulline

with contributions of R.Denz, G-J.Coelingh, A.Verweij, I.R.Ramirez, M.Zerlauth

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Scope:- What is the IST ?- IST@LS1 for QPS, EE, PIC- Answers to the Workshop Questions

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What are the Individual System Tests of QPS, EE & PIC? (I)

IST is a series of (stand alone) tests upon the installation of the QPS, EE and PIC components in an underground area of the LHC to qualify their correct functionality and communication before the first powering of the concerned circuits. Test Procedures from EDMS: “Individual System Tests of the QPS”, 720806, 2006-08-23 “Individual System Tests of 13kA and 600A EE”, 717559, 2006-08-15 “Individual System Tests of the PIC”, 531823, 2005-02-16

3. SCOPE QPS3.1 THE QPS COMPONENTS3.2 SCOPE OF THE TESTS3.2.1 FINAL FUNCTIONAL TESTING AND CONFIGURATION ON THE QPS TEST BENCHES 3.2.2 TESTS IN THE LHC UNDERGROUND AREAS WITH EQUIPMENT BEING NOTCONNECTED TO THE SUPERCONDUCTING ELEMENTS3.2.3 TESTS IN THE LHC UNDERGROUND AREAS WITH EQUIPMENT BEINGCONNECTED TO THE SUPERCONDUCTING ELEMENTS3.2.4 TESTS DURING COOL DOWN3.2.5 TESTS IN THE LHC UNDERGROUND AREAS WITH EQUIPMENT BEINGCONNECTED TO THE COLD SUPERCONDUCTING ELEMENTS

6. THE TEST PROCEDURES FOR THE 13 KA EE FACILITIES 13kA EE6.1 INSULATION TESTS (FIRST PART)6.2 FUNCTIONAL TESTS6.3 POLARITY VERIFICATIONS6.4 SPURIOUS BRANCH OPENING WITHOUT CURRENT IN THE BREAKERS6.5 OPENING TESTS WITH CURRENT IN THE BREAKERS6.6 BRANCH VERIFICATIONS6.7 SHORT-CIRCUIT TESTS FOR WARM CABLES

11. THE TEST PROCEDURES FOR THE 600 A FACILITIES 600A EE11.1 VISUAL INSPECTION OF RACKS AND SYSTEMS11.2 INSULATION TESTS11.3 INTERLOCK AND FAILURE TESTS – TIME MEASUREMENTS11.4 FUNCTIONAL TESTS11.5 COMMUNICATION WORLDFIP11.6 ENDURANCE TEST11.7 SHORT-CIRCUIT TESTS FOR WARM CABLES

5. THE PROCEDURES PIC5.1 INTEGRITY TESTS OF CONNECTIONS5.2 TESTS OF GLOBAL PROTECTION MECHANISMS AND AUXILIARY SYSTEMS.6. THE STATUS OF THE SET-UP AFTER THE TESTS .

QPS – Quench Protection System, MPE/EP; EE – Energy Extraction, MPE/EE;PIC – Powering Interlock Controller, MPE/MS;

https://edms.cern.ch/file/720806/1.0/LHC-DQ-TP-0002-10-00.pdf



https://edms.cern.ch/file/531823/1.0/LHC-CI-TP-0001-10-00.pdf

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What are the Individual System Tests of QPS, EE & PIC? (II)

The final stage of Individual System Tests is the part of so called Powering Tests Phase1 just after the ElQA tests at cold:

The Powering Test activity is divided in two phases:1. Preparation of the Powering Tests where the following tests are carried-out:i. electrical quality assurance at cold (continuity of instrumentation wires,transfer function measurement, insulation tests)ii. individual system tests of the Quench Protection System at cold (individualdischarge of all the quench heater power supplies)iii. interlock tests without current in the magnets for all electrical circuits (PIC1->IST.PIC?)iv. connection of the power converters to the current leadsv. commissioning of the DFBs without current (He levels, condensation,temperature of the current lead ends, lead head heater system, etc.)2. Powering Tests (Arjan’s talk) Engineering Specification from EDMS: “Powering Tests of the SC Circuits of the LHC: Brief Summary”, 847695, 2007-07-13

https://edms.cern.ch/file/847695/1.0/LHC-D-ES-0007-10-00.pdf

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Some statistics from 2012 HWC campaign

IST.QPS – 536 circuitsIST.EE – 226 (24 13kA, 202 600A) circuits IST.PIC1 - 32 controllersapproved before going to Phase2 in 2012.

“Accelerator Test Tracking”, see Kajetan’s slides.

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What is in few lines the best description of the activity? See aboveWhy we do it during LS1? Many components will be upgraded (Bruno’s and Bozhidar’s slides)What are the risks and/or the impact if not done during LS1? ---What is the time period of the activity? From completion of upgrade and until start of HWC (but before final cool-down access limitations).Is it depending to the general LS1 schedule? Yes

Engineering Specification from EDMS:“General Procedure for the Commissioning of the Electrical Circuits of a Sector”, 477145, 2004-09-29

IST of the 13kA EE Systems1. To check that the basic electrical, mechanical and hydraulic parameters of each

system have not changed since last powering.2. To verify the local infrastructure, required for operating the EE facilities, once

connections to the equipment are established.3. To perform functional tests of the complete facility.4. To re-commission the supervision system of each facility.5. To re-commission the DQR cooling stations.6. To verify the adequate activation of the internal fault signals.

Any temperature,but access needed

https://edms.cern.ch/file/477145/1.0/LHC-D-HCP-0001.pdf


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What is in few lines the best description of the activity? See aboveWhy we do it during LS1? Consolidation of 606 Extraction Breakers (Bruno’s and Gert-Jan’s slides)What are the risks and/or the impact if not done during LS1? ---What is the time period of the activity? From completion of upgrade and until start of HWC (but before final cooldown access limitations.)Is it depending to the general LS1 schedule? Yes


IST of the 600A EE Systems

1. To perform functional tests of the complete system. This includes verification of all internal fault signals. Auxiliary power UPS needed.

2. To re-commission the supervision system of each extraction facility.




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S1 What is in few lines the best description of the activity? See aboveWhy we do it during LS1? As a part of re-commissioning (Bruno’s & Ivan slides)What are the risks and/or the impact if not done during LS1? ---What is the time period of the activity? LS1 Is it depending to the general LS1 schedule? Yes


IST of the Powering Interlock System (PIC), 32 systems

1. The verification of the correct functioning of each powering interlock controller before its connection to the power converters and the QPS in the tunnel.

2. The preparation and later commissioning of the interfaces for the short circuit tests of the main dipole and quadrupole circuits, including the energy extraction systems.

3. To re-commission the supervision system of each powering interlock controller.4. PIC1 test to be approved before going to Powering Test Phase2. (t.b.d.)




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What is in few lines the best description of the activity? See aboveWhy we do it during LS1? Many components will be re-installed and upgraded (“Yellow Rack”, R2E, DQHSU, …) (Bruno’s & Jens slides)What are the risks and/or the impact if not done during LS1? ---What is the time period of the activity? From now and until start of Powering TestsIs it depending to the general LS1 schedule? Yes


IST of the QPS @ LS1, 536 circuits1. Verification of the correct installation of all quench protection equipment with

respect to the corresponding implementation plans.2. Re-Commissioning of the QPS supervision system.3. Functional test of all new quench detectors.4. Test of the QPS quench loops, which are internal to this system.5. Functional test of all quench heater circuits at cold.


Cryo OKSector closed

Three major steps after installation: 1. Verification of QPS supervision for all attached systems (2532 DAQ systems)2. Test of all hardware interlocks (7568 boards, 13722 HW interlocks in total)

a. Supposed to be done once per year but so far only for main circuitsb. Problems to test 600A and IPQ, IPD, IT interlocks in the machine due to

interlock architecture (reset of PIC etc.)c. This problem must be resolved as it will be not allowed to restart without

having all interlocks properly tested in the machine (EP/MS)3. Test of all quench heaters @cold. All heater circuits (6076) must be tested once at

full charging voltage to have a reference for the newly installed QH supervision. Procedures need to be updated (triggering by iQPS & nQPS etc.)

4. Software tools concerned must be further developed to speed up testing5. CSCM requires step 1 and 2 to be completed for the corresponding circuit6. Step 2 requires ELQA tests being completed and all instrumentation cables

connected, sector should be closed (mandatory for step 3)7. Functional tests on the surface are managed by EP exclusively with the exception of

the final testing of racks DYPB (EP/EE shared activity) R.Denz

7568 Quench Detection Boards2532 DAQ systems6076 Quench Heater circuits13272 hardware interlocks



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QPS7568 Quench Detection Boards2532 DAQ systems6076 Quench Heater circuits13272 Hardware Interlocks100% needs to operate correctly!Properly done IST is a challenge but no choice!

IST of the QPS @ LS1, 536 circuits

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What is the planned manpower (Internal/External)?Do you identify some missing resources?Do you rely from support from other MPE section(s)EP,EE and MS will be involved with a help of some FSU

What are the contributions from the other groups? (Cabling, Transport, Controls...)Do you identify some potential issues?

What are the Safety measures taken to perform the activity? - Personal Safety: Yes- Tunnel equipment: Yes (bicycle, … ?)

Individual System Test (IST) of QPS, EE & PIC @ LS1

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What SW tools are planned to be used? Since many new boards will be installed, we need the “Production Testers”, “Functional Testers”, “General Lab Testers”, …The database of QPS hardware … (Jens, Arek’s talks)IST follow up software on base of QPS DB? ( as Test Tracking, Kajetan talk) Are they ready to be used? I think, yes but not yet allWho will provide them? MS, EP, EE, PE, (?), …Is there any benefit to further automate the process of your tasks (testing, commissioning)? Yes, especially for Interlock Tests, Quench Heaters Discharge Tests, …What would be the effort implied? Existed applications need to be adapted to the upgraded hardware, What is the long term strategy with regard to maintainability of testing equipment and related software? See Arek’s, Maxime’s, Kaetan’s talk


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Do you foresee other potential showstoppers?

I think, it might be useful to update the Test Procedures documents in EDMS, since some new components, like nQPS, are already installed in the machine, and quite a bit more will be upgraded during LS1.And we need to be ready to adapt to the new commissioning scheme if CSCM will be part of HWC.

Test Procedures from EDMS: “Individual System Tests of the QPS”, 720806, 2006-08-23 “Individual System Tests of 13kA and 600A EE”, 717559, 2006-08-15 “Individual System Tests of the PIC”, 531823, 2005-02-16




https://edms.cern.ch/file/531823/1.0/LHC-CI-TP-0001-10-00.pdf

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Detection Incendie

ODH

EPC 60A

EPC 60A

VSC IV

EPC 60A

EPC 60A

MPE

EE

MPE

EE

MPE EE

DYPBDYPB

DYPB

DYPB

Cool-Down

Cool-Down

Cool-Down

Cool-Down

IC train

ELQA

Powering tests

ELQA

UPS

ELQA

Leak tests

Powering tests

ELQA

Warm Up

IC train

Cool-Down

UPS

Preparation

Flushing

IC train

Powering tests

Powering tests

IC train

IC train

ELQA

Preparation

Flushing

Powering tests

ELQA

Wat

er C

oole

d ca

bles

MKI

gen

erat

ors m

aint

enan

ce

Wat

er C

oole

d ca

bles

A1L5

B4L5

A6L5

WARM UP

ELQA

POWERING TESTS

UPS



PREPARATION

FLUSHING

COOL DOWN

FLUSHING

PREPARATION

C15R1

A22R1

C30R1

C33R1

C33L2

A29L2

B25R2

A23R2

C15L3

Q7R3

Q23R3

Q26R3

Q27R3

B32R3

C17R4

B31R4

A6L1

Colli

mat

or c

ontr

ol

Coll.

A4L1

CA1

L1

BPM

A4R1

Coll.

Colli

mat

or c

ontr

olM

KI g

ener

ator

s

A6L2

BTV

I5L2

BTV

MKI

MKI

A5L2

BPT

A1L2

A

TDI

Col l .BPT

A4L2

A4R2

Col l .

Colli

mat

or c

ontr

ol

MKQ

ARF

ACS

A6L4

BTV

D5L

4

BGI

A5R4

-B5R

4D

5R4

BGI

E5R4

BQSV

A6R4

BCT

A7R4

BQS

Wat

er C

oole

d ca

bles

Colli

mat

or c

ontr

ol

TCLP

Coll. &

XRP

BPM

A1R5

BPM

B4R5

TCLP

B4R5

Coll. &

XRP

Wat

er C

oole

d ca

bles

A4L6

TCD

Q

&TC

STC

DQ

IP6

BTV

A4R6

TCD

Q

&TC

STC

DQ

MKD

mai

nten

ance

& a

dd. t

ank

MKD

mai

nten

ance

& a

dd. t

ank

MKD

& M

KB g

ener

ator

s mai

nten

ance

Colli

mat

or c

ontr

ol

Colli

mat

or c

ontr

ol

A7R7

BTV

Colli

mat

or c

ontr

ol

A4L8

TCP

A

TDI

A4R8

TCP

A5R8

BPT

A5R8

MKI

M

KI

I5R8

BTV

A6R8

BTV

Wat

er C

oole

d ca

bles

Cabl

ing

Cam

paig

n

CV a

ctivi

ties

UPS

relo

catio

nR2

Eca

blin

g fo

r cry

oSh

ield

ing

C15R

1

Powering tests

ELQA

Warm Up

ELQA

Leak tests

A22R

1

C30R

1

C33R

1

C23L

2

A29L

2

UPS

Preparation

Flushing

Warm Up

ELQA

ELQA

Leak tests

A23R

2B2

5R2

IC train

Warm up

ELQA

ELQALeak tests

Q7R

3

Q23

R3

Q26

R3

Q27

R3

B32R

3

Preparation

Flushing

Powering tests

ELQA

C17R

4

B31R

4

UPS

UPS

Preparation

Cool-Down

Flushing

Powering tests

ELQA

ELQA

Warm Up

ELQA

Leak tests

Powering tests

ELQA

Warm Up

ELQALeak tests

UPS

UPS

ELQA

ELQA

Preparation

ELQA

Leak tests

UPS

Powering tests

ELQA

Powering tests

ELQA

Warm Up

IC train

PreparationFlushing

Flushing

UPS

Cool-Down

Powering tests

Preparation

Flushing

IC train

ELQA

Leak tests

Powering tests

ELQA

Warm Up


A1R1

BPM

A6R1

Coll.

MKI

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Beam Commissioning

Physics

Com

mis

ioni

ng o

f eq

uipm

ent

Shie

lddi

ng R

R &

UJp

lug

Rel

oc.

shie

ldin

Access

Pre p.

Dis

man

tling

Pipi

ng

Cabl

e Ca

mpa

ign

Cryo

.Pr ep .

Dis

man

tling

Pipi

ng

Opt. Fib.

PCPi

pes

& U

TAW

ater

Coo

led

cabl

es

Com

mis

ioni

ng o

f eq

uipm

ent

Shie

lddi

ng R

R &

UJp

lug

Rel

oc.

shie

ldin

Access

Cabl

e Ca

mpa

ign

Cryo

.

Opt. Fib.

PC

Ethernet

CV :

UTA

& p

ipes

Cryo

geni

csCa

blin

g Ca

mpa

ign


Pipi

ng &

Venti

latio

n W

ater

Co

oled

ca

bles

O.F

. (II

& II

I)

PC

Safe

Ro

om

(II)

Mov

e ra

cks

Acce

ss


Cabling campaign

Civi

l eng

inee

ring

(inc

l. pr

otec

tion

)

Dis

man

OF

Cryo

geni

cs

Acce

ss

Alar

ms

Cabl

eTr

ayM

ove

rack

s

UTA

Ethe

rne

Chic

ane

Vacu

um


CE

Cool-Down

Pipe

s &

UTA

Wat

er C

oole

d ca

bles

UPS

UPS

UPS

UPSUPS

UPS

UPS

UPS

UPS

UPS UPS

UPS

UPS

UPS

UPS

Q5L

8

C15L

3

B30R

7

B21L

8

Cabling Sart

Cabling Start

Cabling Sart

Civi

l eng

inee

ring(

incl

. pro

tecti

on)

Mur

ty

mpa

nSh

ield

ding

RR

53Sh

ield

ding

RR

57

Safe

Roo

m (

I)

Cabl

eTr

ay

Pipi

ngO

.F. (

I))

Div

erse

Wor

ks

Ethe

rnet

Start Cabling

Mov

e ra

cks

0 0

DYPB

DYPB

DYPB

DYPB + MPE EPDYPB + MPE EP

VSC IV

VSC IV

VSC IV

EPC 60A

EPC 60A

EPC 60A

EPC 60A

EPC 60A

EPC 60A

EPC 60A

EPC 60A

ELQA

Powering tests

MPE EP

MPE EP

MPE EP

MPE EP

MPE EP

DYPB

DYPB

UTA

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n


Cabl

ing

Cam

paig

n

Cabl

ing

Cam

paig

n

Cabl

ing

Ca

mpa

ig

Cabl

ing

Cam

paig

n

ODH

ODH

ODHODHODH

ODH

ODH

ODH

Detection Incendie

Detection Incendie Detection IncendieDetecti

on

Detection Incendie

Detection Incendie

Detection IncendieDetection Incendie



Detection Incendie

Detection Incendie

Detection Incendie Detection Incendie

Detection Incendie

ODHODH

ODHODH

ODH

Detection Incendie

Detection

Detection Incendie

Detection Incendie




Detection Incendie

ODH

Detection Incendie

ODHODH

ODH

ODH

DFBX

Cabl

ing

Cam

paig

n

Ca bli

ng

Cabl

ing

Cam

paig

n

AUG Tests AUG Tests

AUG Tests

AUG Tests AUG Tests

AUG Tests

AUG Tests

DSO Tests

REPAIR LEAKS IN QRL 4-5

AUG Tests

ODHDetection Incendie

ODH

Detection Incendie

Detection Incendie

UPS UPS

UPS


CRYO

CRYO

CRYO

CRYO

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA

DFBA D

FBA

DFBA

DFBA

DFBA

DFBA

DFBX

DFBX

DFBX

DFBX

DFBX

DFBX

DFBX

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

QRL service Modules

MPEEE







Voies Evacuation

Christmas

SF-

M

SF-

W

UW-M

SF-M18

SF-

M1

SF-W

UW-M

UW-

W

UW-M

UW-

W

UW-

M

SF-

M

SF-

W

UW-

W

SF-M

SF-

UW

SF-

UW

SF-

UW

SF-

UW

SF-

M

UW-

W

DYPB

DYPB

DYPB

DYPB

DYPB

Cool-Down

Cool-Down

Cool-Down

Cool-Down

Cool-Down

Powering tests

Cool-Down

Christmas

Cool-Down

ELQA

CSCM

CSCM

CSCM

CSCM

CSCM

CSCM

CSCM

S67, June 2014

From M. Bernardini https://espace.cern.ch/en-dep-mef-lpc/LS1/default.aspx22-N

ov-1

2ZC

h, M

PE W

orks

hop

on L

S1


Are the IST activities included to LS1 Planning?Yes, even if they are not shown unlike many other activities. And the IST need to be finished before the Powering Test (some before CSCM)!

Thanks!

https://espace.cern.ch/en-dep-mef-lpc/LS1/default.aspx

1422-N

ov-1

2ZC

h, M

PE W

orks

hop

on L

S1

Appendix

1522-N

ov-1

2ZC

h, M

PE W

orks

hop

on L

S1


Accelerator Test Tracking (as t.b.d.):

IST.EE – Why is it after CC.ElQA?

IST.QPS – What about to divide to IST.QPS.INT and IST.QPS.QHD?

PIC1.xxx -> IST.PIC – As a last step of IST for PIC?

Documents

Re-Commissioning (IST) of Electrical Systems: QPS, EE & PIC