1. LS1 Cabling Progress LS1 Committee (LSC) – 21 June 2013 Daniel RICCI on behalf of the Cabling and Optical Fibre Section (EN-EL-CF) EDMS 1293605

2. Outline  The LS1 challenge for cabling  Monitoring of cabling activities & current performance  Facing the challenges: where do we stand?  Conclusions 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Cabling = copper (ctrl & DC) cables AND optical fibres 2 of 25

3. The LS1 challenge: the important numbers  37 main projects to carry on + day-by-day installation works (Some examples: R2E, LHC cabling campaigns, WCC hose consolidation, SPS campaigns & irradiated cables TS1+, new SPS fibre infrastructure (BI & others), PSS, LINAC4 & Meyrin campaigns, Computer Centre extension B513, LHC-Experiments fibre upgrade)  Overall estimated budget ~12 MCHF  ~1000 km of copper and optical cables being installed during LS1 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Moreover, activities also include  Managing CERN-wide optical fibre infrastructure (3,000 km installed optical cables)  Qualification, procurement and standardisation of cabling and optical fibre components (3.5 MCHF/year)  Managing cable park (4200 drums) and cable tray infrastructure (350 km)  Monitor cable aging and put in action the replacement campaigns (~1MCHF/machine point) 3 of 25

4. LS1 challenge: planning and resources  Very « dense » planning  Must cope with machine constraints/priorities  Delay on one activity can provoke « domino » effect  ~35 people in CF plus ~100 contractor people  Challenging supervision, training and knowledge transfer of new working method 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Example CF planning (LHC only) New cabling R2E Consolid. LS1 4 of 25

5. The cabling strategy (in a snapshot) see LSC presentation 15/3/2013 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Campaign Booster Campaign SPS-BA1 Campaign LHC-Point1 PROJ 1 Various works TE/ABT PROJ 2 LIU PROJ n Various works BE/BI 3) Optimize work organisation and resource distribution by working by geographical campaigns 5) Project progress and schedule monitoring 1) Enhanced section structure Simulation 2) Anticipate qualification and procurement of material 4) Boost training & project preparation with contractors + fibres… 5 of 25

6. LS1 progress monitoring  Method developed in agreement with the management request to be able to follow activity progress in ‘real-time’  Objectives  Help Project Managers to manage parallel projects and workload  Warn timely on activity delay or anticipation  Prevent resource bottlenecks  Be able to provide detailed status reporting (e.g. for each geographical campaign)  Be a test-bench for LS2  Costs  Dedicated FTEs to implement/following (1.5 FTEs for 2013)  Enforce new work style with contractors  More commitment (mainly time) requested from the Project Managers 21/6/13D. RICCI – CERN, LSC meeting – EDMS 12936056 of 25

7. Monitoring method  Challenge: CF field-activities are composite and of different nature, depending on the project  Project preparation, ordering of material, documentation and other administrative activities done by CF are not included 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Cabling campaign (core) Cable pulling (60%)Connectors (30%)Test (10%) ReworksDe-cabling Mechanics cable trays/racks variable Example of field-activities for copper cables Cabling campaign (core) Cable pulling (60%) Connectors (30%) Test (10%) Reworks De-cabling Reworks Cabling campaign (core) Cable pulling (50%) Connectors (40%) Test (10%) De-cabling Mechanics cable trays/racks timet1 t2 t3 7 of 25

8. Monitoring method  Heterogeneous monitoring tools apply  Quick implementation to be ready at the beginning of LS1 campaigns 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Cabling campaign (core) Cable pulling (60%)Connectors (30%)Test (10%) Reworks De-cabling (variable) Mechanics cable trays/racks (variable)  Weekly check from each concerned Project Managers  Very important to get as accurate feedback as possible  Weekly feedback from Contractors  Filling follow-up sheets (for detailed cross checking)  Drawback: contractors claiming this is not included in the contract and produce more work  Cable database (Cablothèque)  Filling data is part of the contractor’s obligations  Sotware data extraction (EDMS 1245912) 8 of 25

9. Monitoring: forecast  Forecast curve is extracted from scheduled activities (MS-project planning)  Detailed summary of all activities of CF section  Updated weekly 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 50% LS1 Beginning of LS1 End of LS1 9 of 25

10. Monitoring: forecast Simple rules  Each activity  Starting date  0%  Ending date  100%  Linear interpolation  Activity plans weekly updated  with the exception of the campaign already started 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360510 of 25

11. Monitoring: forecast 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Simple rules  Each activity  Starting date  0%  Ending date  100%  Linear interpolation  Activity plans weekly updated  with the exception of the campaign already started 11 of 25

12. Monitoring: progress  Progress curve is extracted from heterogeneous monitoring tools  Very large stream of information to process 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Cabling campaign (core) Cable pulling (60%)Connectors (30%)Test (10%) ReworksDe-cabling Mechanics cable trays/racks Phase 1Phase 2 Phase 3 Phase 4 Phase 5 Phase N Input from contractors Computed % of completion 12 of 25

13. Monitoring plots 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360513 of 25

14. Monitoring plots 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360514 of 25

15. Monitoring plots 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360515 of 25

16. Current performance Dashboard: http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/ 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360516 of 25

17. Monitoring method improvement Development of a new monitoring procedure based directly on GESMAR  All the information concerning the progress of the work is directly filled by contractors  Data extraction from GESMAR + elaboration/plotting by CF (to be included in GESMAR in the future)  First software implementation released  to be taken over now by our contractors 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Cabling campaign (core) Cable pulling (60%)Connectors (30%)Test (10%) Reworks De-cabling (variable) Mechanics cable trays/racks (variable) Integration into GESMAR Cablothèque (module of GESMAR) Many thanks to Serge Oliger! (EN-EL-CD) 17 of 25

18. Facing the challenges: where do we stand?  The technical challenges  CF working method is solid concerning cabling installations  Procurement of material: process well known, largely anticipated  not particular issues so far.  Recrudescence of thefts is worrisome. Consider securing more the sites!  Preparation/execution of projects and cabling campaigns is optimised  However, still very dependent on users timely feedback on final cabling requests!  Contract orders are issued timely and budget is in line with expectations  Coping with more resource needs than initially foreseen for safety and administrative tasks  Procurement and logistics for RP-related material (personal protection equipment, baskets, waste bags/bins, etc.)  Thousands of pieces  Find budget (~500 kCHF), manage purchases, deliveries, storage places, consumption levels, etc.  ALARA preparation and follow up  Lot of preparation: multiple iterations required with RP+contractors to achieve acceptable analysis  Workload on RSSOs is much more than estimated 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360518 of 25

19. Facing the challenges: where do we stand?  The additional staff  As foreseen, the section management/coordination levels are extremely loaded (even overloaded)  Huge efforts to transfer the know-how to the newcomers  Huge efforts to train the project managers (aim is “autonomy”)  Workload for support functions is demanding taking into account the available manpower and skills  support priority being given to installation activities (e.g. planning, QA, access & safety)  Little and time-limited contingency to recover from (unforeseen) resource loss 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Support Function Unit with Support Manager Structure by project cells 19 of 25 Many thanks to Fabio Formenti! (TE-HDO)

20.  Challenge for contractors  Four installation contracts currently operational:  C209 (electrical), C210 (electrical), C202 (fibres), B1213 (WCC)  Contractors are increasing their staff. However, they need to:  be able to constantly find qualified personnel and to train them  cope with CERN planning (peaks and valleys)  cope with radiation rules: no temporary contracts + replace/rotate the personnel achieving the max. allowed dose in radiation areas Facing the challenges: where do we stand? 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360520 of 25

21.  Challenge from contractors  One of the main electrical contractor is still struggling with their internal organisation and expertise level of their personnel  CERN has limited control on this (“delit de marchandage” always behind the corner!)  CF is currently working on contingency actions  Increasing at maximum the work supervision  Organizing more connector trainings/tests for the contractors  Working on a plan of actions in case of one contractor resigns (this will not be cost free…)  Strongly limited in “contract managers”  Even more overload on section coordination! Facing the challenges: where do we stand? 21/6/13D. RICCI – CERN, LSC meeting – EDMS 129360521 of 25

22. Facing the challenges: where do we stand?  Planning challenge  Going well so far. Thanks also to joint effort with planning coordinators  Managed so far to have certain “agility” to smooth the curve peaks  Keep high level of attention to avoid “domino” effects  Attention on how to cope with new (unforeseen) projects  Last contingency slot in April 2014 was already filled by R2E-cryo  In case of more new projects, set new activity list with priorities! 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Many thanks to Katy Foraz’s team! 22 of 25

23. An eye on the field 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 Flexwell (coax) cables in LHC P4 Replacement of WCC hoses in LHC P8-left 23 of 25

24. An eye on the field 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 CTRL cabling in the PSB Optical fibre cabling SPS & LHC 24 of 25

25. Conclusion  27 CF worksites currently ongoing CERN-wide with 4 main installation contractors  A tool for monitoring the LS1 progress for CF is working and available online  now developing a new version fully integrated in GESMAR  The working method is proved and work organisation is optimised around geographical campaigns. The forecast schedule is being kept so far  requires a lot of efforts and commitment from CF people!  Main challenges are: the overload of the section work-coordinators, the risks associated to the quality and (especially) the stability of the contractors  cabling activities are under control but still very sensitive to work plan perturbations  It is important to build-up contingency reserve (to cope with unforeseen circumstances) when activities are performed better than in the plan  attention to the new coming projects! Prioritize and schedule wisely…  The success of the LS1 cabling project is a real team effort!  Many thanks to all the CF colleagues which are making possible a smooth LS1! 21/6/13D. RICCI – CERN, LSC meeting – EDMS 1293605 …and thanks for everyone’s support! 25 of 25