1. SR1 extension follow up
14-Aug-17
Marco Ciapetti

2. Introduction CV problems Ceiling lowering vs. ceiling replacement
Various updates
Proposals from TC to be discussed
Current status of the project
Updated schedule
Things to be decided

3. CV problem 1
EN-CV was supposed to install the pre-treatment device where today there is the smoke extractor.
Alex discovered that the available space is not sufficient and would like SMB to extend the concrete slab.
Unfortunately in the same area there is an underground canal (drain? Sewer?).
EN-CV asked SMB if it is possible to close that canal, since there is another one close by.
Pierre will analyze the situation as soon as he is back at CERN

4. CV problem 2
One duct is in correspondence of the emergency exit. The exact location of the emergency exit is not yet known by TC (SMB still should give this information) and was guessed in the 3D model. However, the position might be different by few centimeters and the conflict with the duct must be avoided  Alex, Pierre

5. CV problem 3
The position of the openings for lights is just indicative: it depends on the type of light and quantity.
This example has been designed using Thierry proposal of 36 Philips SM120V W20L120 1 x LED37S/840 PSD (which are 1200mm x 200mm)
The distance between the main duct and the ceiling is less then 40mm. Furthermore in the model the ceiling is only 100mm thick (no structure has been designed). The duct should be position higher. Is it possible?  Alex Is the position of the openings for lights important for the ducts positioning?  Alex

6. Ceiling lowering vs. ceiling replacement
One possible option up to now was to lower the ceiling of the SR1 extended cleanroom by 1m
In the existing portion of the cleanroom, the current ceiling is around 4.1 m high. Therefore, lowering by 1m means to have a final height in the existing portion of about 3m
For the cleanroom extension the ceiling is supposed to be at the same height of the existing part, but the dimensions of the new door over the rails is 3.5m in height (due to the Ø2.2m of the ITk cylindrical envelope sitting on the wheeled cradle). This makes the door higher than the ceiling  not acceptable
Few points to be considered:
1) Lowering the ceiling less than 1m in the existing portion is not advisable (access problems, working/cabling conditions, etc.)
2) Having a final version of the cradle, is not for the moment
3) 3m seems too low considering the dimensions of the ITk cylindrical envelope

7. Ceiling lowering vs. ceiling replacement
A possible solution is to design the cradle to be adjustable in height or to be able to rotate the ITk around its axis, but this would add more constraints. Is it acceptable? Another possible solution could be to lower the existing ceiling by 1m, keeping higher the extension ceiling. This will increase the inner air volume, will decrease the room for ducts and will cause the need of a vertical junction between the two ceilings. Is it acceptable? Instead of lowering the ceiling in the existing portion, the “best” solution seems to be to remove the current ceiling and replace it with the new one.
Pros:
Avoid reducing drastically the height of the building. A small reduction (around 300mm) will be needed in order to build the ceiling below the metallic structure
Possibility to have one single ceiling both in the existing portion and in the extension
Easier and more comfortable to work on the ceiling (no gap between the two ceilings)
No need to reinforce the current ceiling for working on it (dangerous to step on the current ceiling as it is)
Avoid trap doors (access can be done from outside)  cost reduction
Cons:
Smaller reduction of fresh air volume needed (anyway if the lowering option would have been discarded the fresh air would have been the same)
Costs increase for dismounting the existing ceiling, lights, etc. (no major costs are foreseen)
Possible needs of temporary protection for dust and dirt during the cutting of the existing panels (radiation lab and test area will keep anyway the existing ceiling)
Work on the ducts must wait the end of the internal envelope installation, which, according to the current schedule, should be around April 2018 (Is it a big problem?)

8. Various updates
On 03/08/2017 Piotr removed the C6F14 manifold located on the wall. A stop in the cooling services was needed. Piotr informed all the users and agreed with them the intervention. The operation was successfully completed and everything went back to normal after the intervention.

9. Various open points
4 openings (one at each corner) have been requested (by Thierry on 30/05/2017) on the sandwich panels of the walls in order to install and access the grounding loop. On 06/07/2017 Thierry specified that: the openings shall be at least 400mm x 150mm and positioned at least at 300mm from the floor, but the exact positions on the walls are still unknown (see next slide for proposal by TC)  Thierry
Alex got a comment from Mauro Nonis regarding the possible contamination risk in having an overpressure of +15 Pa in the radiation lab. Users (Jens and Susanne) replied on 06/07/2017 that the risk of contamination due to airborne particles currently does not exist, since the sources are sealed and an unluckily breakdown of irradiated objects could cause a very localized problem. Anyway, in the future, there might be the need to bring and work on some irradiated parts. Ludo is checking this point with Mauro.
Is it needed a formal approval from RP?  Ludo

10. Proposal for openings on the walls for grounding
T.B.D.

11. Proposal for openings to access the ceiling
T.B.D.

12. Proposal for cable trays and enclosures
T.B.D.

13. Current status of the project
SMB completed the concrete slab for extension. Now they are working on the ramp in front of the big door.
The access through that door is still closed. The door will be inaccessible until end of August 2018 ? (T.B.C. by Pierre)
The emergency door beside the main one, during this period must be used only in case of emergency
If some temporary access is needed, please contact Pierre Cardon (167840)

14. Updated Schedule Jun 2017: SMB started civil engineering works
Jul 2017: SMB prepare the foundations
Aug 2017: SMB install the concrete slab and the ramp  in progress
Sep 2017: EN-EL and IT-CS should remove the cables running on the wall to be dismounted (in between the wall and the building wall)
Oct 2017: SMB should install the mechanical steel structure and remove the external wall of the building
Nov 2017: SMB should install the temporary partition wall (1m from existing wall) and remove the internal wall of the current cleanroom. CV should start removing the existing components (stop the ventilation for 6 months)
Dec 2017: target for ending SMB works (end of the month)
Jan 2018: TC should start installing the internal clean room extension
Mar 2018: EN-CV should start working on the HVAC system installation. EN-EL, IT-CS should also start working
Apr 2018: target for ending clean room extension installation and commissioning
May 2018: target for ending ducts and HVAC system. IT-CS and BE-ICS should complete their commissioning
Jun 2018: EN-CV should complete the commissioning
Jul 2018: target for commissioning the SR1 clean room extension

15. Things to be decided Number and position of Ethernet inputs: 25? (tbc)
Total expected power consumption (Pixel/Strip integration, testing, standard activities): (tbc)
Amount of cables and services needed by the user (total cross section, distribution, feasibility of reusing part of the existing cables, etc.)  tbc
Path for cables and services (below fake floor and along pillars or cable trays etc.)  tbc (in September)

16. BACK UP SLIDES

17. SR1 cleanroom extension – WBS (Work Breakdown Structure)
ATLAS
Requirements
ATLAS ITk-IBL
Project
Management
ATLAS TC
Procurement
WP1: Civil Engineering
CERN: SMB
WP2: Cooling
and Ventilation
CERN: EN-CV
WP3: Electrical Installations
CERN: EN-EL
WP4: Cleanroom Internal Envelope
WP5: IT
CERN: IT-CS
WP6: Fire Detection
CERN: BE-ICS
WP7: Rails
CERN: EN-HE-HM
Commissioning
Safety
CERN: HSE-SEE

18. SR1 cleanroom extension – OBS (Organizational Breakdown Structure)
Project board: Ludovico Pontecorvo (163664) – ATLAS Technical Coordinator
Siegfried Wenig (163865) – ATLAS ExGlimos
Marco Ciapetti (169451) – Project Manager
Safety: Valentin Algoet (167993) – HSE-SEE representative John Robert Etheridge (164647) – P1 Safety Coordinator
WP1: Civil Engineering (SMB-SE)  Pierre Cardon (167840)
WP2: Cooling and Ventilation (EN-CV)  Alexandre Joel Broche (166078)
WP3: Electrical Installations (EN-EL)  Thierry Charvet (162352)
WP4: Cleanroom Internal Envelope (EP-ADO)  Marco Ciapetti (169451)
WP5: IT (IT-CS)  Leszek Borakiewicz (169195)
WP6: Fire Detection (BE-ICS)  Denis Raffourt (163219)
WP7: Rails (EN-HE-HM)  Roberto Rinaldesi (166379)
Users: Kendall Reeves (162808) on behalf of ATLAS ITk Didier Ferrere (160515) on behalf of ATLAS IBL

19. SR1 cleanroom extension – PBS (Product Breakdown Structure)
WP1: Civil Engineering (SMB-SE)  Pierre Cardon (167840)
Design + permits + Study
Excavation
Networks modification
Ground flattering + Foundations
Concrete slab installation
Rails trenches filling with concrete
Material procurement for steel structure
Mechanical steel structure
Walls and ceiling extension
Temp protection wall installation
Removal of the existing ext wall
Removal of the existing int wall
Flooring (ESD)
Finishing and Commissioning
WP2: Cooling and Ventilation (EN-CV)  Alexandre Joel Broche (166078)
Design
Existing components removal
Electrical cubicles/cabinets removal
Smoke extractor and ducts removal
Material procurement
New components installation
Electrical cubicles/cabinets installation
Ducts installation
Commissioning
WP3: Electrical Installations (EN-EL)  Thierry Charvet (162352)
Current cables removal
New switchboard construction
New switchboard installation
Cables Installation
Lights/Switches/Sockets installation
WP4: Cleanroom Internal Envelope (EP-ADO)  Marco Ciapetti (169451)
Market Survey + Invitation to Tender
Internal partitioning walls/doors installation
Mechanical structure, installation
Walls/ceiling/door installation
R-C04-B ceiling installation (lowering)
Cable trays/pillars covering
WP5: IT (IT-CS)  Leszek Borakiewicz (169195)
Cables installation
Routers/Sockets installation
WP6: Fire Detection (BE-ICS)  Denis Raffourt (163219)
Services installation
Detectors installation
WP7: Rails (EN-HE-HM)  Roberto Rinaldesi (166379)
Rails installation

20. Safety coordinator
John Robert Etheridge (164647) is the safety coordinator of P1. He will help TC to ensure that all the works will be done according to the CERN safety rules. For all WPs, a VIC shall be prepared after the design phase and presented by the responsible of each WP to the safety coordinator before starting the works. John is invited to this follow-up meeting so that he can be informed about on-going activities and can control that all foreseen/incoming activities are properly planned from the safety point of view.

21. Various solved / agreed points
Susanne re-checked (04/07/2017) and the foreseen future consumption is around 6 kW. Calculation was updated by Alex.
Pierre presented the SMB VIC to the safety coordinator on 12/07/2017.
During the HVAC stop, EN-CV will supply the temporary AHU Trane TSH060 (ordered from November 2017 to June 2018 to be sure to cover the whole period). The device will be stored outside with the duct(s) inside the new room R-C04-A. The R-C014 (rad lab) will be cooled by opening the lateral door, as agreed before. Additional costs will be charged to TC.

22. Electrical matters
Current 160A switchboard will be replaced by a 250A switchboard (maximum possible considering actual electrical consumption, future general needs and current transformer capacity).
The order for the new switchboard has been sent on 07/07/2017. Total cost is ≈35kCHF
According to Thierry calculations (see of 30/06/0217) a maximum of six 380V-32A sockets can be used simultaneously in exceptional cases:
4 devices running on 380V-32A sockets can work at the same time with no constraints
It should be possible to add 2 more temporary
Grounding works are completed

23. Schedule for ITk Pixel tests in SR1
April-August 2017: test of prototype with one full cooling line ~375 W in SR1 (August 2017)
September 2017: commissioning of system setup in SR1 (power needed, few days of outage can be discussed, CO2 partially needed for commissioning)
October-November 2017: assembly of prototype in SR1 (power and CO2 needed, days of outage can be discussed)
November 2017-November 2018: systematic evaluation of demonstrator in SR1, dedicated test bench for comparison of DAQ, readouts, powering, cooling (power and CO2 needed). Short periods of outage can be discussed: a possible solution is to run power extension cables from the nearest building, if needed(tbc)

24. Schedule for ITk Strips tests in SR1
April-September 2017: Testing of pre and post irradiated modules in SR1 + Testing cold (-35°C) with chiller
September-December 2017: assembly of parts for system test setup for a Strip Stave in SR1
January-November 2018: Commissioning of system tests of a stave (CO2 cooling, interlock, DCS, DAQ, cabling)
As agreed with Susanne and Jens, short periods of outage can be discussed

25. New requirements DRAFT cost estimation
SMB
subject
Technical impact
Extra cost estimates
New opening (WIDTH = 2.8m, HEIGHT = 3.5m)
Update of the steel structure design (drawing + calculation note)
Supply and installation of the “door”
2000CHF
15000CHF
2 new rails in the concrete slab
Update of the concrete structure design (drawing + calculation note)
Supply and installation of the rails
1500CHF
30000CHF € (≈20000CHF)
New exterior concrete slab (8m*3m)
concrete structure design (drawing + calculation note)
Civil engineering works
1000CHF
9600CHF
≈50 kCHF
NOTE: A new work package have been created (WP7: “rails”). It is managed by Roberto Rinaldesi (EN-HE) and it will take in account the supply and installation of the rails. WP1 “civil engineering” (SMB) will managed the 2 necessary trenches 400mm x 70mm and pouring of non-shrink grout

26. Ceiling Lowering
A rough cost estimate has been asked to ER2i and STIC (ER2i did not do a survey, while STIC came and studied the situation):
ER2i
STIC
Assumptions:
no intervention is foreseen on electricity (drillings and cuttings are included, but not the equipment, lightings…)
No dismantling of the existing ceiling
CERN shall remove first cable trays
Rough cost estimation:
Handling structure: 32 K€
PU ceiling, 80 mm thickness: 48 k€
Cuttings / drillings: 6 k€
Survey, lifting, project management: 10 k€
Assumptions:
Lighting is quoted separately
Ceiling will have a rigid structure that allows one person to work on it
No dismantling of the existing ceiling
CERN shall remove first cable trays
Rough cost estimation:
Handling + structure + sandwich panels + scaffolding: 63 K€
Lighting embedded in the ceiling (60 units LED): 25 k€
96 k€
88 k€
TC will add the ceiling lowering of the existing part (not the radiation lab) as an option in the TS for the internal envelope

27. Electrical study
Thierry completed the preliminary study for WP3: Regarding lighting, he propose to add 36 of this LED lights:
The lights will be installed below the ceiling (as they are now) and not embedded into the ceiling.
The cost estimation is: ≈10 kCHF (cabling excluded)
In case the ceiling is lowered, new lights will be needed. The additional estimation is done for:
Disconnection and removing existing lights
Buying new lights (33 units)
Connexion and fixing new lights (using existing cables)
≈10 kCHF
Regarding sockets boxes, the job will be done in two steps: 1) disconnecting cables and removing existing boxes; 2) installation of boxes on metal pillars and connection of cables (after the external wall will be dismounted)  1 or 2 hours of power cuts will occur

28. Position of power boxes in SR1 cleanroom
ACCEPTED

29. Existing socket boxes
Currently, there are several sockets boxes on the external wall in existing room.
Position 1 :
3 boxes with 400V - 4x16A socket (x2).
2 boxes with 230V – 2x10A (CH) socket (x4). One on UPS network.
1 box with 230V – 2x16A (CE) socket (x2).
Position 2 :
No need to reuse these, but in case they can be added on the pillars (opposite to the requested boxes)

30. Taken decisions The clean room will be ISO 8 according to ISO 14644-1
All cable trays shall be covered
WP3 (EN/EL) will take care of all the cable trays related to main electrical services, while WP4 (TC) will take care of the cable trays for electrical controls. Users shall specify their needs ASAP
ESD precaution will be obtained with mats, people grounding and NO new antistatic floor is foreseen in the radiation lab

31. Taken decisions
A power outage of 1 or 2 days will take place during TS2 (currently scheduled for mid September 2017) in order to replace the electrical switchboard
The SR1 radiation lab can be used by ITk tasks, but needs to be cleared with 1-2 months notice in case of TC/detector needs during EYETS

32. Taken decisions
13 power boxes will be installed by EN/EL. One power box at each of the 4 pillars between existing room and extension (the central pillar will be removed) and one power box every 3-4 m on the wall (evenly distributed). Each power box shall have at least:
4x 220V - 16A (CH standard)
1x 400V - 32A
Local differential switch for each sockets group (one for 4 sockets 230V-16A  and one for socket 400V-32A)
2 existing sockets boxes will be kept on UPS network (in the pillars area). No additional sockets on UPS network are required
Existing UPS network details: 100kVA lasting approx 10 minutes at 80kW (see from Thierry sent on 28/06/2017)
Lighting will provide the same illumination of the actual clean room (≈400 lux)
Type of lights: LED (to minimize the maintenance)

33. Taken decisions
EN-CV will switch off the air conditioning and ventilation for at least 6 months (schedule should meet SMB’s one)
EN-EL will switch off the electricity for small periods of time (schedule should meet global schedule and users’ schedule)
Overpressure targets:
Overpressure of extended clean room (R-C04-B) is ≥15 Pa
Overpressure of radiation lab (R-C14) is ≥15 Pa
No overpressure in the test zone (R-C04-A), changing room (R-202), other areas
Overpressures of R-C04-B and R-C14 can be manually regulated in order to create slight overpressure of the clean room over the radiation lab if needed

34. Taken decisions
The proposal of extending the changing room R-202 by ≈1m has been accepted. The drawings have been modified
To be removed
≈1 m

35. Taken decisions Eric agreed on 16/05/2017
Two rails are required to drive the coaxial installation of the ITk.
These rails will be:
2 different rails, one flat and the other with a V shape (see drawings from Roberto)
Parallel to the extension long side (centered wrt the opening)
36m long and 2m apart ending 7.5m outside the building
Embedded into the floor
No particular tolerances have been added (default tolerances are considered)
There will be a 3m x 8m concrete slab that will host the outside rails and will create a flat area (currently there is a slope) at the same level of the inner floor
SMB shall update the design of the concrete slab
Eric agreed
on 16/05/2017

36. Taken decisions Eric agreed on 16/05/2017
An additional door has been required on the North-East-short-side wall of the extension, to ease the extraction of the ITk assembly.
SMB will design an opening (2.8m wide and 3.5m high) centered in the N-E short side of the extension .
This opening will be closed with a removable wall (not with an external door). This removable wall can be removed using a crane.
The cleanroom will have a correspondent opening of the same dimensions and will present either an internal double door or another system to guarantee the sealing.
Eric agreed
on 16/05/2017

37. SMB matters
SMB started the earthworks and networks deviation. This task will continue until the end of July.
The problem of the discovered unknown network is solved:
It was an old HV network, not any more under power. It has been removed
This cause 3 days of delay, but not on the critical path
The additional costs have been covered by the contingency
Drawing regarding the concrete are complete and the approval process has been started. You can find them on EDMS here
ECR have been approved on EDMS for the new external concrete slab (here) and for the new lateral opening (here)

38. Cooling and Ventilation stop
The stop of CV system for at least 6 month announced by EN-CV and due to the replacement of the AHU and upgrade of the CV system will cause major problems in the ID test area
Didier, Anatoli and Dave agree that during such a long stop of the air conditioning, the test cannot be performed
A solution has been discussed among Didier, Alex and myself. It has been presented to all involved people and it has been agreed (see next slide)

39. Temporary solution for R-C04-A during CV stop
The main points which have been agreed from both parties are listed below:
EN-CV will switch off at first only the portion of the system close to the demolished wall (where they have to work), keeping on the system on the other side of the cleanroom (test area and radiation lab). This will lower at the minimum the amount of time people working in SR1 are affected from the CV stop.
To grant fresh air (especially when the R-C04-A will be divided from R-C04-B), the upper door above the emergency door of R-C04-A can be kept open (see attached file).
Being an internal building (building into a building), the SR1 cleanroom should not have huge problems regarding the temperature. Especially in winter time and considering the power dissipated into the test area, the temperature should not drop drastically. Anyway, just to be sure to have always acceptable working conditions, one or two mobile inverter air conditioner can be provided (the cost estimate is roughly around 3-4 kCHF each) so that also people in the radiation lab can adjust the temperature in their working area.
Alexandre will add these points (even if they are related to a temporary solution) into the “Upgrade of SR1 clean room” document prepared by him and circulated for approval.

40. Anti-static floor
The current cleanroom (R-C04-A and R-C04-B) has an antistatic (ESD) fake floor, while the radiation lab (R-C14) has not. Tests have been performed by Sylvain Kaufmann (TE-MPE-EM ) on 24/05/2017 in the presence of Marco Ciapetti and Susanne Kuehn. The results are positive:
Even though the resistance to ground vary from tile to tile, it was always 108 ≤ R ≤ 109 Ω
Variation is caused by the cleanliness/dirtiness of the floor: in the same spot, it has been measured before cleaning ≤ R ≤ 108 Ω, while after cleaning (with a humid tissue) 107 ≤ R ≤ Ω. Measures were in some cleaner spots even R ≤ 107 Ω (best result that the used instrument can measure). On top of the ESD pads, we found similar results (even worse than the floor itself, when the pad was not clean).
BEFORE CLEANING
AFTER CLEANING
SAME SPOT
DIRTY SPOT
ON THE PAD
DIRTY SPOT
CLEAN SPOT

41. Bldg re-connection
Lukasz, Damien and Piotr are working on the re-connection of the CO2 barrack Piotr installed the protection wall for the PP2 Pixel rack asked by Didier Damien opened the hole in the radiation lab. This was done in two steps because some cables where passing behind the first hole location.