hwcr, at-acr-in, 12 may 2005 1 cryogenic instrumentation & controls commissioning hardware...
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HWCR, AT-ACR-IN, 12 May 2005 1
Cryogenic Instrumentation & Controls Commissioning
Hardware Commissioning Review
Juan CASAS
HWCR, AT-ACR-IN, 12 May 2005 2
QRL versus LHC
QRL LHC
RIO Specs for UNICOS DONE In Preparation
Controls Specs for UNICOS Under Revision Time Critical
Hardware for Actuators Industrial Type Idem; Commissioned for QRL?
Tunnel Hardware Industrial Type
RadTol:
Critical Procurement Schedule
LSS8L: Internal production
Learning Contingency (50%) Integrated in planning NOT Accepted
Instrumentation Tasks No Repairs, Reporting Only Full Commissioning
Fieldbus Profibus Profibus & WorldFIP
Sectors 8-1 and part of 7-8All Sectors
QRL tasks not included in LHC tasks => extra time…
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QRL & LHC Schedules
QR
L >
18.
5 w
ks
LH
C –
41
wk
s
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QRL Actual ScheduleNote that AL Instrumentation Activity not into ACR-IN tasks
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LHC Pre-requisites
General Services
• UPS
• Tunnel access required during ALL commissioning tasks
• Safe access “paserelle” to tunnel-wall equipment
Controls
• Networks:
– Ethernet
• PLC – Gateway – Data Server communication
• Tunnel WiFi access (Technical & NICE)
– Profibus & WorldFIP
• Optical fiber-Copper couplers
• Gateways
• Hardware (Data server, SCADA, PLCs, Gateways, etc)
• Software for PLCs, Gateways and SCADA
Logistics
• MTF
– non-conformities referenced and retrievable
– Instrument & Host equipment identification (functional and physical) data
• Interpolation data generator
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LHC Resources & Tasks (per sector)
Generic Tools
• Transport Vehicle
• Electrician Tools
• Sensor/actuator simulation devices
• Ladder
• Computer with network access
Generic Tasks
• Track test data on MTF
• Declare & check in MTF for non conformities
•Crate Connection (CIW CC)
Per sector: avg 125 Crates, 10 cables/crate
Crew: 2 Technicians
Tasks:
•Cables Harness
•Crate Positioning
•Electrical connection at both ends
Duration: 10 weeks => 2 crates per working day
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LHC Resources & Tasks (per sector)
RadTol Crate stand-alone commissioning (CIW SU)
Per sector: avg 125 Crates, 10 cables/crate, 1900 channels
Crew: 2 x (1 instrumentation engineer + 1 Technician)
Tasks:
•EMC Cables Test
•Check Pressure sensors and hydraulic connections
•Functional Tests on all channels
•Repair all conforming channels
•Commission front-end electronics
•Check Crate Network Configuration Parameters
Duration: 2 x 9 weeks => 2 crates per working day
WorldFIP Initialization (CIW CE)
Per sector: avg 125 Crates, 2 nodes per crate
Crew: 1 fieldbus engineer + 1 Technician + AB-CO Support
Tasks:
•Connect Crate onto fieldbus network
•Verify Global WorldFIP availabiity
•Check Gateway availability
Duration: 8 weeks => 3 crates per working day
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LHC Resources & Tasks (per sector)
Controls at Warm (CIW CS)
Per sector: 1900 Channels,
Crew: 2 x (1 Control Engineer + 1 Technician)
Tasks:
•Channel Coherence checks SCADA to field:
– Actuators: Intelligent Valves, ON/OFF Valves & Heaters
– Sensors: Pressure, Temperature, Level, Position, etc.
•Synoptic conformance check
•Check that physical readout is coherent with ambient conditions
•Simulate/check logic seuqnces, PIDs, Linearization
Duration: 2 x 16 weeks
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LHC Resources & Tasks (per sector)
Controls during Cool-Down (CIC CT)Per sector: 1900 Channels, Crew: 2 Control Engineer + 1 TechnicianTasks:•Check Sensor evolution•Diagnostics of non conformities left from “Controls @ Warm”•Set appropriate control loop parametersDuration: 10 weeksControls during Nominal (CIC OP)Per sector: 1900 Channels, Crew: 1 Control Engineer + 1 TechnicianTasks:•Diagnostics of non conformities left from “Controls @ Cool-Down”•Set appropriate control loop parametersDuration: 11 weeksSurface Support•Database/Quality Assurance engineer for Thermometer, Parameters (Cabling, configuration, naming, location), sensor calibration (pressure)•Instrumentation Engineer to assess and provide support for field teams
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LHC Resources & Tasks (per sector)
teams/sector Eng Tek UNICOS1. CIW CC Crate Connection 10 1 22. CIW SU Crate Stand Alone Commissioning 10 2 2 23. CIW CE WorldFIP Initialization 8 1 1 14. CIW CS Controls at Warm 16 2 2 2 0.55. CIC CT Controls during Cool-Down 10 1 2 1 0.55. CIC OP Controls during Nominal 11 1 1 1 0.56. CIW SP on call 0.5 2
duration [week]
Professional Profile
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Shortcomings•InfrastructureEthernet connection very cumbersome:
– individual modem VDSL + base WIFI => additional jumping onto equipment– Several teams working in adjacent cells
• Please provide WIFI as a standard infrastructure inside the tunnel during commissioning– Access to BOTH technical and NICE networks
•ControlsReliability of controls:
– Communication Problems hamper operation– PVSS SCADA to be improved– Too many software versions
Profibus: Schneider fieldbus configuration tool is far from user friendly•LogisticsMTF:
– Non-conformities instrument retrieval interface for instrumentation required but non-existent– inner triplet data status?– Naming uniqueness
MTF interface required for tunnel reportingIS MTF ADEQUATE FOR INSTRUMENTATION COMMISSIONING TASKSDatabase/Quality Assurance Support shall be very responsive:
– Close to end-user– For AT-ACR depends on a temporary unit of personnel (fellow)
Automated Test Equipment development:– delayed continuously by on-site (SMI2, AL premises, etc) instrumentation support.
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Shortcomings: MTF data retrieval
This quad does have:
1.Cold-mass t
hermometer
2.Electric
al Heater
3.…
How do I know that NC No 90 refers to
an electrical Heater?
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Shortcomings: MTF data retrieval
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Naming Conventions: How it works
PhysicalEquipment
Serial number
MTFSlot name + Tag name
Serial number
LHC Reference DBSlot name
Serial number
The slot name + tag name used by the Controls/Operation must coincide with the slot name + tag name registered in LHC Reference DB and in MTF.
Project engineerTag name
Controls/Operation
Slot name + Tag name
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• All machine components MUST be registered in MTF
• All instrumentation MUST be assigned to machine assemblies in MTF
Naming Conventions: How is it used? (1)
The tag name (e.g. TT821) MUST be included when the instrumentation is assigned to a machine assembly in MTF
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• The slot names MUST be identical
MQ.28LiMQ.29Li
QRLAA.30Li
MQ.27Li
QRLAB.28Li
MBC...MBA.29Li MBC...MBA.28Li
MQ.28LiMQ.29Li
QRLAA.29Li
MQ.27Li
QRLAB.27Li
MBC...MBA.29Li MBC...MBA.28Li
AT/ACR name (used by Controls/Operation)
Official name (used by MTF)
Naming Conventions: How is it used? (2)
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D4.6R7Q5R7
QRLIA.2R7
Q6R7
QRLEA.6R7
D3.6R7
…
… …
DFBM.6R7
D4.6R7Q5R7
QRLIA.6R7
Q6R7
QRLEA.6R7
D3.6R7
…
… …
DFBM.6R7
Naming Conventions: How is it used? (3)
• The slot names MUST be identical
AT/ACR name (used by Controls/Operation)
Official name (used by MTF)
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Naming Conventions: Summary
QRLAA.30L8QRLAA.29L8
What??? QRLAA.29L8
is not on MTF!!!
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Major Shortcomings•Missing Manpower
Cryogenic commissioning consist of a set of specialized tasks:
– Will there be a good match between professional qualifications & tasks?
– Is training required?
• If YES: additional resources shall be already at CERN
• 3-6 month seem the strict minimum
LHC schedule show activities in up to 3 sectors at the same time
– 1 team (warm commissioning) would then be missing
ACR-IN tasks planning does not foresee support for external teams
– Additional manpower autonomous from day 1; otherwise work can be significantly delayed
Is it possible to consolidate critical know-how/ressources:
• Database/Quality Assurance support relies on temporary personnel
• Additional process control engineers is required
•Various
No contingency allocation!
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