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EPC Equipment Commissioning and Hardware Testing Master Schedule and Safety Planning Guidelines

This comprehensive guide details the schedule, organization, and procedures for EPC equipment commissioning, IST, and hardware testing, emphasizing safety scenarios and best practices. It covers sectorization, IST/HWC periods, EPC needs, and requests, providing a detailed roadmap for efficient project completion.

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EPC Equipment Commissioning and Hardware Testing Master Schedule and Safety Planning Guidelines

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  1. EPC converters in SPS complex ISTs and Hardware commissioning • Master schedule • Organisation, definition & application on converter • EPC equipment (up to medium power & Main converters) • Sectorisation • IST/HWC periods (for EPC projects) • EPC needs & requests • Follow up form • Safety Scenario #1 (no current before HWC) L. De Oliveira 15th Sept. 2019

  2. Actualschedulefor SPS complex: 21th Sept. 2020 10th august 2020 16th November 2020 18th Sept. 2020 IST period Hardware commissioning DSO tests (8 weeks) (6 weeks) Master schedule

  3. Organisation, definition & application on converter • EPC context • Master + EPC work lockouts • If necessary AC lockouts move to DC • Converter installation/modification • Electronic tests on EPC equipment • (Control, intlk tests)  Imag=0A • 18kV consolidation pre-tests • (EN-EL hand over to EPC) • Long Shutdown: (Manage by EN-ACE) • Machine in access and partially not powered • Coordination of activities through facility coordinators • Individual system tests • Dry runs Machine OPEN Machine OPEN + ACE access control • IST : (Manage by EN-ACE) • Need to be carried out before dry runs and hardware commissioning tests • Not executed in operational environment, not relying on operational tools nor (necessarily) scenario • Defined by equipment experts (example: conditioning of kickers) •  Currentsent to load IF & only IF • Following the Building planning • Balisage on load (single magnet) • Sectorization (multiple magnets) • If not fulfill conditions  Tests during HWC •  NO current on load • Following the Building planning • Balisage on load (single magnet) • Sectorization (multiple magnets) • I ≠ 0A  Tests during HWC • HWC :(Manage by BE-OP) • Machine closed • Individual system tests (on particular system) • Final qualification of all equipment and controls for beam according to operational scenarios and with operational tools Machine CLOSED •  Currentsent to load IF • Following the OP planning • Tests indicated (surface & underground) •  Currenton load • Following the OP planning • Power tests indicated (surface & underground)

  4. IST / HWC for EPC equipment:  Standard process • Converter inspected by HSE (Electrical) and ready to be powered • Power Converter connected to the AC network and the responsibility transferred to EPC • Power Converter connected to the Water Circuit • Control infrastructure validated • EIS out-of-chain and interface validated • Power converter water interlock operational • [WIC] <=> [power converter] interface comissionning • Insulation tests on the DC magnets + cables • Connection to Magnet • Current loop tuning (10 % I.nom) • Polarity check (circuit and magnet) • Current loop tuning at I.max • Heat run at I.mag • [BIS Interlock / External conditions] <=> [power converter] interface comissionning. Start point for IST period Service IST period (Load disconnected) Start point for HWC • Possible during IST period if: • Balisage on magnet • Isolated test sector Powering test HWC period Hardware commissioning With Power Important to consider for EPC: OPTIMIZATION with EPC follow-up form • Commissioning OR restart tests • Range of power converter ( load distribution around the machine) • Check if particularsectorcanbefullyisolated for powering test (TT20/TT40/…) • Balisage in the machine ! (EPC on surface and MSC in underground) • Ensureavailibilityof different services (AC + cooling + WIC + etc…) to maximum anticipatedISTs! • Implement in the planning the different possible slots (in function on constraints, buildings, lines, …)

  5. To consider for IST: • HSE agreement = Start point for IST • No current on machine (move lockout to DC) • No co-activities around converter locations • Plan HSE inspection • Availibilityof different services (AC + cooling + WIC + etc…) • Plan Hand-over tasks (with EN-EL) • Plan EPC preliminary tests (up to Uloop) • Plan Functional tests with ICS (converters interlocked on new EIS-PPS) • Avoid sectorization / balisage tasks SAFETY PLANNING To consider for powering tests (HWC): • Connection to magnet = Start point for HWC • DSO test validated • Dedicated for powering tests = CURRENT on machine • Possibility to control converters at same time (independently of location) • Optimize test sequences (EPC follow-up form to reduce impact of powering tests)

  6. Lock-Out Requests during IST • Proposition to move Separation from the ERD… to the DC outputs (when possible) • Energisation to Magnet impossible through converters • Lock-out for other sctivities& “MiseHors Tension machine SPS” still valid DC DC DC Magnet Magnet Magnet

  7. Commissioningfollow-up form: x1 BA indicated per column x1 per project = Exemple withMACAO Eachtaskseparated in the time Control all converters at the same time https://edms.cern.ch/document/2254611/1

  8. Summary for MACAOs: (x10 buildings) DSO tests 18 to 21th Sept. 2020 10th august 2020 16th November 2020 LS2 IST HWC (6 weeks) (8 weeks) Lockouts move to DC cables Imag= 0 Imag≠ 0 • Test periods for TI2 / TI8: • Is it possible to insert in the Master schedule? • Advance HWC only for these injection lines, for debug phase • (critical projects in term of time: MACAOs; Type 7) • Durations? Keep standart IST period SAFETY guaranted No sectorisation tasks

  9. Thanks for your attention…. Any questions ???

  10. EPC equipment (low/medium power) in SPS complex:** Mains SMD/SMQ not considered ** NEW Already in operation NEW NEW • Other EPC consolidation projectsduring LS2: • EIS upgrade • SPS Mains upgrade • (Quad output filter + CIS + control) • Impact of 18kV grid consolidation •  Recomissioning of x22 departures Test during HWC Test during IST period • New Equipment must beconsideringduring IST period (or before) • 336 Macaos + 45 AuxPS + 2 new 18kV castresintransformers • Re-start tests post LS2 • 232 converters

  11. EPC equipment (high power) in SPS complex: 1 day test per converter (except Mains) Test during IST (x23) Test during HWC (x25) Test during IST

  12. Location of loadspowered by EPC equipment (high power) in SPS complex: ** for sectorisation ** TT20 TS3 Sextant 3 Exemple on TS4 with RPPDO.BB4.MSE4183M BA3/BB3 • No possible sectorisations for: • Main Dipoles • Main Quadrupoles • Sextupoles • Octupoles PPG3003 PPG21030 TS2 Sextant 2 PPG4003 TS4 Sextant 4 BA2 Mur de séparation BA4/BB4 TT41 TI8 SPS PPG2003 PPG5003 Verification : * Each converter (high power). * Number of magnets. * Location of first and last magnet in series. * Sectorisation possible on sextant or transfer line. * Lockouts dedicated for ARC- / LSS / ARC+ (if possible for MACAOs) * Identification of doors for sectorisation * Remove partial lockouts. * Particular case (MBE.2103M) BA1 BA5 TS1 Sextant 1 TS5 Sextant 5 PPG1003 PPG102828 PPG6003 BA6 TI2 PPG61031 Exemple on TS6 with RPPDB.BA6.MSE6183M TT60 TS6 Sextant 6 TT10

  13. First draft - EPC planning for IST: 15 participants 1stversion • 45 AuxPS converters (new converters or new electronic) • 336 correctors (MACAOs) • 3 converters with new cast resin transformers (18kV) • Converters impacted by EIS upgrade (except Mains/oct/sext)

  14. Updated EPC planning for IST: • 45 AuxPS converters (new converters or new electronic) • 336 correctors (MACAOs) • 3 new cast resin transformers (18kV) • Converters impacted by EIS upgrade (except Mains/oct/sext)

  15. First draft-EPC planning for Hardware commissioning: OP tests on SMD/SMQ(3weeks) 1stversion • 232 AuxPS converters • 336 correctors (MACAO) • 23 High power converters (MBE+MSE…) • 14 SMD + 3 SMQ + 3 Octupoles + 7 Sextupoles • NB: no details in this planning for SMD/ SMQ tests during HWC (in preparation) • But minimum of 6 weeks required for EPC tests!! Participant for test: 2x2 teams (composed from 26 persons) Duration: 9 weeks WORK = 180 homme-jours

  16. 2x2 teams (composed from 26 persons) Duration: 8 weeks Updated EPC planning for Hardware commissioning: • Annual restart : 232 AuxPS converters • 23 High power converters (MBE+MSE…) • 14 SMD + 3 SMQ + 3 Octupoles + 7 Sextupoles • NB: no details for SMD/ SMQ tests during HWC (dedicated planning) • But minimum of 6 weeks required for EPC tests!! WORK = 160 homme-jours

  17. Historicalfrom hardware commissioningafter LS1 (SPS complex): Total of 32,5 days = 209 HJ • BUT during LS1: • No heavy EPC consolidation project • No works on 18kV electrical grid • AWAKE not started (no test in BB4) • More staff available for tests None negligible differences: +15% of time work More EPC consolidation projects Number of projects involve a great dispatching (in term of staff) Impacts of SPS 18kV network consolidation on EPC to considerer

  18. Needs for EPC group: • Declare and announce prerequisites and service availabilities in the SPS planning • * General service (AC, light, water, wifi) • * HV Circuits locked-out by the network separation procedures • * Hand-over to TE/EPC (18kV departures) • * Controls, Ethernet, Interlock system, WIC, BIS • * etc… • Identify and plan in accordance with ACE, all preliminary tests • * DSOs • * EIS-PPS • * Control tests on EPC equipment (no power) • Depending buildings, ADVANCE start dates for IST periods(6 weeks per building) • BA1: IMPOSSIBLE to advance • BA2: mid-July 2020 to be analysed • BA3: mid-June 2020Shadow with RF conditioning BB3:idem BA3 • BA4: from April 2020 more flexible BB4: mid-February 2020 (TT40) • BA5: July 2020  Shadow with ABT ISTs 2ndweek of April 2020 • BA6: mid-march 2020  more flexible • BA7: from May 2020 • SR2: from April 2020 • SR8: from February 2020 • As muchas possible, ANTICIPATE tests of EPC consolidation projects(without power beforethe IST period) !! • Hardware commissioning FOCUS on: • * Power tests on SMD/SMQ, Sextupoles and Octupole converters • * Restart tests on equipment in operation before LS2 Important for EPC • IST period FOCUS on: • * Tests of converters involved in consolidation projects

  19. Commissioningfollow up form (for EPC equipment): • XeXecutes & leads the task / work A is Available and Assist (do not lead) • Iis Informed only • /A\Authorizes the step, checking that equipment & people safety is ensured Procedure already use for the converter commissioning on Booster’s consolidation

  20. Safety all along LS2, IST and HWC: Location of Electrical risks • Active lockouts (converter responsible) can be moved to DC part (if necessary and possible), and clearly identified (even for SMD/SMQ) • All longer, time/period test requests during the long shutdown must be announced for agreement • Organisation/safety to be discussed in LS2C with compensatory measures •  Authorization from HSE / ACE • exemple: Lockout move to DC cables • During LS2 period, even none powering tests (on single converter), always request green light of ACE • During IST and HWC periods, for powering tests on converters, request green light from ACE / OP • Before starting any powering tests: • Green light from ACE (during IST) • Green light from OP (during HWC) • Identification of test in progress on all building doors (where is located the equipment) • Local balisage in case of particular circuit test, during IST • Area closed (identified) and controlled by ccc, during HWC LS2 only on surface IST & HWC on surface and underground

  21. Thanks for your attention…. Any questions ???

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