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Cryogenic Instrumentation & Controls Commissioning

Cryogenic Instrumentation & Controls Commissioning. Hardware Commissioning Review Juan CASAS. QRL versus LHC. QRL & LHC Schedules. QRL > 18.5 wks. LHC – 41 wks. QRL Actual Schedule. Note that AL Instrumentation Activity not into ACR-IN tasks. LHC Pre-requisites. General Services UPS

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Cryogenic Instrumentation & Controls Commissioning

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  1. Cryogenic Instrumentation & Controls Commissioning Hardware Commissioning Review Juan CASAS HWCR, AT-ACR-IN, 12 May 2005

  2. QRL versus LHC HWCR, AT-ACR-IN, 12 May 2005

  3. QRL & LHC Schedules QRL > 18.5 wks LHC – 41 wks HWCR, AT-ACR-IN, 12 May 2005

  4. QRL Actual Schedule Note that AL Instrumentation Activity not into ACR-IN tasks HWCR, AT-ACR-IN, 12 May 2005

  5. 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 HWCR, AT-ACR-IN, 12 May 2005

  6. 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 HWCR, AT-ACR-IN, 12 May 2005

  7. 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 HWCR, AT-ACR-IN, 12 May 2005

  8. 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 HWCR, AT-ACR-IN, 12 May 2005

  9. LHC Resources & Tasks (per sector) Controls during Cool-Down (CIC CT) Per sector: 1900 Channels, Crew: 2 Control Engineer + 1 Technician Tasks: • Check Sensor evolution • Diagnostics of non conformities left from “Controls @ Warm” • Set appropriate control loop parameters Duration: 10 weeks Controls during Nominal (CIC OP) Per sector: 1900 Channels, Crew: 1 Control Engineer + 1 Technician Tasks: • Diagnostics of non conformities left from “Controls @ Cool-Down” • Set appropriate control loop parameters Duration: 11 weeks Surface 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 HWCR, AT-ACR-IN, 12 May 2005

  10. LHC Resources & Tasks (per sector) HWCR, AT-ACR-IN, 12 May 2005

  11. Shortcomings • Infrastructure Ethernet 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 • Controls Reliability 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 • Logistics MTF: • Non-conformities instrument retrieval interface for instrumentation required but non-existent • inner triplet data status? • Naming uniqueness MTF interface required for tunnel reporting IS MTF ADEQUATE FOR INSTRUMENTATION COMMISSIONING TASKS Database/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. HWCR, AT-ACR-IN, 12 May 2005

  12. Shortcomings: MTF data retrieval • This quad does have: • Cold-mass thermometer • Electrical Heater • … • How do I know that NC No 90 refers to an electrical Heater? HWCR, AT-ACR-IN, 12 May 2005

  13. Shortcomings: MTF data retrieval HWCR, AT-ACR-IN, 12 May 2005

  14. Naming Conventions: How it works LHC Reference DB Slot name Controls/Operation Slot name + Tag name PhysicalEquipment Serial number MTF Slot name + Tag name Serial number Serial number Project engineer Tag name 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. HWCR, AT-ACR-IN, 12 May 2005

  15. Naming Conventions: How is it used? (1) • All machine components MUST be registered in MTF • All instrumentation MUST be assigned to machine assemblies in MTF The tag name (e.g. TT821) MUST be included when the instrumentation is assigned to a machine assembly in MTF HWCR, AT-ACR-IN, 12 May 2005

  16. QRLAA.30Li QRLAA.29Li QRLAB.28Li QRLAB.27Li MBC...MBA.29Li MBC...MBA.29Li MQ.28Li MQ.28Li MBC...MBA.28Li MBC...MBA.28Li MQ.29Li MQ.29Li MQ.27Li MQ.27Li Naming Conventions: How is it used? (2) • The slot names MUST be identical AT/ACR name (used by Controls/Operation) Official name (used by MTF) HWCR, AT-ACR-IN, 12 May 2005

  17. … … QRLIA.2R7 QRLIA.6R7 QRLEA.6R7 QRLEA.6R7 Q5R7 Q5R7 … … … … D3.6R7 D3.6R7 D4.6R7 D4.6R7 Q6R7 Q6R7 DFBM.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) HWCR, AT-ACR-IN, 12 May 2005

  18. Naming Conventions: Summary What??? QRLAA.29L8 is not on MTF!!! QRLAA.29L8 QRLAA.30L8 HWCR, AT-ACR-IN, 12 May 2005

  19. 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! HWCR, AT-ACR-IN, 12 May 2005

  20. HWCR, AT-ACR-IN, 12 May 2005

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