1 Machine Checkout and Setup Periods Jan Uythoven Thanks to: O.Aberle, R.Bailey, F.Bordry,...
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Transcript of 1 Machine Checkout and Setup Periods Jan Uythoven Thanks to: O.Aberle, R.Bailey, F.Bordry,...
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Machine Checkout and Machine Checkout and Setup PeriodsSetup Periods
Jan Uythoven
Thanks to: O.Aberle, R.Bailey, F.Bordry, O.Brunner, L.Bottura, E.Carlier, P.Charrue, E.Ciapala, S.Claudet, R.Denz, D.Forkel-
Wirth, B.Goddard, M.Jimenez, R.Jones, M. Lamont, V. Mertens, P.Ninin, B.Puccio, S.Ramberger, F.Rodriguez
Mateos, R.Schmidt, L.Serio, B.Todd, M.Zerlauth
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 2
Machine Checkout: Machine Checkout: WHEN ?WHEN ?
Year 1: Following Hardware Commissioning Assume all equipment tests are done in the past 18 months Most of the system tests are done in the past 18 months
Subsequent years: Following Shutdown Work Assume most equipment tests are done
Machine Checkout First time machine complete cold and closed All systems running together from the control room
Before First Beam
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 3
Tasks - SummaryTasks - Summary Redo a subset of tests performed during the Hardware
Commissioning period Because some tests more than a year ago Because the final configuration of the system might be different,
especially the interface to other equipment If hardware commissioning period was squeezed in time, this will have
been at the cost of the system tests As a result: will need more time for the Machine Checkout
New Tests Additional system tests All systems together – machine wide, interdepedencies Machine completely closed, last access / final checks
Under the responsibility of the Operations Group Green light from DSO, info for INB
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 4
First beam
Phases of Machine Phases of Machine CheckoutCheckout
Hardware Commissioning Sectors 1-2 and 2-3 Cooldown of all
sectorsELQA tests Close
machine completely; Contr. Access
Complete Machine Cycle from CCCDSO tests
Tim
e
Equipment tests per 2 sectors:Interlocks,Power ConvertersRF, kickers, BDI,..
Machine Checkout phase I
Machine Checkout phase II
Machine Checkout phase III
Some phases in parallel
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 5
Phase IPhase I Infrastructure for the complete machine
Water, Ventilation, Power, Controls Network Radiation Protection (RAMSES)
Check response ionisation chambers Interface with other systems
UPS, AUG Cooldown of the complete machine
Sectors T up to 200 K: need 10 days for cooldown If T > 80 K: need to redo Electrical Quality Assurance tests
(ELQA), first time 3 weeks If T < 100 K: cooldown needs about 5 days
Up to about 5 weeks for sectors warmed up > 80 K. Need to start cooldown in parallel with Hardware Commissioning. Manpower.
When full inventory of He available?
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 6
Phase I, continuedPhase I, continuedAccess SystemAccess System
Close the complete machine Test of LHC Access Control System (LACS) Test of LHC Access Safety System (LASS)
New tasks – before only done per sector (during HC) New tasks: interface adjacent sectors, machine wide
Important Safety Element in point X must interface over the global machine and beam dump in point 6
Interface with Radiation Protection equipment: access veto Interface with HR data base, biometrical data Some equipment was not in final state during Hardware Commissioning tests Exercise procedures for ‘patrouille’, giving access, back from access, …
Start first with sectors needed for Machine Checkout equipment tests phase II
If necessary, time to sort out problems parallel to phase II programme
Ideally only controlled access from phase I onwards
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 7
Phase IIPhase II Per two sectors
Check interlocks: PIC, WIC, QPS See
Test all power converters, two sectors at a time
See
Simultaneously in other sectors Other equipment checks, see
Determines the pace of tests in Phase II
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 8
Phase II Phase II Interlock SystemsInterlock Systems
Before power converters can be tested, test interlock system Quench Protection System (QPS)
Visual check of equipment, half day per sector Automatic test procedure, 8 hours (same as monthly procedure): fires the
quench heaters without current in magnets Test interface to BIS -> check in phase III
Powering Interlock Controller (PIC) Takes information from the QPS Automated test procedures and visual control Needs about 8 hours for testing
Warm Interlock Controller (WIC) No automated procedures foreseen Some manual testing and visual control: 8 hours
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 9
Phase IIPhase IIPower ConvertersPower Converters
Followed by testing of Power Converters two sectors at a time Run all converters to full power, perform tests at full power Calibration already done during Hardware Commissioning 12 h continuous running at full power Need about half a week per two sectors
Proceed around the ring
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 10
Phase IIPhase IIControl SystemControl System
Control System Communication Mechanisms Field buses operational machine wide. All elements to be
checked: need about 8 days Already start during phase I
FrontEnds, BackEnds and general services Should have been made available during the Hardware
Commissioning period sector by sector and left running Timing generation and distribution
6- 8 days for the first year Databases access
1 day, at least
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 11
Phase IIPhase IIControl System, ctd.Control System, ctd.
Application software Tested continuously during the last months / years Specific projects need testing
Interlocks, realtime feedback, logging, postmortem, safe beam flag etc.
Estimate 10 days for test …..??? Final tests when complete machine available:
See phase III
Message from many (CO, OP and BDI):
DRY RUNS, dry runs & DRY RUNS
Quoting TI 8 experience
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 12
Other Equipment tests:Other Equipment tests:RFRF
Basic work of testing cavities, cryo, LLRF and control during hardware commissioning period
Number of tests which would clearly accelerate RF operations and improve performance:
- Reliability of RF system: power & cryogenics- Software and diagnostics developments / improvements- New conditioning hardware for subsequent years- RF noise and ripple measurements- Customisation of klystrons (positioning of resonance)- Linearisation of klystron response- Effect of detuning and coupler position on loop stability- Optimisation of loops for higher intensity- Fine adjustment of trip level for fast transients- Setting-up of the longitudinal damper- Preparation of feed-forward and 1-T feedback
Ed’s Wish List
RF will use the time made available
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 13
Other Equipment tests: Other Equipment tests: Warm MagnetsWarm Magnets
Visual inspection No spanners lying around… All protection covers in place
Cooling system o.k. All valves open No visible leaks
Expect 1 day work per sector, 8 days total
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 14
Other Equipment Tests:Other Equipment Tests:VacuumVacuum
Assume machine already cold & closed
Check interlocks Sector valves Connection to BIC
Not to forget Vacuum interlocks on transfer lines: 2 days
3 days per octant2 teams in parallel 12 days
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 15
Other Equipment tests:Other Equipment tests: Collimators and Beam AbsorbersCollimators and Beam Absorbers
Redo some of the hardware commissioning tests in local & remote Motor control, position switches Temperature sensors, cooling system
Interfaces with more intelligent software from the CCC to manage settings Not defined yet, should include BIC
Couple of days In parallel with other tests
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 16
Other Equipment tests: Other Equipment tests: Pulsed MagnetsPulsed Magnets
Beam dump kickers (MKD and MKB point 6) Injection kickers (MKI points 2 and 8) Tune and Aperture kickers (MKQA point 4) For all of them
Verification of local interlocks Pulse at full power – MKI some re-conditioning time Interface with many systems across the machine
RF point 4 (rev. freq.) Energy from dipoles either side point 6 Timing, controls, machine protection, post mortem OASIS, logging Cross connections between MKI and MKD
Couple of days per system
Couple of WEEKS
Maximum in HC, start early, profit from RELIABILITY RUN
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 17
Other Equipment tests: Other Equipment tests: BDIBDI
Large distributed systems: BPMs & BLMs Hardware fully checked during HC, but re-check Main tasks: software and logging, links to other users
Interlocked Systems – check interface BIC (phase III) BLM, BCT point 4, BPMs point 6, LDM (Longitudinal Density Monitor)
Diagnostics systems – no special requirements Q and Q’ measurements, Schottky systems, Sychrotron radiation
monitors, OTR screens, Wire scanners
Experience has shown that BDI ALWAYS wants to have another access
CONTROL SYSTEM DRY RUNS, distributed over about
2 months, so start BEFORE the machine checkout
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 18
Phase IIIPhase III Status after Phase I & II
All equipment and systems (re-)tested, sector by sector Individual interlocks tested Controlled access
Phase III Machine wide tests from the CCC Go through complete machine cycles without beam Accent will be on control system and application software Interleaved with final tests of access system and green light by DSO In principle no access should be necessary any more Control System Tests: Build on experience !
To be tested throughout the yearS with the maximum number of ‘dry runs’ TI 8 tests with beam Hardware Commissioning of all sectors including system tests Sector test with beam
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 19
Phase IIIPhase IIIComplete Machine Cycle Complete Machine Cycle
Without BeamWithout Beam Initial machine cycle (45 minutes) to get to initial field conditions
No further tests possible – real magnetic field to be found out with beam Generate functions for the power converters Download all functions to power converters – synchronous ramping of all
power converters including energy ramping of beam dumping system Settings management, trimming of functions
Machine wide timing of the systems, pre-pulses etc. Timing (slow and fast), OASIS to set timing of kickers Interface with RF, injection kickers, beam dump kickers, machine protection system
Applications – communication with all equipment All fixed displays, video, trajectory and orbit correction Feedback applications: trajectory, tune, chromaticity, transverse, longitudinal Logging of all parameters during the cycle Vacuum displays, alarm screens, radiation monitoring
Interface with the Beam Interlock System Safe beam flag depending on energy Post mortem after beam dump
Some kind of sequencer to automate tasks (LHCexec)
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 20
Phase III, continuedPhase III, continued
Now obligatory to have machine completely closed If search broken during phase II: Complete patrouille with several teams:
2 days Re-test complete access system before DSO test: 2 x 12 hours
Machine protection system has probably been touched upon during phase II Followed by Beam Interlock System (BIS) tests (or BIC)
Need “Green Light” from all systems – towards the end of test period 16 different users, 150 ‘user boxes’
Every box needs to receive an interlock, provoked by the equipment connected to it. Check 4 x dump request per equipment.
Estimate 3 x 8 hours to test – 2 days Rubber stamping of systems by DSO – data for INB
Need about 1 day, if everything goes fine Rubber stamping by ‘Mr. Interlock’
Need formal test procedures and acceptance criteria
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 21
Time RequiredTime Required
Phase I: 1 week minimum Cooldown and closing machine
Phase II: 3 weeks minimum Interlocks, equipment &
system tests Phase III: 2 weeks minimum
Complete cycles without beam Final test access system and BIS DSO tests
Minimum of 6 weeks on planning!
Partially parallel with hardware commissioning
Equipment setup with beam, see
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 22
Equipment Tests With Equipment Tests With BeamBeam
BDI Calibration BPMS, BCTs Set-up of tune and chromaticity measurements
RF Low level control (typically 3 weeks) Phasing Feed back
Control system Logging beam data, post mortem Steering – feedback
Machine protection tests Check interlocks of the system Safe beam flag
Beam Dumping System Beam dump to be set up at the different energies Verification of post mortem, logging and analysis
Cryogenics with significant beam load
Continuously during the first
weeks / months of operation
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 23
Not to underestimate:Not to underestimate:Transfer LinesTransfer Lines
TI 8 will need recommissioning Tested before
With beam up to TI 8 TED end 2004, Not tested yet: last 100 m + collimators Sector test end 2006
But will need to be recommissioned before first beam TI 2: never fully commissioned before
Will probably only be ready for commissioning at about the same time as the last LHC sector (transport of all LHC magnets through the TI 2 tunnel)
Could be done in parallel with hardware commissioning of the last sector: preferred solution but impact on HC schedule
Other option is to do this in parallel with ring 2 beam commissioning: higher risk in case of problems
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 24
Machine Checkout Machine Checkout For Subsequent YearsFor Subsequent Years
No Hardware Commissioning period but shutdown work to be finished
Outline stays the same with similar tests Some tests should be faster, because systems are better
known Foresee about 5 weeks minimum: longer than SPS / LEP
because systems are more complex, machine protection to be taken more seriously
Compare LEP and SPS:About 2 weeks of pre-closure and 2 weeks of real machine checkout when machine is
for OP 2 weeks of LEP / SPS ‘cold checkout’ similar
to 2 weeks of phase III of what is presented for
the LHC
Jan Uythoven, AB/BT
Chamonix@CERN 2005, Machine Checkout
Page 25
ConclusionsConclusions After the hardware commissioning period the machine is not
ready for beam Confirmed by experience from LEP & SPS, need a period to get ready for
beam under the responsibility of OP Even with all equipment groups 100 % ready on time (!): complete systems
tests remain and their interdependencies need to be verified At least 6 weeks of tests need to figure on the LHC planning for
Machine Checkout Start earlier for cooling down the sectors warmed up > 80 K for ELQA tests,
in parallel with hardware commissioning Start earlier for software and machine protection: DRY RUNS
to be planned and scheduled Many tasks in parallel: need careful planning and good coordination
Some running in of equipment with beam is also required BDI being the obvious candidate, but also RF, beam dumping system
Don’t forget the transfer lines Same applies every year after a shutdown