LHC Hardware Commissioning Review

11 May 2005, 14:00 → 13 May 2005, 16:30 Europe/Zurich

864-1-C02 (CERN, Prévessin)

Steve Myers

Technical Review of Hardware Commissioning: (1)Review programme, the logic, the coherence and consistency (2)Highlight shortcomings in organisation, coordination, incompatibility (3)Resources

Wednesday 11 May

Opening address by the Review Chairperson

1 Opening address by the Review Chairperson

Speaker: Steve Myers

Organisation and coordination of the HC

Convener: Roberto Saban (TS-HDO)

2 Organization and Coordination of the Hardware Commissioning

The logic of the different phases of the commissioning will be reminded and the preparation will be briefly described. The day to day organization in the field (control room, facilities, programme, manpower for coordination, etc) will be discussed. The measures put in place for personnel safety will be presented. On the canvas of the different phases of commissioning, the instances where decisions are required will be shown and the decision owner will be identified. Communication channels inside the commissioning community and towards the external world will be listed. Based on the study of failure scenarios which was undertaken by the working group, the identified showstoppers will outlined and recovery and fall-back solutions –when they exist- will be suggested.

Speaker: Roberto Saban (TS-HDO)

slides Introduction_RSa_final.pdf slides

Quality Assurance and documentation of results

Convener: Felix Rodriguez-Mateos (TS-HDO)

3 Quality Assurance and Documentation of Results

The coordination for the Hardware Commissioning (HC) activities will involve the handling of a large quantity of documents (test sequences and procedures, technical notes, schedules, test results, etc) which must be related to both the hardware baseline databases and the general planning files. This talk will describe the main ideas on how all the information related to the coordination for Hardware Commissioning will be structured and managed with the ultimate goal of integrating commissioning data within the Manufacturing and Test Folders (MTF) of the different equipment and of the Hardware Commissioning itself. In this way, the Quality Assurance process will be completed. The user requirements for a logbook for the Hardware Commissioning activities will also be discussed.

Speaker: Felix Rodriguez Mateos (TS-HDO)

slides HC_Review_doc_&_QA_frm+EBS.pdf  

4 Database management for the ELQA activities – A case study

The installation and commissioning of the LHC will produce a huge amount of data that will be collected and stored on different system databases. The MTF will bring together subsets of these data considered to be relevant for the traceability of test results during hardware commissioning. The talk will describe the interfaces between system databases and the MTF for the Electrical Quality Assurance (ELQA) activities. The motivation for a system database and the associated structure for the sharing of data between system database and the MTF will be described. Particular attention will be addressed to the criteria for the selection and the format of data to be shared. Finally the communication channels and the foreseen structure for an efficient flow of information between the ELQA activities and the hardware commissioning activities will be discussed.

Speaker: Davide Bozzini (AT-MEL)

slides DB.pdf slides

15:40 coffee break

Controls and Communications

Convener: Robin Lauckner (AB-CO)

5 The Hardware Infrastructure

The installation of the LHC control system hardware is a major step to be completed before the start of the LHC hardware commissioning phase. The control of the core LHC systems involved during hardware commissioning (power converters, power interlock system, quench protection system) requires in practice the full installation of most of the LHC control system hardware and associated low-level services. This presentation summarises the key operational hardware platforms that will be installed around the machine for hardware commissioning and their associated services (VMEbus systems, industrial PC based systems as WorldFIP bus arbiters, terminal servers, remote reboot systems for PCs and PLCs, timing distribution hardware), the dedicated distributed communication networks (Ethernet, General Machine Timing, WorldFIP), the Field Control Rooms and the low-level administration and diagnostic programs. The planning for the control system installation as organized today in the AB controls group is explained (hardware design, procurement, assembly, burn-in, functional test, installation and validation), along with the dependencies on cabling campaigns. The AB/CO control system operational support policy will also be presented.

Speaker: Marc Vanden Eynden (AB-CO)

slides LHC-HWCR_MvdE.pdf  

6 The Applications Infrastructure

Applications for LHC hardware commissioning are being built as part of the development effort put in place since 2002 for the LHC era applications. For classic operations, like Power Converters controls, we aim to reuse the software developed for TI8. At the same time a huge effort is underway to introduce new industrial controls for the supervision of several important systems like the QPS, QRL and PIC, in the traditional controls approach. Our strategy is to develop once, using a simple and iterative development model and to exploit every possible controls milestone, using dry runs, to validate the complete integration of our systems and to improve the functionality. Our software development is based on standard CO components and general services, some already available and tested successfully for TI8. In the front ends, a framework for building device servers (FESA) is offered to the equipment groups. The Java controls applications are built on top of existing core business logic, while the supervisory applications are based on SCADA (PVSS) systems. Both the SCADA and Java based controls are coupled via CMW for data exchange. General CO services for handling and displaying Alarms, post-mortem, measurements and logging, fixed displays and console manager are being finalised and will be available for the hardware commissioning phase. The Technical Network will be used for the network communications and a new security policy will be applied to isolate this network from outside intrusion and to manage, monitor and secure the connectivity inside the domain. This autumn, the hardware commissioning will be a major milestone and a new phase for controls. It is the first time that existing and new mainstream and industrial based software will be integrated seamlessly to interchange data, while automated procedures will provide efficient means for repetitive tasks. At the same time the strict network security policy will have to be taken into account to allow for the smooth running of the commissioning.

Speaker: Eugenia Hatziangeli (AB-CO)

slides EH.pdf  

Infrastructure

Convener: Thomas Pettersson (TS-CSE)

7 Utilities, access and safety

The presentation will cover the state of readiness of the LHC utilities: AC distribution, cooling and ventilation, transport (lifts), safety and access systems. The request of the survey group for a strong overall co-ordination will be presented. A brief overview of the commissioning tests, in particular for the cooling and ventilation, safety and access systems will be given. The operation and maintenance procedures for the utilities will be briefly described including the on-call service delays for each utility. The access system with all its doors and gates will only be completely commissioned after the machine has been commissioned to simplify access for the HWC team.

Speaker: Thomas Pettersson (TS-CSE)

slides slides TSV.pdf

Thursday 12 May

Vacuum

Convener: Pierre Strubin (AT-VAC)

8 Room temperature vacuum systems

A description of the individual system tests and HC tests will be given, including the equipment, manpower & conditions required to perform the tests. Failure scenarios and their impact will be enumerated. The overlap between RT vacuum system installation & HC will be highlighted and the potential difficulties explained.

Speaker: Jose Miguel Jimenez

slides JMJ.pdf slides

9 Cryogenic vacuum systems

A description of the individual system tests and HC tests will be given, including the equipment, manpower & conditions required to perform the tests. Vacuum system failure scenarios and their impact will be enumerated.

Speaker: Paul Cruikshank

slides cruikshank.pdf  

Cryogenics

Convener: Laurent Tavian (AT-ACR)

10 Sector Cooldown and Cryogenics Commissioning

The prerequisite, requirements and constraints for a sector cool-down will be reminded. The different phases of cool-down, commissioning and operation for magnet powering will be reviewed with particular emphasis on what will be tested or verified for the first time (i.e. tests which could not be performed on String 1 & 2 and tests on equipments which are commissioned for the first time). Aspects related to safety, equipments damage and operation crew organization will also be analyzed. A qualitative investigation of possible show stoppers and shortcuts with consequences will be given.

Speaker: Luigi Serio (AT-ACR)

slides Luigi_Serio.pdf  

11 Cryogenic Instrumentation and Controls Commissioning

This talk will address the current status of the controls for the LHC, the schedule for the procurement of the tunnel electronics and control logic, the tasks associated with both the QRL reception test and the full LHC sector commissioning, and will give some comments on the feasibility with respect to the official LHC schedule. The cryogenic instrumentation and controls are required for both the QRL reception test and the full sector commissioning; unfortunately most of the instrumentation and controls are different. This talk will highlight the main differences between the two systems and the tasks associated with the LHC commissioning, taking into account whether a QRL has been previously commissioned in a given sector or not.

Speaker: Juan Casas Cubillos (AT-ACR)

slides HWCR.ACR_IN.pdf  

10:15 coffee break

Cryogenics (cont)

Convener: Laurent Tavian (AT-ACR)

12 Hardware Commissioning of DFBs and DSLs

The DFBs, DSLs and connection cryostat, once installed and connected, form an integral part of the magnet powering scheme as well as the cryogenic system. This is reflected in the hardware commissioning. The test activities comprise: pressure and leak tests, high voltage tests (warm, before and after connecting and cold), instrumentation checks, control procedure validation (including interlocks), cryogenic operation with circuit powering (levels and temperatures, steady state and transitory).

Speaker: Antonio Perin (AT-ACR)

slides HC_Review_05_DFB_DSL.pdf  

Electrical circuits and magnets (warm and cold)

Convener: Frederick Bordry (AB-PO)

13 The normal conducting magnets and their circuits

Hardware commissioning of the magnet systems comprises the test of its individual components as much as their interaction within the system. Only the latter operation shall be addressed in the Hardware Commissioning Review. The tests of the magnets are therefore discussed as a pre-requisite. On this basis, their initial state is defined and shall be taken into account for the system tests. For completeness, the list of normal conducting magnet circuits and their peculiarities is summarized.

Speaker: Suitbert Ramberger (AT-MEL)

slides slides SR.pdf

14 Superconducting circuits: a generic view

The basic problems in operating electrical circuits containing superconducting elements and the essential safety issues are recalled. There from, the relative importance of the various safety- related components are deduced and their impact on the schedule and operation, in case of failure, explained.

Speaker: Karl-Hubert Mess (AT-MEL)

slides KHM.pdf slides

12:15 lunch break

Electrical circuits and magnets (warm and cold) (cont)

Convener: Frederick Bordry (AB-PO)

15 Superconducting circuits: what remains to be done during hardware commissioning?

The various steps of electrical quality assurance prior and during the powering tests will be discussed. Possible interference with the individual system tests of the quench protection and energy extraction system will be addressed. After a short review of the individual system tests prior to hardware commissioning, the test programme required for the proper qualification of the quench protection and energy extraction system will be presented. Finally an estimate of the necessary resources in case of equipment failure will be given.

Speaker: Reiner Denz (AT-MEL)

slides RD.pdf slides

16 Power converters and DC cables

The main topic of this talk is the validation of the warm part of the electrical circuit (power converters and DC cables) before powering tests with the magnets. In the first part, reception tests and installation of equipments are presented: reception tests of power converters in surface halls, installation of the power converters, installation and initial tests of the DC cables. Then the short- circuits tests are explained and justified: why to do these tests, which tests are requested, initial conditions for these tests, time duration and human resources, what is the impact if some tests are suppressed? Finally, the special tests during the powering tests with the magnets are presented and discussed: current loops setting, first powering of the dipole magnets and Inner Triplet circuits, calibration of the high precision circuits.

Speaker: Hugues Thiesen (AB-PO)

slides HT.pdf slides

17 Power Interlock Controllers: WIC

On reception of the hardware for each Warm Magnet Interlock Controller (WIC) installation, the system will be constructed in the lab. This will facilitate testing of the hardware and the correct operation of the systems software and functionality. All input signals will be stimulated and the expected response of the system and the output for the respective power converter can then be verified. Each system is then installed in the LHC tunnel at the required location, and the connections made to each Magnet and Power Converter. The system is re-tested with the actual hardware connected, according to previously defined test procedures. Additional tests of the field- bus links and the deployed PLC components will complete the commissioning procedures and the warm magnet interlock system is declared operational and ready for the connection of power cables and the following powering procedures.

Speaker: Robert Harrison (AB-CO)

slides RH_WIC_HWcomm_Review_Final.pdf  

15:45 coffee break

Electrical circuits and magnets (warm and cold) (cont')

Convener: Frederick Bordry (AB-PO)

18 Power Interlock Controllers: PIC

Before installation in the tunnel, the powering interlock controller (PIC) will be completely assembled and tested on all its functionality on the surface. One powering subsector in the tunnel will be managed by one dedicated powering interlock controller (two in the case of the long arc cryostat). For this, a dedicated test system is able to emulate all signals that the later on connected systems will exchange with the PIC. Hardwired interfaces with the power converters, the quench protection system, the AUG, the UPS systems and the beam interlock controller are verified along with the functionality of the PLC program and the communication with the supervision application. After this surface validation, the PIC is transported to the tunnel and installed in the foreseen rack. During the phase of individual system tests (IST), the same procedures as already performed on the surface are repeated. After the successful termination, the interlock cables from the power converters and the quench protection system are connected and the PIC functionality is validated with the real clients, using automated procedures as defined and prepared by SACEC (Software for Automated Commissioning of Electrical Circuits). These tests are performed once with the power converters still in short circuit (power cables not yet connected to the current leads) and once after the connection to the magnet string. Upon termination, powering tests can start for this powering subsector.

Speaker: Markus Zerlauth (AB-CO)

slides   Talk_MZ_HCReview.pdf

19 Powering tests

The main topic of the talk is the validation for operation of the electrical circuits as a single system. In the light of the previous talks and the hardware commissioning documentation, each step of the powering tests will be revisited and their time durations justified. Risks, failure scenarios, and foreseen fall back solutions will be presented. The requirements and priorities for (i) the software applications to run the tests, (ii) the necessary Post-Mortem and graphical user interfaces, (iii) the analysis tools and (iv) the automated procedures which will be needed to conduct the commissioning of the electrical circuits safely and in time will be discussed.

Speaker: Felix Rodriguez Mateos (TS-HDO)

slides powering_tests_frm.pdf  

Friday 13 May

Beam systems

Convener: Hermann Schmickler (AB-BDI)

20 The Commissioning of the LHC Beam Interlock System

The Beam Interlock System (BIS) forms the backbone of the LHC Machine Protection System, allowing 100’s of distributed User Systems to inhibit beam operation and request Beam Dump from all around the LHC. he requirement for rapid response time of the BIS is coupled with very high safety constraints, as whilst providing a secure and robust protection. The system should not be a source of unnecessary beam dumps. After a brief reminder of the architecture and the technological choices, this presentation shows the sequence of the steps which leads to the commissioning of the Beam Interlock System. At the end of this phase, the system is fully tested from any connected User System to the LHC Beam Dumping System interface. The presentation describes how the commissioning is firstly performed in stand-alone mode through extensive checks from any User System connection to the Beam Permit generation. The second part of the commissioning involves each connected User Systems in order to guarantee their own beam dump request capability.

Speaker: Benjamin Todd (AB-CO)

slides BIS_HCReview_BTodd.pdf  

21 Hardware commissioning of BDI equipment

Installation of the various accelerator equipment will begin shortly. It is based on a very tight schedule. In order to be ready for hardware commissioning many basic equipment tests will have to be done during this installation period, such as cabling, basic hardware operation and some of the power tests. Those will all be done under the responsibility of the corresponding equipment group. Very little interdependence is expected. The hardware commissioning itself of all above systems is also based on a tight schedule with important dependencies on other systems. The principal milestones and activities related to installation and commissioning will be reviewed, critical points will be underlined and the main concerns brought up. Special emphasis will be given to the critical elements, for which a delay in installation and testing can disturb the powering and cryogenics commissioning of the LHC arcs.

Speaker: Roland Jung (AB-BDI)

slides RJ.pdf slides

22 Hardware commissioning of RF equipment

Installation of the various accelerator equipment will begin shortly. It is based on a very tight schedule. In order to be ready for hardware commissioning many basic equipment tests will have to be done during this installation period, such as cabling, basic hardware operation and some of the power tests. Those will all be done under the responsibility of the corresponding equipment group. Very little interdependence is expected. The hardware commissioning itself of the RF system is also based on a tight schedule with important dependencies on other systems. The principal milestones and activities related to installation and commissioning will be reviewed, critical points will be underlined and the main concerns brought up. Special emphasis will be given to the critical elements, for which a delay in installation and testing can disturb the powering and cryogenics commissioning of the LHC arcs.

Speaker: Olivier Brunner (AB-RF)

slides LHC_HC_review_-_RF_OBru.pdf  

23 Hardware commissioning of ATB equipment

Installation of the various accelerator equipment will begin shortly. It is based on a very tight schedule. In order to be ready for hardware commissioning many basic equipment tests will have to be done during this installation period, such as cabling, basic hardware operation and some of the power tests. Those will all be done under the responsibility of the corresponding equipment group. Very little interdependence is expected. The hardware commissioning itself of the ATB equipment is also based on a tight schedule with important dependencies on other systems. The principal milestones and activities related to installation and commissioning will be reviewed, critical points will be underlined and the main concerns brought up. Special emphasis will be given to the critical elements, for which a delay in installation and testing can disturb the powering and cryogenics commissioning of the LHC arcs.

Speaker: Oliver Aberle (AB-ATB)

slides hc_reviewATB_OA.pdf  

24 Hardware commissioning of BT equipment

Installation of the various accelerator equipment will begin shortly. It is based on a very tight schedule. In order to be ready for hardware commissioning many basic equipment tests will have to be done during this installation period, such as cabling, basic hardware operation and some of the power tests. Those will all be done under the responsibility of the corresponding equipment group. Very little interdependence is expected. The hardware commissioning itself of the BT equipment is also based on a tight schedule with important dependencies on other systems. The principal milestones and activities related to installation and commissioning will be reviewed, critical points will be underlined and the main concerns brought up. Special emphasis will be given to the critical elements, for which a delay in installation and testing can disturb the powering and cryogenics commissioning of the LHC arcs.

Speaker: Brennan Goddard (AB-BT)

slides Brennan.pdf  

Compatibility of Hardware Commissioning with Installation

Convener: Claude Hauviller (TS-IC)

25 Compatibility of Hardware Commissioning with Installation: Machine

The “proper” hardware commissioning will start once the machine and experimental elements in the tunnel are installed and the individual systems tests are done, in both sectors around an even point. This implies co-activities between the two phases; as for example individual systems tests (such as short circuit tests, etc.) will be done during the installation phase without disturbing its advancement; magnets will be transported through one sector during its hardware commissioning, etc.. The co-activities between installation (machine and experiments) and hardware commissioning, will be presented, as well as solutions adopted so far for an easy cohabitation.

Speaker: Katy Foraz (TS-IC)

slides HC_Review_05_05ter_KF.pdf  

26 Compatibility of Hardware Commissioning with Installation: Experiments

The installation of the experimental areas will be briefly reviewed with particular attention paid to the installation of the radiation shielding and vacuum beam pipes which may interfere with the Hardware Commissioning of the magnets located close by (low beta triplets and compensator magnets). The LHCb detector installation and the Hardware Commissioning of the Cryogenic equipment located in the UX85 cavern will be mentioned too. Issues related to the access system connecting the machine and experimental underground areas will be addressed if any. In addition, the installation of the experimental detectors in the machine tunnel, i.e. Roman Pots and Zero Degree Calorimeters, will be briefly discussed. Finally, the coordination between the Hardware Commissioning and the Experiments Installation will be clarified.

Speaker: Daniela Macina (TS-LEA)

slides DM.pdf slides

10:00 coffee break

From Hardware Commissioning to Cold Checkout

Convener: Simon Baird (AB-CO)

27 From Hardware Commissioning to Machine Checkout

Three phases of getting the complete LHC from the Hardware commissioning into a full Machine Checkout have been outlined in the last LHC Chamonix Workshop. These are: 1. Cooldown and Closure of the complete machine 2. System and Equipment tests per sector 3. Complete Machine cycles The Hardware Commissioning team is responsible for the Hardware Commissioning itself and AB/OP will be responsible for the phase 3. However, for phases 1 & 2, the responsibility is less clear. The aim of this presentation is to answer the following questions. Or at least show where clearer answers are needed. • During Hardware Commissioning, which cycles will have been tested? And to what “beam energy”? o Can a sector be considered as “ready for beam” immediately after the Hardware Commissioning? • Who is responsible for the sectors between the end of Hardware Commissioning and the start of the Machine Checkout (during phases 1 & 2 above)? o What happens to a sector after the Hardware Commissioning and before the Machine Checkout? o Who “re-commissions” these sectors to get them ready for the Machine Checkout?

Speaker: Simon Baird (AB-OP)

slides From_Hardware_Commissioning_to_Machine_Check-out.pdf  

Putting it all together

Convener: Roberto Saban (TS-HDO)

28 Putting it all together

Following the presentations of all the speakers, the list of the outstanding open issues will be drawn up; each entry will be briefly described and an action plan will be suggested.

Speaker: Roberto Saban (TS-HDO)

slides RSaP_corrected.pdf slides

11:50 lunch break

Closed session

Convener: Steve Myers (AB)

Close-out

Convener: Steve Myers (AB)