ls1 cabling progress ls1 committee (lsc) – 21 june 2013
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EDMS 1293605. LS1 Cabling Progress LS1 Committee (LSC) – 21 June 2013. Daniel RICCI on behalf of the Cabling and Optical Fibre Section (EN-EL-CF). Outline. The LS1 challenge for cabling Monitoring of cabling activities & current performance Facing the challenges: where do we stand? - PowerPoint PPT PresentationTRANSCRIPT
LS1 Cabling Progress
LS1 Committee (LSC) – 21 June 2013
Daniel RICCI on behalf of the Cabling and Optical Fibre Section (EN-EL-CF)
EDMS 1293605
D. RICCI – CERN, LSC meeting – EDMS 1293605
Outline
The LS1 challenge for cabling Monitoring of cabling activities & current
performance Facing the challenges: where do we stand? Conclusions
21/6/13
Cabling = copper (ctrl & DC) cables AND optical fibres
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D. RICCI – CERN, LSC meeting – EDMS 1293605
The LS1 challenge:the important numbers
37 main projects to carry on + day-by-day installation works(Some examples: R2E, LHC cabling campaigns, WCC hose consolidation, SPS campaigns & irradiated cables TS1+, new SPS fibre infrastructure (BI & others), PSS, LINAC4 & Meyrin campaigns, Computer Centre extension B513, LHC-Experiments fibre upgrade)
Overall estimated budget ~12 MCHF
~1000 km of copper and optical cables being installed during LS1
21/6/13
Moreover, activities also include Managing CERN-wide optical fibre infrastructure
(3,000 km installed optical cables) Qualification, procurement and standardisation of
cabling and optical fibre components (3.5 MCHF/year) Managing cable park (4200 drums) and cable tray
infrastructure (350 km) Monitor cable aging and put in action the
replacement campaigns (~1MCHF/machine point)
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LS1 challenge:planning and resources
Very « dense » planning Must cope with machine constraints/priorities Delay on one activity can provoke « domino »
effect
~35 people in CF plus ~100 contractor people
Challenging supervision, training and knowledge transfer of new working method
21/6/13
Example CF planning (LHC only)
New
cablin
gR
2E
Conso
lid.
LS1
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D. RICCI – CERN, LSC meeting – EDMS 1293605
The cabling strategy(in a snapshot)
see LSC presentation 15/3/2013
21/6/13
Campaign Booster
Campaign SPS-BA1
Campaign LHC-Point1
PROJ 1 Various works TE/ABT
PROJ 2 LIU
PROJ n Various works BE/BI
3) Optimize work organisation and resource distribution by working by geographical
campaigns 5) Project progress and schedule monitoring
1) Enhanced section structure
Simulation
2) Anticipate qualification and procurement of material
4) Boost training & project preparation with contractors
+ fibres…
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D. RICCI – CERN, LSC meeting – EDMS 1293605
LS1 progress monitoring
Method developed in agreement with the management request to be able to follow activity progress in ‘real-time’
Objectives Help Project Managers to manage parallel projects and workload Warn timely on activity delay or anticipation Prevent resource bottlenecks Be able to provide detailed status reporting (e.g. for each geographical
campaign) Be a test-bench for LS2
Costs Dedicated FTEs to implement/following (1.5 FTEs for 2013) Enforce new work style with contractors More commitment (mainly time) requested from the Project Managers
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Monitoring method
Challenge: CF field-activities are composite and of different nature, depending on the project Project preparation, ordering of material, documentation and other administrative
activities done by CF are not included
21/6/13
Cabling campaign (core)
Cable pulling (60%)Connectors
(30%)Test
(10%)
ReworksDe-
cabling
Mechanicscable
trays/racks
variablevariable variablevariable
Example of field-activities for copper cables
Cabling campaign (core)
Cable pulling (60%)Connectors
(30%)Test
(10%)
ReworksDe-cabling Reworks
Cabling campaign (core)
Cable pulling (50%) Connectors (40%)Test
(10%)
De-cabling
Mechanicscable trays/racks
timet1 t2 t3
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Monitoring method
Heterogeneous monitoring tools apply Quick implementation to be ready at the beginning of LS1 campaigns
21/6/13
Cabling campaign (core)
Cable pulling (60%)Connectors
(30%)Test
(10%)
ReworksDe-
cabling (variable)
Mechanicscable
trays/racks(variable)
Weekly check from each concerned Project Managers Very important to get as accurate feedback as possible
Weekly feedback from Contractors Filling follow-up sheets (for detailed cross checking) Drawback: contractors claiming this is not included in the contract
and produce more work
Cable database (Cablothèque) Filling data is part of the contractor’s obligations Sotware data extraction (EDMS 1245912)
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Monitoring: forecast
Forecast curve is extracted from scheduled activities (MS-project planning) Detailed summary of all activities of CF section Updated weekly
21/6/13
2013:Janvier
FevrierMarsAvril
MayJuin
Juillet
Aout
Septembre
Octobre
Novembre
Decembre
2014:Janvier
FevrierMarsAvril
MayJuin
Juillet
2014:Aout
0.0
20.0
40.0
60.0
80.0
100.0
Cabling and Optical Fibre Forecast curve
%Forecast
50% LS1
Beginning of LS1
End of LS1
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Monitoring: forecast
Simple rules Each activity
Starting date 0% Ending date 100% Linear interpolation
Activity plans weekly updated with the exception of the
campaign already started
21/6/13
Task Name Start Finish w10 w11 w12 w13 w14 w15 w16 w17 w18 w19 w20 w21 w22 w23 w24 w25 w26 w27 w28 w29 w30 w31
BA5 27/3/13 1/7/13 4 10 17 24 31 38 45 52 59 66 72 79 86 93 100 100 100 100 100
BA4 27/5/13 6/8/13 9 18 27 36 45 55 64 73 82 91
CNGS 15/7/13 24/7/13 50 100 100
BA3 27/3/13 9/7/13 3 9 16 22 29 35 42 48 55 61 68 74 80 87 93 100 100 100 100
BA1 29/4/13 7/10/13 4 8 13 17 21 25 29 33 38 42 46 50 54 58
Mars Avril May Juin Juillet
Mars Avril May Juin Juillet0
20
40Cabling Forecast curve - SPS
%Forec...
BA5
BA4
CNGS
BA3
BA1
020406080
100
Campaign Status - SPS
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Monitoring: forecast
21/6/13
Task Name Start Finish w10 w11 w12 w13 w14 w15 w16 w17 w18 w19 w20 w21 w22 w23 w24 w25 w26 w27 w28 w29 w30 w31
BA5 27/3/13 1/7/13 4 10 17 24 31 38 45 52 59 66 72 79 86 93 100 100 100 100 100
BA4 27/5/13 6/8/13 9 18 27 36 45 55 64 73 82 91
CNGS 15/7/13 24/7/13 50 100 100
BA3 27/3/13 9/7/13 3 9 16 22 29 35 42 48 55 61 68 74 80 87 93 100 100 100 100
BA1 29/4/13 7/10/13 4 8 13 17 21 25 29 33 38 42 46 50 54 58
Mars Avril May Juin Juillet
Mars Avril May Juin Juillet0
20
40Cabling Forecast curve - SPS
%Forec...
BA5
BA4
CNGS
BA3
BA1
020406080
100
Campaign Status - SPS
Simple rules Each activity
Starting date 0% Ending date 100% Linear interpolation
Activity plans weekly updated with the exception of the
campaign already started
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Monitoring: progress Progress curve is extracted from heterogeneous monitoring tools
Very large stream of information to process
21/6/13Cabling campaign (core)
Cable pulling (60%) Connectors (30%)Test
(10%)
ReworksDe-cablingMechanics
cable trays/racks
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase N
Input from
contractors
Computed % of completion
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Monitoring plots
21/6/13
CABL. C
AMP.
BA5
(Eq
1)
CABL. C
AMP.
BA4
(Eq
1)
CABL. C
AMP.
CNG
S (E
q 1)
CABL. C
AMP.
BA6
(Eq
1)
CABL. C
AMP.
TI8
(Eq
1)
CABL. C
AMP.
BA3
(Eq
2)
CABL. C
AMP.
BA2
(Eq
2)
CABL. C
AMP.
e BA7
(Eq
2)
CABL. C
AMP.
TI2
(Eq
2)
CABL. C
AMP.
BA1
(Eq
3)
REPL. C
ABL. IR
R. TS1
+
NEW C
ABL. T
S1+ (E
q 3)
CONNEC
TIQUE:
RAL
P2 (E
q 4)
CONNEC
TIQUE:
RAL
P1 (E
q 4)
CONS.
DC C
ABL. S
PS T
DC20
20406080
100
Control & DC Cabling Campaign Status - SPS/Prevessin
Updated: week 21/2013
Actual Forecast Completed
FIB. O
PT. S
PS B
A5: p
uit
FIB. O
PT. S
PS B
A5: T
S5+
FIB. O
PT. S
PS B
A5: T
S5-
FIB. O
PT. S
PS B
A6: p
uit
FIB. O
PT. S
PS B
A6: T
S6+
FIB. O
PT. S
PS B
A6: T
S6-
FIB. O
PT. S
PS B
A1 (p
uit)
FIB. O
PT. S
PS B
A1: T
S1+(tu
nnel
)
FIB. O
PT. S
PS B
A3: p
uit
FIB. O
PT. S
PS B
A4: p
uit
SP
S PO
WER
CABLE
CONS.
CCC u
pgra
de -
BE91
0
20
40
60
80
100
Optical Fibre Project Status - SPS/PrevessinUpdated: week 21/2013
Actual Forecast Completed
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Monitoring plots
21/6/13
2013
:Jan.
..Mar
sMay
Decem
bre
Fevr
ier
Juill
et0.0
20.0
40.0
60.0
80.0
100.0
Control & DC Cabling Progress Curve - SPS/Prevessin
Updated: week 21/2013
%Forecast
%Actual
Pro
gre
ss (
actu
al vs f
ore
cast)
2013
:Jan.
..Mar
sMay
Decem
bre
Fevr
ier
Juill
et0.0
20.0
40.0
60.0
80.0
100.0
Optical Fibre Progress Curve - SPS/Prevessin
Updated: week 21/2013
%Forecast
%Actual
Pro
gre
ss (
actu
al vs f
ore
cast)
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Monitoring plots
21/6/13
2013
:Janv
ier
Mars
May
Decem
bre
Fevr
ier
Juill
et0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Cabling and Optical Fibre Overall Progress curve
Updated: week 21/2013
%Forecast
%Actual
Pro
gre
ss (
actu
al vs f
ore
cast)
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Current performance
Dashboard: http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/
21/6/13
2013:Janvier
Fevrie
rMars
AvrilMay
JuinJu
illet
Aout
Septembre
Octobre
Novembre
Decembre
2014:Janvier
Fevrie
rMars
AvrilMay
JuinJu
illet
2014:Aout0
10
20
30
40
50
60
70
80
90
100
Cabling and Optical Fibre Overall Progress curve (updated 13/6/2013)
%Baseline (Feb2013)
%Forecast
%Actual
Prog
ress
[%]
0102030405060708090
100
Control & DC Cabling Overall Progress curve (updated 13/6/2013)
%Baseline (Feb2013)%Forecast%Actual
Prog
ress
[%]
2013:Janvie
rMars May
Decembre
Fevri
erJuille
t0
102030405060708090
100
Optical Fibre Overall Progress curve(updated 13/6/2013)
%Baseline (Feb2013)%Forecast%ActualPr
ogre
ss [%
]
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Monitoring method improvement
Development of a new monitoring procedure based directly on GESMAR All the information concerning the progress of the work is directly filled by
contractors Data extraction from GESMAR + elaboration/plotting by CF (to be included in
GESMAR in the future) First software implementation released to be taken over now by our
contractors
21/6/13
Cabling campaign (core)
Cable pulling (60%)Connectors
(30%)Test
(10%)
ReworksDe-
cabling (variable)
Mechanicscable
trays/racks(variable)
Integration into GESMAR
Cablothèque (module of GESMAR)
Many thanks to Serge
Oliger! (EN-EL-CD)
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Facing the challenges: where do
we stand? The technical challenges
CF working method is solid concerning cabling installations Procurement of material: process well known, largely anticipated not
particular issues so far. Recrudescence of thefts is worrisome. Consider securing more the sites!
Preparation/execution of projects and cabling campaigns is optimised However, still very dependent on users timely feedback on final cabling requests!
Contract orders are issued timely and budget is in line with expectations Coping with more resource needs than initially foreseen for safety
and administrative tasks Procurement and logistics for RP-related material (personal protection
equipment, baskets, waste bags/bins, etc.) Thousands of pieces Find budget (~500 kCHF), manage purchases, deliveries, storage places,
consumption levels, etc. ALARA preparation and follow up
Lot of preparation: multiple iterations required with RP+contractors to achieve acceptable analysis
Workload on RSSOs is much more than estimated
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Facing the challenges: where do
we stand? The additional staff
As foreseen, the section management/coordination levels are extremely loaded (even overloaded) Huge efforts to transfer the know-how to the newcomers Huge efforts to train the project managers (aim is “autonomy”) Workload for support functions is demanding taking into account the available
manpower and skills support priority being given to installation activities (e.g. planning, QA, access & safety)
Little and time-limited contingency to recover from (unforeseen) resource loss
21/6/13
Support Function Unit with Support Manager
Structure by project cells
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Many thanks to
Fabio Formenti!
(TE-HDO)
D. RICCI – CERN, LSC meeting – EDMS 1293605
JanvierMars
May
Decembre
Fevrier
Juillet
0
20
40
60
80
100
120
140Contractor Load Curve (updated 27/5/2013)
Total CF
Cont
ract
ors
staff
[peo
ple]
Challenge for contractors Four installation contracts currently operational:
C209 (electrical), C210 (electrical), C202 (fibres), B1213 (WCC) Contractors are increasing their staff. However, they need to:
be able to constantly find qualified personnel and to train them cope with CERN planning (peaks and valleys) cope with radiation rules: no temporary contracts + replace/rotate
the personnel achieving the max. allowed dose in radiation areas
Facing the challenges: where do
we stand?
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Challenge from contractors One of the main electrical contractor is still
struggling with their internal organisation and expertise level of their personnel CERN has limited control on this (“delit de marchandage”
always behind the corner!) CF is currently working on contingency actions
Increasing at maximum the work supervision Organizing more connector trainings/tests for the
contractors Working on a plan of actions in case of one contractor
resigns (this will not be cost free…) Strongly limited in “contract managers”
Even more overload on section coordination!
Facing the challenges: where do
we stand?
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Facing the challenges: where do
we stand? Planning challenge
Going well so far. Thanks also to joint effort with planning coordinators Managed so far to have certain “agility” to smooth the curve peaks Keep high level of attention to avoid “domino” effects
Attention on how to cope with new (unforeseen) projects Last contingency slot in April 2014 was already filled by R2E-cryo In case of more new projects, set new activity list with priorities!
21/6/13
Many thanks to
Katy Foraz’s team!
0
5
10
15
20
25
30
35 Example of contractor load curve (PS/Meyrin)
05/03/2013
27/05/2013
Cont
ract
or s
taff
[peo
ple]
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An eye on the field
21/6/13
Flexwell (coax) cables
in LHC P4
Replacement of WCC
hoses in LHC P8-left
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An eye on the field
21/6/13
CTRL cabling in the PSB
Optical fibre cabling SPS &
LHC
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Conclusion 27 CF worksites currently ongoing CERN-wide with 4 main installation contractors
A tool for monitoring the LS1 progress for CF is working and available online now developing a new version fully integrated in GESMAR
The working method is proved and work organisation is optimised around geographical campaigns. The forecast schedule is being kept so far
requires a lot of efforts and commitment from CF people!
Main challenges are: the overload of the section work-coordinators, the risks associated to the quality and (especially) the stability of the contractors
cabling activities are under control but still very sensitive to work plan perturbations
It is important to build-up contingency reserve (to cope with unforeseen circumstances) when activities are performed better than in the plan
attention to the new coming projects! Prioritize and schedule wisely…
The success of the LS1 cabling project is a real team effort! Many thanks to all the CF colleagues which are making possible a smooth LS1!
21/6/13…and thanks for everyone’s support!
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