LSC - 28 February 2014 - M. Pezzetti – Cryogenics 1

R2E mitigation for LHC cold compressor equipment progress.

28 February 2014

M. Pezzetti

EDMS Id: 1346282 v.1

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R2E LHC cold compressors

• Project Overview• Actual status• Next Steps

A special THANKS to all the people concerned:ICL, R2E, RWG, EN/STI, EN/EL, EN/CV, TE/CRG…..

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Last 09 April 2013 TE/TM meeting :

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QURC R2E project overview:

P4 high priority, to be done during LS1.

• ICL positioning validation• P4 equipment inventory, very short time! (https://edms.cern.ch/comment/1323557)

• ECR (edms1346280) driven by cryogenic but all group involved

• R2E/P4 Planning (w.r.t LS1 planning)• EN/EL (DIC : 350 cables)• Special cable magnet bearing assembly (https://edms.cern.ch/comment/1342848)

• Magnet Bearing electronics MBC170(prototype validated, ordered, production delivery March 2014)

• RadWG (new w.r.t TETM of april’13) valve positioner & I/O cards (https://edms.cern.ch/document/1340848/1)

(ordered, in production delivery beginning April 2014)• Cryo RF relocation (development, construction & installation May/June)

AMB special cable FINAL length = 45 meters

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Cryo cabinet relocation (Cable length 45m)[UX45 – level 2] QURC [8 cabinet QURC (AMB, Drive, local PLC & 45 SIPART positioner ][US45 - level 1] QUI [1 cabinet (PROFIBUS & 20 SIPART positioner)][UX45 – level 1] QURC a-b [2 cabinet (PLC, PROFIBUS)][UX45 – level 0] Cryo RF [4 cabinet (PROFIBUS & 20 SIPART positioner)]

TOTAL 15 cabinets to be redesign and relocated in UL44/46.

R2E P4 relocation to be done in LS1

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2013 2014

Preparation (cables & cabinets)

ECR document, Integration activities

EN/EL QURC QUI RF

01 02 03 04 05 06

S34 CoolDown

07

S45 CoolDown

08 09

CRYO maintenance CRYO OP Re-commissioning

New MECOS AMB@P4AMB final validation20K Stand alone50-60% torque

R2E/P4 work PLANNING

Intense co-activities period!!!

Main tasks to be done:• Preparation (cables & cabinets) until end of February• EN/EL cabling campaign 01 March – 30 June• Installation new magnetic bearing electronic mid-April final validation in May/June

R2E project Schedule for LS1 7

EN Point 4

Maria Barberan courtesy

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Project organization (main tasks)Project coordination

M. Pezzetti (TE-CRG)Dep.: B. Ivens (TE-CRG)

R2E Project and coordination / planning

M. Brugger (EN/STI) / AL Perrot (EN-MEF)

LS1 scheduling

M. Barberan Marin (EN-MEF)

Technical coordinator

B. Ivens (TE-CRG)

EN/EL cabling

JC. Guillame (EN-EL)

Cabinet Design & Construction

B. Ivens (TE-CRG)

AMB Technical contact

M. Pezzetti (TE-CRG)

Cryo Operation

L. Herblin (TE-CRG)

Electronics experts

J. Casas (TE-CRG) / F.Formenti (TE)

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Main personnel resources

Electrical work TE-CRG-CE: 1 staff (B. Ivens) + 4 FSU

EN-EL CABLING: CEGELEC + 1 staff / 1 FSU

Magnetic bearing elect.: being defined, estimated 1 engineer + 1 technician.

Approx. 10 persons involved for the main tasks (during 3-4 months).

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R2E P4 budget status (budget code 99547)

TE/CRG cabling manufacturing 75 kCHF (old figures 50 kCHF) new!

New AMB MECOS electronics (R&D + prod.)

150 kCHF (30 kCHF 2013 / 120 kCHF 2014)

EN/EL cabling 250 kCHF, 2014 budget (to be validated by EN/EL) new!

new SIPART 250 (Ph1 cabling (20 kCHF 2014)- Ph2 installation (230 kCHF 2015 or later) new!

AMB Commissioning 20 kCHF/ 2014 budget new!

RF + Others 100 kCHF (HW + FSU manpower) new!

TOTAL ~800 kCHF

To be compared R2E/P8 budget was 700 KCHF (without RF relocation).

S. Claudet courtesy

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QURC R2E project overview:

P8 low priority, LS2. stand by, Ph1 : ICL (already done!) and EN/EL DIC identification w.r.t technical solution as equal to P4. Cold compressor Special cables (already bought!) 75 kCHF.R2E condition don’t change until LS2.

P6 low-low priority, LS2. Stand by, preparation activities for Ph1 will start this years with ICL, P6 equipment inventory and DIC identification.R2E condition measurement in 2015/2016.

P6 no R2E mitigation need.

US85 level 0

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ConclusionNo show stopper identified.

Integration P4-P8 approved, P4 equipment inventory done, ECR release (February), planning agreed with LS1 coordination, new magnetic bearing electronic prototype validated, special cables ready (10 March MECOS validation at CERN).

P4 DIC (Demande Installation Cables) approved/scheduled by EN/EL.

Next steps Cabling & installation (from March 2014 to end of June, no margin).Special cable fragile Close supervision during cabling campaign.

Tight timeline & intense co-activities between cabling, cryo technical and maintenance.

-> need a close technical supervision/coordination follow-up.

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AMB key points

EMCCabling

Connectors

External & Redundant

48 VDCPower Supply

AMB Advance

technology(~10 years)

Special cables Technology @

CERN

Diagnostic knowledge improved

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P4 Relocation UL positions

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R2E – QURC UX452

• Relocation QURC-EMC1/4 (VFD & AMB electronics)• SIPART positionners -> splitting positionner

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R2E – QURC UX451

QURCA/B-EM01• CPU deja dans UL44 QUPC armoire (CB 2011-12)• Cartes E/S schneider a extraire (blocks phoenix reste dans EM01) et creer une nouvelle armoire QURCA/B-EM02• PLC securite CCS a extraire et mettre dans la meme nouvelle armoire

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R2E – QUICA UX450

QUICA-EM01• CPU deja dans UL44 QUPC armoire (CB 2011-12)• Cartes E/S schneider a extraire (blocks phoenix reste dans EM01) et creer une nouvelle

armoire QUICA-EM02• Link/couplers a extraire et mettre dans la meme nouvelle armoire• SIPART positionneurs des vannes -> positionneurs deportee (tirroirs)

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R2E – QYC03/4 UX45½

• Deplacer les tirroirs, les platines et les alims labo (chauffages)• deplace de 2 racks actuelle vers 4 racks pour avoir plus de place disponible• Les equipements sont mellange on va les spliter dans 2 distinct ensembles, gauche et

droite.

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Diagnostic Unit Project Overview

Internal Failures External-Internal/External

Failures

Power Amplifiers Failure Rotor deformation/bent rotor

Position Sensors Failure Rotor rub

Actuators Failure Rotor Impact

Controller

Failure

Loss of I/O board channel Rotor contact

Computer hardware failure Rotor mass loss

Computer software error

Tab.1

Component Faults

Power Amplifiers

power supply fault

input signal faults

bridge faults

Sensors

loose wire connection

power supply fault

Calibration fault

Sensor malfunctions

Actuators

Intermittent contact

Insulation deterioration

Power supply faults

Controller

Intermittent contact

Dielectric breakdown in capacitors

Dielectric breakdown in transistors

Connections insulation deterioration

External Faults

Motion of system base

Cracked rotor

Misalignment

Dynamic rotor loading

First STEP:Fault Detector Design and Implementation

Fault Models

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P4 SEU Mitigation for valve positionner Controller

Cross Section estimation

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Cryo. equipment to be relocated

Current location/name

Future location/name

Remark(s) DIC/#cables/installation order

Cryo RF cavities UX45 level 0QYC03-04

UL44/46QYC01-02

Full relocation NOK/52priority: 4

QURC

cold compressors

UX45 level 2QURCA-EMC01-04QURCB-EMC01-04

UL44/46QURCA-EMC01-04QURCB-EMC01-04

Full relocation QURCA:OK/93Priority: 2QURCB:OK/93Priority: 3

cold box 1.8 K UX45 level 1QURCA-EM01QURCB-EM01

UL44/46QURCA-EM02QURCB-EM02

Part of eqpt to be relocated (DP/PA link coupler, power controllers for electrical heaters)

valves positioners SIPART

UL44QURC-QUI EM03

Included in QURC/QUI DIC

QUI (cryo. Distrib. Box 4.5 K)

UX45 level 0QUICA-EM01valves positioners

UL44QUICA EM02QURC-QUI EM03

Part of eqpt to be relocated (profibus link, coupler and I/O schneider card)

OK/76Priority: 1

3