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LHC enhanced Quench Protection System project

LHC enhanced Quench Protection System project. Review committee meeting February 24 th –26 th 2009. Presentation outline. Upgrade motivations Main requirements for the project Previous internal review of new electronics for QPS Project organization Project planning Outsourcing

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LHC enhanced Quench Protection System project

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  1. LHC enhanced Quench Protection System project Review committee meeting February 24th–26th 2009 Fabio Formenti - Feb. 25th, 2009

  2. Presentation outline • Upgrade motivations • Main requirements for the project • Previous internal review of new electronics for QPS • Project organization • Project planning • Outsourcing • Project management: main follow up meetings • Quality assurance: main points • Conclusions Fabio Formenti - Feb. 25th, 2009

  3. Upgrade motivations • Top priorities before next machine startup • improved coverage of quench detection due to: • - Abnormal splice joint resistance • (from Sept. 19th 2008 task force incident analysis) • - Heat, beam loss, …etc…, induced symmetric quench • (decision at Chamonix meeting, Feb. 2nd-6th, to run from day 1 at high energy) • improved fault reliability of 230V UPS system • (decision at Chamonix meeting, Feb. 2nd-6th) • Optional need for later machine startup: • capability to monitor magnet ground voltage variations • (this case is not treated now) Fabio Formenti - Feb. 25th, 2009

  4. Total ~5900 boards Main goals for the project • Avoid changing the present magnet quench protection system • It is proven to perform as expected • Avoid re-commissioning • Add more electronics and infrastructure for bus bar joints and symmetric quench protections: • ~500 DQAMG type S controller boards • ~2500 DQQBS bus detection boards • ~2000 DQQDS symmetric quench detection boards • ~450 DQLPUS power supply units • ~450 Crates with backplanes • ~4400 Cables to dipoles and quadrupoles, total length ~230 km • ~1600 Interlock patch panel • Duplicate UPS power distribution system • ~900 Power packs • ~1600 Distribution patch panels (may be two different types) • ~1600 New power cables to QPS racks • ~1600 QPS racks to update cable layout • ~80 Protection units for the insertion region magnets (triplets) Another ~900 boards Fabio Formenti - Feb. 25th, 2009

  5. Internal review of new electronics for QPS • Held on Jan. 13th • Mainly aimed at production readiness • Report available on INDICO • (http://indico.cern.ch/getFile.py/access?resId=0&materialId=minutes&confId=51077 • Note: it needs NICE login) • Main recommendations concerned: • Management, planning and resources • Radiation Tolerance • Technical issues for electronics • (EMC, cabling, power, electronics reliability, electronics implementation, documentation) • Production and its follow up • Quality assurance • 22 recommendations in total that are being applied according to project progression • => a meeting with referees will be organized for providing status <= Fabio Formenti - Feb. 25th, 2009

  6. Project organization • Project breakdown structure has been defined (started beginning January) • Project leader: Knud Dahlerup-Petersen • Project technical coordinator: Fabio Formenti • 17 upgrade Work Packages • it reflects today’s understanding, however trend seems pointing to a growth • e.g. protection of insertion regions, more routine activities, other new priorities (maybe this review recommendations?) • 10 different responsibles of Work Packages • Go to working document => Fabio Formenti - Feb. 25th, 2009

  7. Project planning (PRELIMINARY ESTIMATE!) • Chosen MS Project as project management tool to implement resource planning (as part of QA) • Detailed dates, milestones and resource assignment (ongoing process) • -> The document is now being revised because of new defined priorities (symm. quench & UPS) • Included: all upgrade WPs and most urgent M&O tasks impacting on resource sharing • Timescale of QPS Electronics Upgrade Project: started Sept. 1st 08 – ending milestone Aug. 31st 09 • Planning based on: 40h/w working time • not included (yet?) other holidays than week-ends and official holidays • contingency cannot simply apply -> rescheduling and adding resources • Go to working document => Fabio Formenti - Feb. 25th, 2009

  8. Outsourcing • Sharing of responsibilities: • specifications, supervision, follow up and commissioning -> MPE group • specific competences -> support from TE, BE, EN, PH and external institutes • production -> industry • Detailed Work Package definition for activities to be outsourced is in final editing • Outsourcing is the only flexibility for this project planning • To be effective, large WPs should be released to well selected competent teams • Go to working document => Fabio Formenti - Feb. 25th, 2009

  9. Project management: follow up meetings • Observation: many meetings and discussions are organized… • … but this also takes time to the ongoing activities • => Carefully attendance to most relevant meetings • and when agenda is highly pertaining <= • Project status report meetings (Siemko) • When: every Friday, since January 1st • Who: MPE management and engineering staff • What: major technical issues, outsourcing coordination, planning & project management status • Technical report meetings (Dahlerup Petersen) • When: every Monday, since 13/02/09 • Who: all MPE-CP section people and collaborators involved in the QPS project • What: detailed technical issues, activity status, incoming week work planning, supplier follow up, component procurement, logistics • Hardware commissioning meeting (Schmidt) • Starting soon (March 19th) Fabio Formenti - Feb. 25th, 2009

  10. Project management: contribution to other meetings • CCC machine re-commissioning meetings • When: every Monday • Who: management, project responsibles, coordinators • What: activity status of magnet repair and new protection system • (basically information meeting) • Shut down planning meeting • When: every Thursday • Who: CERN activity responsibles, external work contractors • What: global upgrade planning coordination • … this is not surely fully exhaustive list … Fabio Formenti - Feb. 25th, 2009

  11. Quality assurance • Not trying to compromise on this issue • Main points being implemented: • Maximum availability of technical documentation (drawings, procedures, testers, s/w, etc.) on public domain (e.g. EDMS, DFS/public) • Thorough prototype verification in house by designers • Radiation tests of all key electronics components • Careful industry selection to conform to international quality standards (ISO9000) • Maximum of system component traceability, use of manufacturing and installation databases • Rigorous pre-production qualification and production acceptance tests with standardized procedures • Full system pre-commissioning in QPS lab and test result database • Installation with trained operators and verification tests by different team • Final commissioning supervised by QPS team engineers Fabio Formenti - Feb. 25th, 2009

  12. Conclusions • Bus bar quench detection • Symmetric quench detection (new priority) Motivate upgrade of QPS system • UPS improved redundancy (new priority) • => Some new 6800 electronics cards to build and commission in tight time schedule <= • => Some 1600 QPS racks to update <= • Work breakdown structure has been defined for all main upgrade activities • => Routine activities, e.g. related to s34 reparation, compete for resource sharing <= • Schedule follow up and resource management have been introduced in planning tool • => It is under revision for complying with new added priorities <= • Outsourcing becomes a necessity and is being implemented • => We are editing tasks to define precise competences <= Fabio Formenti - Feb. 25th, 2009

  13. Extras Example: cable installation test Fabio Formenti - Feb. 25th, 2009

  14. 1. HV test (500V) Fabio Formenti - Feb. 25th, 2009

  15. The automated HV tester system Power taken from QPS crate or tunnel blue power boxes Safe ground connection Fabio Formenti - Feb. 25th, 2009

  16. Analog cables (blue) and interlock cables (white) are only connected to the tester at its near end (the other end is left open) Fabio Formenti - Feb. 25th, 2009

  17. Automatic testing (it takes about 8 minutes) Temperature and humidity shall be verified Testing … … and storing test report Fabio Formenti - Feb. 25th, 2009

  18. 2. Continuity test Fabio Formenti - Feb. 25th, 2009

  19. Coming in front of QPS crate (below B dipole) Identification of right location in cable database Connecting tester to power (taken from QPS crate) Fabio Formenti - Feb. 25th, 2009

  20. Connecting cables to tester First check done with other cable side open (tester lights must be OFF) Analog cables (blue) and interlock cables (white) have to be connected to good tester port following the database Fabio Formenti - Feb. 25th, 2009

  21. Putting diode taps at other ends of cables HV check mark must already be present Fabio Formenti - Feb. 25th, 2009

  22. The two cable ends could be up to a few 100 meters away Fabio Formenti - Feb. 25th, 2009

  23. Testing and labelling Tester lights ON if diode tap is connected to a good cable end Put barcode labels at two cable ends and annotate cable database Fabio Formenti - Feb. 25th, 2009

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