1. 1 Machine Checkout and Setup Periods Jan Uythoven Thanks to: O.Aberle, R.Bailey, F.Bordry, O.Brunner, L.Bottura, E.Carlier, P.Charrue, E.Ciapala, S.Claudet, R.Denz, D.Forkel- Wirth, B.Goddard, M.Jimenez, R.Jones, M. Lamont, V. Mertens, P.Ninin, B.Puccio, S.Ramberger, F.Rodriguez Mateos, R.Schmidt, L.Serio, B.Todd, M.Zerlauth

2. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 2 Machine Checkout: WHEN ?  Year 1: Following Hardware Commissioning  Assume all equipment tests are done in the past 18 months  Most of the system tests are done in the past 18 months  Subsequent years: Following Shutdown Work  Assume most equipment tests are done  Machine Checkout  First time machine complete cold and closed  All systems running together from the control room  Before First Beam

3. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 3 Tasks - Summary  Redo a subset of tests performed during the Hardware Commissioning period  Because some tests more than a year ago  Because the final configuration of the system might be different, especially the interface to other equipment  If hardware commissioning period was squeezed in time, this will have been at the cost of the system tests  As a result: will need more time for the Machine Checkout  New Tests  Additional system tests  All systems together – machine wide, interdepedencies  Machine completely closed, last access / final checks  Under the responsibility of the Operations Group  Green light from DSO, info for INB

4. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 4 First beam Phases of Machine Checkout Hardware Commissioning Sectors 1-2 and 2-3 Cooldown of all sectors ELQA tests Close machine completely; Contr. Access Complete Machine Cycle from CCC DSO tests Time Equipment tests per 2 sectors: Interlocks, Power Converters RF, kickers, BDI,.. Machine Checkout phase I Machine Checkout phase II Machine Checkout phase III Some phases in parallel

5. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 5 Phase I  Infrastructure for the complete machine  Water, Ventilation, Power, Controls Network  Radiation Protection (RAMSES)  Check response ionisation chambers  Interface with other systems  UPS, AUG  Cooldown of the complete machine  Sectors T up to 200 K: need 10 days for cooldown  If T > 80 K: need to redo Electrical Quality Assurance tests (ELQA), first time  3 weeks  If T < 100 K: cooldown needs about 5 days Up to about 5 weeks for sectors warmed up > 80 K. Need to start cooldown in parallel with Hardware Commissioning. Manpower. When full inventory of He available?

6. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 6 Phase I, continued Access System  Close the complete machine  Test of LHC Access Control System (LACS)  Test of LHC Access Safety System (LASS)  New tasks – before only done per sector (during HC)  New tasks: interface adjacent sectors, machine wide  Important Safety Element in point X must interface over the global machine and beam dump in point 6  Interface with Radiation Protection equipment: access veto  Interface with HR data base, biometrical data  Some equipment was not in final state during Hardware Commissioning tests  Exercise procedures for ‘patrouille’, giving access, back from access, …  Start first with sectors needed for Machine Checkout equipment tests phase II  If necessary, time to sort out problems parallel to phase II programme Ideally only controlled access from phase I onwards

7. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 7 Phase II  Per two sectors  Check interlocks: PIC, WIC, QPS  See  Test all power converters, two sectors at a time  See  Simultaneously in other sectors  Other equipment checks, see Determines the pace of tests in Phase II

8. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 8 Phase II Interlock Systems  Before power converters can be tested, test interlock system  Quench Protection System (QPS)  Visual check of equipment, half day per sector  Automatic test procedure, 8 hours (same as monthly procedure): fires the quench heaters without current in magnets  Test interface to BIS -> check in phase III  Powering Interlock Controller (PIC)  Takes information from the QPS  Automated test procedures and visual control  Needs about 8 hours for testing  Warm Interlock Controller (WIC)  No automated procedures foreseen  Some manual testing and visual control: 8 hours

9. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 9 Phase II Power Converters  Followed by testing of Power Converters two sectors at a time  Run all converters to full power, perform tests at full power  Calibration already done during Hardware Commissioning  12 h continuous running at full power  Need about half a week per two sectors  Proceed around the ring

10. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 10 Phase II Control System  Control System Communication Mechanisms  Field buses operational machine wide. All elements to be checked: need about 8 days  Already start during phase I  FrontEnds, BackEnds and general services  Should have been made available during the Hardware Commissioning period sector by sector and left running  Timing generation and distribution  6- 8 days for the first year  Databases access  1 day, at least

11. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 11 Phase II Control System, ctd.  Application software  Tested continuously during the last months / years  Specific projects need testing  Interlocks, realtime feedback, logging, postmortem, safe beam flag etc.  Estimate 10 days for test …..???  Final tests when complete machine available: See phase III Message from many (CO, OP and BDI): DRY RUNS, dry runs & DRY RUNS Quoting TI 8 experience

12. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 12 Other Equipment tests: RF  Basic work of testing cavities, cryo, LLRF and control during hardware commissioning period  Number of tests which would clearly accelerate RF operations and improve performance: - Reliability of RF system: power & cryogenics - Software and diagnostics developments / improvements - New conditioning hardware for subsequent years - RF noise and ripple measurements - Customisation of klystrons (positioning of resonance) - Linearisation of klystron response - Effect of detuning and coupler position on loop stability - Optimisation of loops for higher intensity - Fine adjustment of trip level for fast transients - Setting-up of the longitudinal damper - Preparation of feed-forward and 1-T feedback Ed’s Wish List RF will use the time made available

13. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 13 Other Equipment tests: Warm Magnets  Visual inspection  No spanners lying around…  All protection covers in place  Cooling system o.k.  All valves open  No visible leaks  Expect 1 day work per sector, 8 days total

14. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 14 Other Equipment Tests: Vacuum  Assume machine already cold & closed  Check interlocks  Sector valves  Connection to BIC  Not to forget  Vacuum interlocks on transfer lines: 2 days 3 days per octant 2 teams in parallel 12 days

15. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 15 Other Equipment tests: Collimators and Beam Absorbers  Redo some of the hardware commissioning tests in local & remote  Motor control, position switches  Temperature sensors, cooling system  Interfaces with more intelligent software from the CCC to manage settings  Not defined yet, should include BIC  Couple of days  In parallel with other tests

16. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 16 Other Equipment tests: Pulsed Magnets  Beam dump kickers (MKD and MKB point 6)  Injection kickers (MKI points 2 and 8)  Tune and Aperture kickers (MKQA point 4)  For all of them  Verification of local interlocks  Pulse at full power – MKI some re-conditioning time  Interface with many systems across the machine  RF point 4 (rev. freq.)  Energy from dipoles either side point 6  Timing, controls, machine protection, post mortem  OASIS, logging  Cross connections between MKI and MKD Couple of days per system Couple of WEEKS Maximum in HC, start early, profit from RELIABILITY RUN

17. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 17 Other Equipment tests: BDI  Large distributed systems: BPMs & BLMs  Hardware fully checked during HC, but re-check  Main tasks: software and logging, links to other users  Interlocked Systems – check interface BIC (phase III)  BLM, BCT point 4, BPMs point 6, LDM (Longitudinal Density Monitor)  Diagnostics systems – no special requirements  Q and Q’ measurements, Schottky systems, Sychrotron radiation monitors, OTR screens, Wire scanners Experience has shown that BDI ALWAYS wants to have another access CONTROL SYSTEM DRY RUNS, distributed over about 2 months, so start BEFORE the machine checkout

18. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 18 Phase III  Status after Phase I & II  All equipment and systems (re-)tested, sector by sector  Individual interlocks tested  Controlled access  Phase III  Machine wide tests from the CCC  Go through complete machine cycles without beam  Accent will be on control system and application software  Interleaved with final tests of access system and green light by DSO  In principle no access should be necessary any more  Control System Tests: Build on experience !  To be tested throughout the yearS with the maximum number of ‘dry runs’  TI 8 tests with beam  Hardware Commissioning of all sectors including system tests  Sector test with beam

19. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 19 Phase III Complete Machine Cycle Without Beam  Initial machine cycle (45 minutes) to get to initial field conditions  No further tests possible – real magnetic field to be found out with beam  Generate functions for the power converters  Download all functions to power converters – synchronous ramping of all power converters including energy ramping of beam dumping system  Settings management, trimming of functions  Machine wide timing of the systems, pre-pulses etc.  Timing (slow and fast), OASIS to set timing of kickers  Interface with RF, injection kickers, beam dump kickers, machine protection system  Applications – communication with all equipment  All fixed displays, video, trajectory and orbit correction  Feedback applications: trajectory, tune, chromaticity, transverse, longitudinal  Logging of all parameters during the cycle  Vacuum displays, alarm screens, radiation monitoring  Interface with the Beam Interlock System  Safe beam flag depending on energy  Post mortem after beam dump  Some kind of sequencer to automate tasks (LHCexec)

20. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 20 Phase III, continued  Now obligatory to have machine completely closed  If search broken during phase II: Complete patrouille with several teams: 2 days  Re-test complete access system before DSO test: 2 x 12 hours  Machine protection system has probably been touched upon during phase II  Followed by Beam Interlock System (BIS) tests (or BIC)  Need “Green Light” from all systems – towards the end of test period  16 different users, 150 ‘user boxes’  Every box needs to receive an interlock, provoked by the equipment connected to it. Check 4 x dump request per equipment.  Estimate 3 x 8 hours to test – 2 days  Rubber stamping of systems by DSO – data for INB  Need about 1 day, if everything goes fine  Rubber stamping by ‘Mr. Interlock’  Need formal test procedures and acceptance criteria

21. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 21 Time Required  Phase I: 1 week minimum  Cooldown and closing machine  Phase II: 3 weeks minimum  Interlocks, equipment & system tests  Phase III: 2 weeks minimum  Complete cycles without beam  Final test access system and BIS  DSO tests Minimum of 6 weeks on planning! Partially parallel with hardware commissioning Equipment setup with beam, see

22. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 22 Equipment Tests With Beam  BDI  Calibration BPMS, BCTs  Set-up of tune and chromaticity measurements  RF  Low level control (typically 3 weeks)  Phasing  Feed back  Control system  Logging beam data, post mortem  Steering – feedback  Machine protection tests  Check interlocks of the system  Safe beam flag  Beam Dumping System  Beam dump to be set up at the different energies  Verification of post mortem, logging and analysis  Cryogenics with significant beam load Continuously during the first weeks / months of operation

23. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 23 Not to underestimate: Transfer Lines  TI 8 will need recommissioning  Tested before  With beam up to TI 8 TED end 2004,  Not tested yet: last 100 m + collimators  Sector test end 2006  But will need to be recommissioned before first beam  TI 2: never fully commissioned before  Will probably only be ready for commissioning at about the same time as the last LHC sector (transport of all LHC magnets through the TI 2 tunnel)  Could be done in parallel with hardware commissioning of the last sector: preferred solution but impact on HC schedule  Other option is to do this in parallel with ring 2 beam commissioning: higher risk in case of problems

24. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 24 Machine Checkout For Subsequent Years  No Hardware Commissioning period but shutdown work to be finished  Outline stays the same with similar tests  Some tests should be faster, because systems are better known  Foresee about 5 weeks minimum: longer than SPS / LEP because systems are more complex, machine protection to be taken more seriously Compare LEP and SPS: About 2 weeks of pre-closure and 2 weeks of real machine checkout when machine is for OP 2 weeks of LEP / SPS ‘cold checkout’ similar to 2 weeks of phase III of what is presented for the LHC

25. Jan Uythoven, AB/BTChamonix@CERN 2005, Machine Checkout Page 25 Conclusions  After the hardware commissioning period the machine is not ready for beam  Confirmed by experience from LEP & SPS, need a period to get ready for beam under the responsibility of OP  Even with all equipment groups 100 % ready on time (!): complete systems tests remain and their interdependencies need to be verified  At least 6 weeks of tests need to figure on the LHC planning for Machine Checkout  Start earlier for cooling down the sectors warmed up > 80 K for ELQA tests, in parallel with hardware commissioning  Start earlier for software and machine protection: DRY RUNS to be planned and scheduled  Many tasks in parallel: need careful planning and good coordination  Some running in of equipment with beam is also required  BDI being the obvious candidate, but also RF, beam dumping system  Don’t forget the transfer lines  Same applies every year after a shutdown