1. A technical proposal for the consolidation of the LHCA cryogenic elec/control system for the HL-LHC era.
07/10/2017
Simon MARTIN
Marco PEZZETTI
Simon MARTIN

2. Technical status Electrical part
07/10/2017
Process
Instrument
Connection Field Box
Electrical
Cabinets
Cabling
Simon MARTIN

3. QSCA Upgrade Reflection Input Output
07/10/2017
Input
Output
Equipment:
▫ Cabinet
▫ Field Box
▫ Link Cabling
▫ Field cabling
▫ Plant Instrumentation
Component selection
Technical Choice
+Functionality
+Availability
+Safety
-Maintenance
Technical subset :
▫ Safety chain
▫ Protection chain
▫ EMC
▫ Elec Distribution
▫ Hardware Interface
▫….
Technical optimisation ratio:
Maximum technical result
Minor resources/cost
Technical requirements :
▫ Standards
▫ Electrical Spec
▫ EMC rules
Simon MARTIN

4. SUMMARY of technical solution presented :
QSCA Upgrade SOLUTION
07/10/2017
SUMMARY of technical solution presented :
▫ Push button Safety chain
▫ 3.3kv motor rotation test
▫ 3.3kv Cellule signal exchange
▫ Elec Distribution
▫ Hardware Interface
▫ Field box
▫ Field Cabling & Cable tray
▫ Instrumentation connection
Simon MARTIN

5. Push-Button Safety Chain
QSCA- Cabinet-Zoom
Push-Button Safety Chain
07/10/2017
Goals
-SIL level increased
-Hardware simplified
 unique safety relay
-No relay forced
Simon MARTIN

6. Rotation Test PROTOCOL
QSCA- Cabinet-Zoom
Rotation Test PROTOCOL
07/10/2017
Status
During the test of electric motors, an operator has to force a relay. There is the risk that he makes a mistake and he activates another motor under maintenance. This is a risk for the operator who does the maintenance because he could be involved in a serious accident. !
No TEST
Goals
-Make safe and error free 3.3kv motor rotation test.
-Motor test with remote control.
-Simplified and standardized operation.
-No manual relay forced, no human mistake !
-TEST MODE introduced in the UNICOS Control system.
Simon MARTIN

7. 3.3kV Cellule Order and Status
QSCA- Cabinet-Zoom
3.3kV Cellule Order and Status
07/10/2017
NEW
Circuit Breaker position status
Goals
-Make safe 3.3kv cellule orders (Unlock & Start) with SIL1 relay
No possibility of forcing
-Increase information of 3.3kv cellule status with “circuit breaker position status”
Warning if 3.3kv cellule padlocked
Simon MARTIN

8. QSCA- Cabinet-Zoom Distribution BT (400V)
07/10/2017
Goals
-Distribution & Protection simplified (new design, new component…)
-Main maintenance switch positioned on front doors.
-Easy and faster operation recovery:
In case of failure, “spare maintenance switch” have been added
Simon MARTIN

9. QSCA- Cabinet-Zoom Distribution TBT 24V
07/10/2017
Old 24V distribution “Serial Loop”
New 24V distribution with “Parallel
BusBar”
NEW
24V Bus Bar
Goals
Each device is supply from bus bar:
-More flexibility to add or remove device
- Easier diagnostic
- Easier component disconnection & isolation
- Better availability in case of failure of a component (degraded mode)
Simon MARTIN

10. Interface connexion from field
QSCA- Cabinet-Zoom
Interface connexion from field
07/10/2017
Goals
-Remove as possible Burndy Connector to reduce quantity of connexion
-Field interface clearly defined
Unique bloc terminal on bottom of cabinet.
-Easy upgrade and modification (more flexible with accessible spare)
Simon MARTIN

11. Overview of new CE standard cabinet
Cabinet conclusion
Overview of new CE standard cabinet
07/10/2017
Simon MARTIN

12. QSCA- Field Box-Zoom Cable Gland
07/10/2017
Status
- Oil infiltration
- Cable gland plate damaged
Goal
-Prevent infiltration by gravity
Drilling only on bottom plate
-Index Protection increased
-Easy upgrade and modification
Simon MARTIN

13. QSCA- Field Box-Zoom Removal of electronic
07/10/2017
Goal
-Reducing equipment failure
Active component removal
-Reducing connection problem
Screw less terminal bloc
Problematic
Field box bad environment:
Vibration
Aggressive oil
Heating
Screw terminal bloc
Simon MARTIN

14. QSCA- Cabling & Instrumentation Cable tray & Protection
07/10/2017
Status
Light cable tray & damaged cable clamp in bad environment (UV, Aggressive oil, Heating).
 Cabling unprotected and damaged
Goal
-Cable protection increased
Cable tray cover added
 Cable sheath
Simon MARTIN

15. QSCA- Cabling & Instrumentation
Connector M12 Moulded as much as possible
07/10/2017
Status
Lot of failures (Short circuit with ground) are caused by bad connection inside EV connector.
Maintenance human mistake (re-assembly).
Goal
Reducing equipment failure
 as possible welded and moulted connector
 adaptor M12 connector to EV connector
Industrial component following standard must be preferred than a special part developed at CERN
Simon MARTIN

16. CONCLUSION
07/10/2017
The technical upgrade methodology/solution come out from CE section, other laboratory and industry experiences…Several technical solutions presented have been already installed in the various TE-CRG projects with very good results.
Safety : functionalities have been upgraded to the actual international norms.
Functionalities : technical installation present the same level of operation functionality.
Availability : technical installation have been design to have better availability (to be confirmed by time..) (i.e. degraded mode operation have been installed: separation of electrical and instrumentation circuit)
Maintenance : is easier by design : cabinet layout low density, better distribution, new terminal block…
Simon MARTIN