hwcr, at-acr-in, 12 may 2005 1 cryogenic instrumentation & controls commissioning hardware...

HWCR, AT-ACR-IN, 12 May 2005 1

Cryogenic Instrumentation & Controls Commissioning

Hardware Commissioning Review

Juan CASAS


QRL versus LHC

QRL LHC

RIO Specs for UNICOS DONE In Preparation

Controls Specs for UNICOS Under Revision Time Critical

Hardware for Actuators Industrial Type Idem; Commissioned for QRL?

Tunnel Hardware Industrial Type

RadTol:

Critical Procurement Schedule

LSS8L: Internal production

Learning Contingency (50%) Integrated in planning NOT Accepted

Instrumentation Tasks No Repairs, Reporting Only Full Commissioning

Fieldbus Profibus Profibus & WorldFIP

Sectors 8-1 and part of 7-8All Sectors

QRL tasks not included in LHC tasks => extra time…


QRL & LHC Schedules

QR

L >

18.

5 w

ks

LH

C –

41

wk

s


QRL Actual ScheduleNote that AL Instrumentation Activity not into ACR-IN tasks


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


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



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



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



Controls during Cool-Down (CIC CT)Per sector: 1900 Channels, Crew: 2 Control Engineer + 1 TechnicianTasks:•Check Sensor evolution•Diagnostics of non conformities left from “Controls @ Warm”•Set appropriate control loop parametersDuration: 10 weeksControls during Nominal (CIC OP)Per sector: 1900 Channels, Crew: 1 Control Engineer + 1 TechnicianTasks:•Diagnostics of non conformities left from “Controls @ Cool-Down”•Set appropriate control loop parametersDuration: 11 weeksSurface 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



teams/sector Eng Tek UNICOS1. CIW CC Crate Connection 10 1 22. CIW SU Crate Stand Alone Commissioning 10 2 2 23. CIW CE WorldFIP Initialization 8 1 1 14. CIW CS Controls at Warm 16 2 2 2 0.55. CIC CT Controls during Cool-Down 10 1 2 1 0.55. CIC OP Controls during Nominal 11 1 1 1 0.56. CIW SP on call 0.5 2

duration [week]

Professional Profile


Shortcomings•InfrastructureEthernet 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

•ControlsReliability 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•LogisticsMTF:

– Non-conformities instrument retrieval interface for instrumentation required but non-existent– inner triplet data status?– Naming uniqueness

MTF interface required for tunnel reportingIS MTF ADEQUATE FOR INSTRUMENTATION COMMISSIONING TASKSDatabase/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.


Shortcomings: MTF data retrieval

This quad does have:

1.Cold-mass t

hermometer

2.Electric

al Heater

3.…

How do I know that NC No 90 refers to

an electrical Heater?


Shortcomings: MTF data retrieval


Naming Conventions: How it works

PhysicalEquipment

Serial number

MTFSlot name + Tag name

Serial number

LHC Reference DBSlot 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 engineerTag name

Controls/Operation

Slot name + Tag name


• 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


• The slot names MUST be identical

MQ.28LiMQ.29Li

QRLAA.30Li

MQ.27Li

QRLAB.28Li

MBC...MBA.29Li MBC...MBA.28Li

MQ.28LiMQ.29Li

QRLAA.29Li

MQ.27Li

QRLAB.27Li

MBC...MBA.29Li MBC...MBA.28Li

AT/ACR name (used by Controls/Operation)

Official name (used by MTF)



D4.6R7Q5R7

QRLIA.2R7

Q6R7

QRLEA.6R7

D3.6R7

…

… …

DFBM.6R7

D4.6R7Q5R7

QRLIA.6R7

Q6R7

QRLEA.6R7

D3.6R7

…

… …

DFBM.6R7


• The slot names MUST be identical

AT/ACR name (used by Controls/Operation)

Official name (used by MTF)


Naming Conventions: Summary

QRLAA.30L8QRLAA.29L8

What??? QRLAA.29L8

is not on MTF!!!


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!

hwcr, at-acr-in, 12 may 2005 1 cryogenic instrumentation & controls commissioning hardware...

Documents

lhc resources tasks

control engineer

tasks hwcr

qrl lhc schedulesqrl

warm ciw csper sector

cooldown cic ctper sector

nominal cic opper sector

working dayhwcr