1. HWCR, AT-ACR-IN, 12 May 2005 1 Cryogenic Instrumentation & Controls Commissioning Hardware Commissioning Review Juan CASAS

2. HWCR, AT-ACR-IN, 12 May 2005 2 QRL versus LHC QRLLHC RIO Specs for UNICOSDONEIn Preparation Controls Specs for UNICOSUnder RevisionTime Critical Hardware for ActuatorsIndustrial TypeIdem; Commissioned for QRL? Tunnel HardwareIndustrial Type RadTol: Critical Procurement Schedule LSS8L: Internal production Learning Contingency (50%)Integrated in planningNOT Accepted Instrumentation TasksNo Repairs, Reporting OnlyFull Commissioning FieldbusProfibusProfibus & WorldFIP Sectors8-1 and part of 7-8 All Sectors QRL tasks not included in LHC tasks => extra time…

3. HWCR, AT-ACR-IN, 12 May 2005 3 QRL & LHC Schedules QRL > 18.5 wks LHC – 41 wks

4. HWCR, AT-ACR-IN, 12 May 2005 4 QRL Actual Schedule Note that AL Instrumentation Activity not into ACR-IN tasks

5. HWCR, AT-ACR-IN, 12 May 2005 5 LHC Pre-requisites General Services UPS Tunnel access required during ALL commissioning tasks Safe access “paserelle” to tunnel-wall equipment Controls Networks: –Ethernet PLC – Gateway – Data Server communication Tunnel WiFi access (Technical & NICE) –Profibus & WorldFIP Optical fiber-Copper couplers Gateways Hardware (Data server, SCADA, PLCs, Gateways, etc) Software for PLCs, Gateways and SCADA Logistics MTF –non-conformities referenced and retrievable –Instrument & Host equipment identification (functional and physical) data Interpolation data generator

6. HWCR, AT-ACR-IN, 12 May 2005 6 LHC Resources & Tasks (per sector) Generic Tools Transport Vehicle Electrician Tools Sensor/actuator simulation devices Ladder Computer with network access Generic Tasks Track test data on MTF Declare & check in MTF for non conformities Crate Connection (CIW CC) Per sector: avg 125 Crates, 10 cables/crate Crew: 2 Technicians Tasks: Cables Harness Crate Positioning Electrical connection at both ends Duration: 10 weeks => 2 crates per working day

7. HWCR, AT-ACR-IN, 12 May 2005 7 LHC Resources & Tasks (per sector) RadTol Crate stand-alone commissioning (CIW SU) Per sector: avg 125 Crates, 10 cables/crate, 1900 channels Crew: 2 x (1 instrumentation engineer + 1 Technician) Tasks: EMC Cables Test Check Pressure sensors and hydraulic connections Functional Tests on all channels Repair all conforming channels Commission front-end electronics Check Crate Network Configuration Parameters Duration: 2 x 9 weeks => 2 crates per working day WorldFIP Initialization (CIW CE) Per sector: avg 125 Crates, 2 nodes per crate Crew: 1 fieldbus engineer + 1 Technician + AB-CO Support Tasks: Connect Crate onto fieldbus network Verify Global WorldFIP availabiity Check Gateway availability Duration: 8 weeks => 3 crates per working day

8. HWCR, AT-ACR-IN, 12 May 2005 8 LHC Resources & Tasks (per sector) Controls at Warm (CIW CS) Per sector: 1900 Channels, Crew: 2 x (1 Control Engineer + 1 Technician) Tasks: Channel Coherence checks SCADA to field: –Actuators: Intelligent Valves, ON/OFF Valves & Heaters –Sensors: Pressure, Temperature, Level, Position, etc. Synoptic conformance check Check that physical readout is coherent with ambient conditions Simulate/check logic seuqnces, PIDs, Linearization Duration: 2 x 16 weeks

9. HWCR, AT-ACR-IN, 12 May 2005 9 LHC Resources & Tasks (per sector) Controls during Cool-Down (CIC CT) Per sector: 1900 Channels, Crew: 2 Control Engineer + 1 Technician Tasks: Check Sensor evolution Diagnostics of non conformities left from “Controls @ Warm” Set appropriate control loop parameters Duration: 10 weeks Controls during Nominal (CIC OP) Per sector: 1900 Channels, Crew: 1 Control Engineer + 1 Technician Tasks: Diagnostics of non conformities left from “Controls @ Cool-Down” Set appropriate control loop parameters Duration: 11 weeks Surface Support Database/Quality Assurance engineer for Thermometer, Parameters (Cabling, configuration, naming, location), sensor calibration (pressure) Instrumentation Engineer to assess and provide support for field teams

10. HWCR, AT-ACR-IN, 12 May 2005 10 LHC Resources & Tasks (per sector)

11. HWCR, AT-ACR-IN, 12 May 2005 11 Shortcomings Infrastructure Ethernet connection very cumbersome: –individual modem VDSL + base WIFI => additional jumping onto equipment –Several teams working in adjacent cells Please provide WIFI as a standard infrastructure inside the tunnel during commissioning –Access to BOTH technical and NICE networks Controls Reliability of controls: –Communication Problems hamper operation –PVSS SCADA to be improved –Too many software versions Profibus: Schneider fieldbus configuration tool is far from user friendly Logistics MTF: –Non-conformities instrument retrieval interface for instrumentation required but non-existent –inner triplet data status? –Naming uniqueness MTF interface required for tunnel reporting IS MTF ADEQUATE FOR INSTRUMENTATION COMMISSIONING TASKS Database/Quality Assurance Support shall be very responsive: –Close to end-user –For AT-ACR depends on a temporary unit of personnel (fellow) Automated Test Equipment development: –delayed continuously by on-site (SMI2, AL premises, etc) instrumentation support.

12. HWCR, AT-ACR-IN, 12 May 2005 12 Shortcomings: MTF data retrieval This quad does have: 1.Cold-mass thermometer 2.Electrical Heater 3.… How do I know that NC No 90 refers to an electrical Heater?

13. HWCR, AT-ACR-IN, 12 May 2005 13 Shortcomings: MTF data retrieval

14. HWCR, AT-ACR-IN, 12 May 2005 14 Naming Conventions: How it works Physical Equipment Serial number MTF Slot name + Tag name Serial number LHC Reference DB Slot name Serial number The slot name + tag name used by the Controls/Operation must coincide with the slot name + tag name registered in LHC Reference DB and in MTF. Project engineer Tag name Controls/ Operation Slot name + Tag name

15. HWCR, AT-ACR-IN, 12 May 2005 15 All machine components MUST be registered in MTF All instrumentation MUST be assigned to machine assemblies in MTF Naming Conventions: How is it used? (1) The tag name (e.g. TT821) MUST be included when the instrumentation is assigned to a machine assembly in MTF

16. HWCR, AT-ACR-IN, 12 May 2005 16 The slot names MUST be identical MQ.28Li MQ.29Li QRLAA.30Li MQ.27Li QRLAB.28Li MBC...MBA.29LiMBC...MBA.28Li MQ.28Li MQ.29Li QRLAA.29Li MQ.27Li QRLAB.27Li MBC...MBA.29LiMBC...MBA.28Li AT/ACR name (used by Controls/Operation) Official name (used by MTF) Naming Conventions: How is it used? (2)

17. HWCR, AT-ACR-IN, 12 May 2005 17 D4.6R7 Q5R7 QRLIA.2R7 Q6R7 QRLEA.6R7 D3.6R7 … …… DFBM.6R7 D4.6R7 Q5R7 QRLIA.6R7 Q6R7 QRLEA.6R7 D3.6R7 … …… DFBM.6R7 Naming Conventions: How is it used? (3) The slot names MUST be identical AT/ACR name (used by Controls/Operation) Official name (used by MTF)

18. HWCR, AT-ACR-IN, 12 May 2005 18 Naming Conventions: Summary QRLAA.30L8QRLAA.29L8 What??? QRLAA.29L8 is not on MTF!!!

19. HWCR, AT-ACR-IN, 12 May 2005 19 Major Shortcomings Missing Manpower Cryogenic commissioning consist of a set of specialized tasks: –Will there be a good match between professional qualifications & tasks? –Is training required? If YES: additional resources shall be already at CERN 3-6 month seem the strict minimum LHC schedule show activities in up to 3 sectors at the same time –1 team (warm commissioning) would then be missing ACR-IN tasks planning does not foresee support for external teams –Additional manpower autonomous from day 1; otherwise work can be significantly delayed Is it possible to consolidate critical know-how/ressources: Database/Quality Assurance support relies on temporary personnel Additional process control engineers is required Various No contingency allocation!

20. HWCR, AT-ACR-IN, 12 May 2005 20