hardware commissioning

Hardware Commissioning

PreparationDocumentationMTFProgramme

StatusThe ReviewThe commissioning activity in 2005-2006Resources

OutlookThe new schedule

Roberto Saban on behalf of the Hardware Commissioning Team

MAC19 060616

Roberto Saban TS MAC 19 060616

The methodin

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After the qualification qualification for operation of the for operation of the individual systemsindividual systems of a sector (vacuum, cryogenics, quench protection, interlocks, powering, etc.),

each sector will be each sector will be commissioned as a commissioned as a wholewhole up to the powering to nominal current of all the circuits.Validation and Validation and specific studiesspecific studies will be carried-out on the first commissioned sector.

What testsWhat tests• the procedures and the sequencethe procedures and the sequence

How How • what conditions are required to startwhat conditions are required to start• what conditions determine it is finishedwhat conditions determine it is finished• what conditions are required during the testswhat conditions are required during the tests

Sytem owners define and carry-outSytem owners define and carry-out

Hardware Commissioning Coordination Hardware Commissioning Coordination ensures that the conditions required existensures that the conditions required exist

What testsWhat tests• the procedures and the sequencethe procedures and the sequence

How How • what conditions are required to startwhat conditions are required to start• what conditions determine it is finishedwhat conditions determine it is finished• what conditions are required during the testswhat conditions are required during the tests

Hardware Commissioning Coordination Hardware Commissioning Coordination with System Owners define and carry-outwith System Owners define and carry-out

and ensures that the conditions required and ensures that the conditions required existexistP

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The logicPre

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subsystems ready

all systems ready for machine check out

individualsystem tests

hardwarecommissioning

two types of documents : as designedas tested

impact on equipment safety impact on equipment/system performance impact on machine performance


Commissioning Procedures & Failure Scenarios

Progress has been made in convincing our colleagues from the equipment groups of the usefulness of the documentation

Documentation describing the Individual System Test and Hardware Commissioning Procedures now exist for most of the systems

Only a few documents describing Failure Scenarios have been prepared

A standard chapter on Safety was introduced in all of them following the guidelines of the Safety Coordinators

These documents are used as a hard reference by those who carry out the tests in the field; these documents are alive: in fact, the have undergone updates following experience when carrying them outP

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SECTOR 7-8Sector

Region Components

Equipment group

Superconducting

Circuits

RQS.A78B2.RR77

Equipment

Arc 78Arc 78

Power Converter

ISTIST

The Manufacturing & Test FolderPre

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EDMS – MTF for Circuit Related Components:

AC Distribution Powering Interlock for warm and cold circuits Quench Protection System Energy ExtractionControl Cooling & Ventilation Cooling Power Cables Electrical Quality Assurance Power Converter Short Circuit Tests DFBs CryogenicsVacuum Access & Safety

EDMS – MTF for Beam Related Components:

Beam Instrumentation Controls + Beam Energy Meter Collimators Kicker System Diluters Beam Interlock System Beam Dumping System Beam Injection SystemRF



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Data already uploaded for Sectors 78, 45 and 81 ! (~1000 slots filled in)


The commissioning programmePre

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tion

Front 1Front 2 Front 1 Front 2

Left Right

6.6 km

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 day to day coordination : the human resourcesPre

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tion

operationsupport to operationdata recordingreporting

Field Control Room or CCC

Sector A1 Engineer1 Technician

1 AB Operator

Sector B1 Engineer1 Technician

Progress TrackingPlanningRe-schedulingMeetingsCrisis ManagementMTFDatabaseAnalysisInformation processingPublications

Project Management

1 Project Leader1 Mr.Circuit & DPL1 Database/Web Expert1 Administrative Assistant

hardware orientedsmall repairmissing detailsaccess/balisage

Field Preparation

LHC Safety Coordinationadvise on safety mattersenforce safety in the field


The review & its recommendationsS

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Some organisational matters were judged worth further attention.

It was noted that Hardware Commissioning will be the first occasion where the safety measures (responsibility, training, access conditions, signalling, etc.) put in place for LHC will be evaluated for the first time. Furthermore, Hardware Commissioning will be a test of the new organisation of Safety at CERN; its impact must be monitored.

A number of issues related to controls & informatics were noted.

Important technical issues related to either the conditions under which the tests are carried-out (e.g. the ventilation of the tunnel during the tests) or the tests themselves were considered; some of them must be reconsidered in the light of the present installation and commissioning scenario.


The commissioning activity in 2005-2006

Three underground powering areas around even points were tested with the power converters connected to the cables (water and air cooled)

Sta

tus

DFBs

fieldcontrolroom

PowerConverters

EnergyExtractionSystems

One smaller underground powering area close to Point 7 is being tested now.


The commissioning activity in 2005-2006S

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The supply air temperature of the HVAC units is regulated at 17.5 ± 1.5 ˚C except ESCL 7,9,10,11 and 12. ESCL1 PID is optimized for hi-speed fan . ESCL7 showed a regulation problem since a manual valve had remained closed. ESCL9 to 12 inefficiency problem.

Data provided by ST-CV


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The temperature at the ducts showed maximum values of 74 ˚C 10h after start up PC. At 03:15 cables 1808470 showed 154 ˚C at their end. Tightening problem solved at 04:30.


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ResourcesS

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The new scheduleO

utl

ook

A piece of cake

The nightmare


The new schedule

It looks it can be done with a few reserves like the activation of the tunnel during this first run, the commissioning of the access safety and access control system, the approval of the as-built access safety and access control system by the INB authorities, the fact that we would start with a machine which is not so well aligned (no smoothing)

Careful tuning of co-activities is needed Some additional resources will be needed in

2007 (man power and hardware) Resources not originally planned for will be

needed in 2008 The program for 2008 must be closely watched

to ensure that the remaining commissioning can really be done in the three months allocatedO

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ook


Conclusions

Preparation “finished” Awareness of safety and equipment

integrity must be continuously stimulated

First experience in the field positive but the real heat is not yet on

The resources were found but must be monitored in the light of the changing scenario

Delicate scheduling of the activities to match the available resources and the requirements of the scheduleH

ard

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hardware commissioning

Documents

inroberto saban tsmac

hour daysroberto saban

beam related components

individual system test

beam instrumentation

access conditions

tests themselve

circuit related components