Powering tests

1. Powering tests The outcome of the work conducted within HCWG and many discussions among colleagues

2. Outline • Starting conditions and pre-requisites • Powering of the warm magnet circuits • Powering of the superconducting circuits • Estimates of the durations • Controls applications and tools required to start up • How to improve and save time • Special tests on the first sector • Failure scenarios and implications • Outlook: LSS L8 • Appendix: the role of “Mr Circuit”

3. Starting conditions and pre-requisites (1/2) • Equipment • All components of the circuit installed, in nominal configuration and nominal operating conditions • Infrastructure • Electrical distribution (including UPS) • Cooling and ventilation • Safety • AUG, fire detection, red telephones, evacuation signals, oxygen deficiency detectors, emergency lighting, water-level detection • Alarm transmission and monitoring (CSAM) operational • Access • Access is only authorized to personnel involved in the tests • Fencing and signals will be put in place

4. Starting conditions and pre-requisites (2/2) • Individual System Tests • Completed and summary results registered in MTF • Tests of Power Converters in short-circuit • Completed and summary results registered in MTF • Interlock tests • Completed and summary results registered in MTF • Controls • FCR installed and operational • Equipment supervision applications operational • Applications ready to run and monitor equipment • Timing • Logging, Alarms, Post-Mortem repositories operational • Post-Mortem tools to view data and perform analysis operational

5. warm magnet circuits IST:WELQA- Electrical Quality Assurance Power Converters not connected to Magnets HCA:WIC- Individual System Tests of Powering Interlock Control connexion of power cables to the power converters HCA:WPCTL HCA:WPC1 HCA:WPC2 and HCA:POL Powering of the electrical circuits one by one or in groups at low and nominal currents Power Converters connected to Magnets HCA:HR Commissioning of all the warm electrical circuits of the machine Point powered in unison to nominal current during 24h HCA:WST System tests from the CCC

6. powering of the warm magnet circuits • HCA:WPCTL • HCA:WPC1 • HCA:WPC2 • At zero current, verification of the interlock system • At minimum current, verification that the PC is connected to the right magnet • Setting up of current loop • Verification of thermal behaviors (8h heat run) • Verification of communications through WorldFip • HCA:POL • Verification of the correct current direction and approximate level • HCA:HR (24h run, with exception of the injection circuits) • Performed per machine point • At nominal current level • HCA:WST • System tests performed from the CCC • Every circuit has to be powered at least once with a nominal LHC cycle • Status after: Warm circuits ready for machine checkout

7. 300 K 90 K 1.9 K superconducting magnet circuits Individual System Tests of Powering Interlock Control Test of power converters connected to the DC cables in short circuit, including controls for powering, ramp, monitoring Individual System Tests of the Quench Protection and Energy Extraction Systems Electrical Quality Assurance Power Converters not connected to Magnets Post-Mortem System tests Interlock tests of a powering subsector prior and after connection of the power cables to the DFB leads connexion of power cables to the current leads Commissioning of the electrical circuits one by one or in groups at low, intermediate and nominal currents Power Converters connected to Magnets Commissioning of all the electrical circuits of the sector powered in unison to nominal current with nominal ramp rates

8. powering of the superconducting magnet circuits 1/2

9. powering of the superconducting magnet circuits 2/2

10. test programme per circuit class

11. Q4’05 Q1’06 Q2’06 Q3’06 Q4’06 Q1’07 Q2’07 Q3’07 may jun jul aug oct jan feb mar apr oct nov dec jan feb mar apr sep nov dec may jun jul aug Sector 12 Sector 23 Sector 34 Sector 45 Sector 56 Sector 67 Sector 78 Sector 81 expected durations of the powering tests 75 days 56 days How are these durations calculated? 47 days 55 days 55 days 45 days 56 days 75 days

12. the two methods applied Method 1 • The String 2 experience was scaled (time of tests) • Every equipment specialist was consulted and gave an estimate of the time needed to commission a circuit as a function of its type Method 2 • Once the HCP on powering was prepared in more detail, the times per step (test) were calculated • No time for analysis was allocated at first

13. Units are 15-h days method 1: time allocated per circuit

14. two shifts = 15 hour days Front 1 arc and the matching section on the even side Front 2 arc, the matching section on the odd side and the inner triplets on both sides Number of circuits Total per type 15-h days per circuit circuit types MB MQ, MQX Separately powered quadrupoles and dipoles 600 A circuits 80-120 A orbit correctors Total # of days 11.0 5.5 1.7 0.8 0.3 8 32 78 436 274 88 176 133 349 82 828 Left Right Front 2 Front 1 Front 1 Front 2 6.6 km (60 A orbit correctors in the tunnel not included) circuits and fronts

15. the sequence of tests around an even point • Specialized teams • RB, RQ and RQX never at the same time flexibilitywrt the unexpected

16. refined estimate of the times required for the test (1/2) preparations ramp up execution ramp down/ discharge recovery analysis e.g. fire quench heaters or calibrate DCCT arming systems • e.g. quench: • cryogenics • energy extraction conditions • quench heater supplies recharged • PM buffers sent • etc… This pattern is repeated for each test at a given current level

17. require battery tests refined estimate of the times required for the test (2/2) Reference for the General Schedule

18. tools absolutely required for day 1… • supervisions of the different equipment (PC, PIC, QPS, Cryo, Vac, cooling & ventilation, …) • control applications to drive and monitor the equipment (see Markus’ talk) • Logging, LASER, Post-Mortem • standard tools for manual analysis using data from Post-Mortem (in general, nothing different from individual magnet benches or String 2): • view data (y=f(t), engineering units) • several curves from different systems on same plot • zooming, cursors, etc tools absolutely required to gain time • automated procedures for simultaneous commissioning of multiple circuits • the sequencer shown by Markus is an excellent tool for this purpose • once validated, they will be very useful to gain time in the case of the commissioning of the corrector circuits • safety of equipment does not rely on them (as requested by AB-CO) • high energy circuits (RB, RQX, …not many) will be done one by one • tools for automated analysis • these tools will be commissioned themselves during the commissioning of the first two sectors • still to be agreed upon what information to integrate within this automated analysis (sequence of events, data integrity, time constants, etc)

19. how to improve and save time? (1/2) • training as much as possible using LSS L8 tests • being organized and ready from day 1 • respecting procedures • applying the quality assurance programme • obtaining support from the MTF and database team • optimization of the MTF configuration for hardware commissioning • exchange of data between the central database and the specialist owned databases • support from the Controls/Operation Groups • programmed procedures for battery tests to be commissioned as soon as possible • dry runs well in advance • PM tools ready • reliable analysis is a must • procedures after failure scenarios … to be done

20. how to improve and save time? (2/2) Streamlining of tests with experience • Being protection systems, functionalities of the interfaces of PIC and QPS must always be checked at 100% • All bus bar connections (cold and also warm) have to be checked with high current • Quenching of magnets is required also to verify the performance of the cryogenic system • Risks of skipping some tests there where it pays off: 600 A and 60 A circuits • if one of the 202 energy extraction systems does not operate properly, the impact will be severe • 60 A circuits are high inductance, high specific energy

21. failure scenarios • discussed at EEWG and HCWG at requests from MARIC and MAC • see Karl Hubert’s talk for most severe cases • some other which are included in a document in preparation are: • PC: Fire • Cables: Massive water leak • S.c. elements: • Bad splice overheating in a sc circuit: detect, open and repair • Bad splice resistance in the normal state (String-2 case) => very difficult diagnostics • Energy extraction failure scenarios • All instrumentation lost for s.c. magnet, lead or circuit • Redundancy lost for the instrumentation of magnet, leads or circuit => recovery procedure • Impossible to power a circuit due to either dead short to ground inside the cold masses or open circuit (?)  list of circuits which are critical for first beam in 2007 (O. Bruening) • reactivity: who, what, when? are defined in advance (within possible) • … anyway, the worst failures will be the ones we did not think about (KHM) • take advantage of Tevatron, HERA, RHIC

22. special tests on the first sector(s) 1/2 • Cryogenics • AT-ACR would validate the quench recovery and subsequent cooldown procedure and control logic • therefore various tests at progressively increasing energy per sector are required, including quenching more than the expected full cell • PIC • Reaction times of interlock (especially RB circuit with EE on either side) • BIC interface (although commissioned at a later stage) • Endurance tests -Post Mortem Interface -Validation of automated procedures in ML8 and XL8 (in parallel with manual commissioning) -Training of personnel • QPS • Validation of digital quench detector firmware • Adjustment of digital filters and inductance tables • Test of selected heater firing @ injection current • General • Mains failure • EMC tests (AB-CO, AB-PO, AT-MEL)

23. special tests on the first sector(s) 2/2 • Also in the first sector • Commissioning of automatic test procedures • Preparation of automatic powering procedures and battery tests • Interfaces to Post-Mortem • Analysis tools • … will be used for the first time.

24. Outlook to LSS L8 • Unique occasion for the: • Validation of powering procedures • Early identification of errors, shortcomings and possible corrections • Training of the teams • The perfect dress rehearsal

25. A few words on the role of the coordination …

26. Measurements Measurements Measurements IST IST IST MTF Measurements OK OK OK HC Procedure OK MTF Coordinator for the LHC magnet circuits • Ensures that the hardware commissioning procedure validates the circuit for nominal operation as defined in the Design Report/LHC Reference Database. • Ensures that all the Individual System Tests related to equipment connected to the circuit have been carried-out, the data has been stored and interpreted by the responsible person • Ensures that each step of the test procedure is carried-out as described in the hardware commissioning procedure document • Ensures that the data associated to each step of the test procedure is recorded and adequately stored in the MTF • Interprets the data and depending on it allows/refuses the execution of the following step of the test procedure • Answers for the data and history of the commissioning of each circuit throughout the IST and the Hardware Commissioning

27. Coordination for the warm part of the sc circuits • Interfaces: • Power cables – DFB (in particular current leads, but also all the other equipment to be connected  studies and integration) • Power cables – power converters • Power cables – water cooling • Power converters – water cooling • Phases: • (Validation of individual systems) • Installation and first connection • Hardware Commissioning • Operation & Maintenance • Groups involved: • AB-PO, AT-MEL, AT-ACR, TS-CV, TS-EL, TS-HDO, TS-IC, SC-GS

28. Goals for the Coordination for the warm part of the sc circuits • Clarify interfaces • Coordinate the definition of sequences and the write-up of procedures • Assessment on the feasibility • Define responsibilities over the different phases …with special attention to: • Planning • Co-activities • Safety

29. Thanks

30. powering profiles This was the procedure applied to String-2 circuits • With the implementation of adapted quench detection thresholds • (1/10 for the plateaux, see Reiner’s talk) this procedure will relax • the specification for the control application current nominal I First power One of the subsequent power runs  step 2  time 2 step 1 time time 1

31. power tests foreseen for MB circuits

32. Analysis of provoked events • right equipment • number of data blocks and their integrity • sequence of actions (PIC, PC, QPS, cryo?) • QD: • fixed pattern for QS during provoked quenches • threshold verification • EE: voltage across dump resistor • Flags: • QD  Coherency flag, QD0, ST_Magnet_OK • EE  to be defined in detail • PC: decay time constant • signals from quench heater power supplies: • U levels • time constant