Download - Powering tests

HC Review F. Rodriguez-Mateos

Powering testsPowering tests

The outcome of the work conducted The outcome of the work conducted within HCWG and many discussions within HCWG and many discussions among colleaguesamong colleagues


OutlineOutline

Starting conditions and pre-requisites Powering of the warm magnet circuits Powering of the superconducting circuits Estimates of the durations Controls applications and tools required to

start up How to improve and save time Special tests on the first sector Failure scenarios and implications Outlook: LSS L8

Appendix: the role of “Mr Circuit”


Starting conditions and pre-requisites (1/2)Starting conditions and pre-requisites (1/2)

Equipment All components of the circuit installed, in nominal

configuration and nominal operating conditions Infrastructure

Electrical distribution (including UPS) Cooling and ventilation

Safety AUG, fire detection, red telephones, evacuation

signals, oxygen deficiency detectors, emergency lighting, water-level detection

Alarm transmission and monitoring (CSAM) operational

Access Access is only authorized to personnel involved in

the tests Fencing and signals will be put in place


Starting conditions and pre-requisites (2/2)Starting conditions and pre-requisites (2/2)

Individual System Tests Completed and summary results registered in MTF

Tests of Power Converters in short-circuit Completed and summary results registered in MTF

Interlock tests Completed and summary results registered in MTF

Controls FCR installed and operational Equipment supervision applications operational Applications ready to run and monitor equipment Timing Logging, Alarms, Post-Mortem repositories

operational Post-Mortem tools to view data and perform

analysis operational


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connexion of power cablesto the power converters

IST:WELQA- Electrical Quality Assurance

warm magnet circuitswarm magnet circuits

HCA:WPCTLHCA:WPC1HCA:WPC2 and HCA:POLPowering of the electrical circuits one by one or in groups at low and nominal currents

HCA:HRCommissioning of all the warm electrical circuits of the machine Point powered in unison to nominal current during 24h

HCA:WIC-Individual System Tests of Powering Interlock Control

HCA:WST System tests from the CCC


powering of the warm magnet circuitspowering of the warm magnet circuits

HCA:WPCTL HCA:WPC1 HCA:WPC2

At zero current, verification of the interlock system At minimum current, verification that the PC is connected to the

right magnet Setting up of current loop Verification of thermal behaviors (8h heat run) Verification of communications through WorldFip

HCA:POL Verification of the correct current direction and approximate level

HCA:HR (24h run, with exception of the injection circuits) Performed per machine point At nominal current level

HCA:WST System tests performed from the CCC Every circuit has to be powered at least once with a nominal LHC

cycle Status after: Warm circuits ready for machine checkout


Interlock tests of a powering subsector prior and after connection of the power cables to the DFB leads

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300 K

1.9 K

90 K

Test of power converters connected to the DC cables in short circuit, including controls for powering, ramp, monitoring

connexion of power cablesto the current leads

Electrical Quality Assurance

superconducting magnet circuitssuperconducting magnet circuits

Individual System Tests of the Quench Protection and Energy Extraction Systems

Post-Mortem System tests

Commissioning of the electrical circuits one by one or in groups at low, intermediate and nominal currents

Commissioning of all the electrical circuits of the sector powered in unison to nominal current with nominal ramp rates

Individual System Tests of Powering Interlock Control


powering of the superconducting magnet circuitspowering of the superconducting magnet circuits

HCA:PIC2 Stand-by current

to commission the protection functionalities of the powering interlock controllers and all its connected systems with current through the circuits to verify the compatibility of the switch-on and switch-off processes of the converters with the sensitivity of the protection systems (namely QPS)

HCA:PLI1HCA:PLI2HCA:PLI3HCA:PLI4

Injection level20% of Inom

50% of Inom

80% of Inom

to set up the power converter current loopsto validate the protection mechanisms under real powering conditions and with limited amount of energy in the circuitsto validate quench-related procedures, e.g. cryogenic recovery proceduresto validate the sensitivity and compatibility during ramps of the systems susceptible to noise pick-up, couplings, etcto perform a last check on the polarities of the circuits by verifying voltages across current leads (at low current using QPS signals)

1/21/2


powering of the superconducting magnet circuitspowering of the superconducting magnet circuits

HCA:PNO Nominal current to verify that the power converters work correctly during the ramp of the currentto calibrate the DCCTs for the main power converters and the Inner Triplet power converters and to verify that the calibration systems work correctlyto validate the protection mechanisms under real powering conditions and with nominal energy in the circuitsto verify the quench current level of each circuitto validate quench-related procedures, e.g. cryogenic recovery procedures

HCA:PAC Nominal current(all circuits of a sector)

to verify the tracking of the currentto verify thermal performance of the ventilation and water cooling systems in underground areasto have a 24-h reliability run in order to detect premature failures due to wrong settings or possible assembly errors

2/22/2


test programme per circuit classtest programme per circuit class

Main Circuits

(RB, RQF, RQD)

Magnets with Quench

Heaters and 600 A

Circuits with Energy

Extraction System

600 A Circuits with Energy Extraction

System

60 or 120 A Orbit Correctors

System declared commissioned after this step

HCA:PLI 1 x x x

HCA:PLI 2 x x x

HCA:PLI 3 x x x Quench Detection/Heater

firing

HCA:PLI 4 x

HCA:PNO x x x x Power Converter and Energy Extraction

HCA:PAC x x X partly All


Q4’05 Q1’06 Q2’06 Q3’06 Q4’06 Q1’07 Q2’07

Sector 12

Sector 23

Sector 34

Sector 45

Sector 56

Sector 67

Sector 78

Sector 81

nov dec jan feb mar apr augmay jun jul sepoct nov dec jan feb mar apr may jun juloct aug

Q3’07

56 days

47 days

56 days

75 days

75 days

45 days

55 days

55 days

expected durations of the powering testsexpected durations of the powering tests

How are these durations calculated?


the two methods appliedthe two methods applied

Method 1 The String 2 experience was scaled (time of tests) Every equipment specialist was consulted and gave an

estimate of the time needed to commission a circuit as a function of its type

Method 2 Once the HCP on powering was prepared in more detail, the

times per step (test) were calculated No time for analysis was allocated at first


method 1: time allocated per circuit method 1: time allocated per circuit

Circuit typePC PIC QPS Total

sMain Dipoles 6 2 3 11Main and Inner Triplet Quadrupoles 3 1 1.5 5.5Separately PoweredQuadrupoles and Dipoles

0.5 0.5 1 1.7600 A with and withoutEnergy Extraction

0.25 0.25 0.3 0.880-120 A Orbit correctors 0.25 0.25 - 0.3

Units are15-h days


circuits and frontscircuits and fronts

Front 1Front 2 Front 1 Front 2

Left Right

6.6 km

Front 1 arc and the matching section on the even side

Front 2 arc, the matching section on the odd side and the inner triplets on both sides

two shifts = 15 hour days

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circ

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8817613334982

828

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MBMQ, MQXSeparately powered quadrupoles and dipoles600 A circuits80-120 A orbit correctorsTotal # of days

11.05.51.70.80.3

83278

436274

15-h

days

per

circ

uit

circ

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types

(60 A orbit correctors in the tunnelnot included)


the sequence of tests around an even pointthe sequence of tests around an even point

flexibility wrt the unexpected •Specialized teams•RB, RQ and RQX never at the same time


refined estimate of the times required for the test (1/2)refined estimate of the times required for the test (1/2)

preparations ramp up executionramp down/discharge

recovery analysis

arming systems e.g.fire quench heatersorcalibrate DCCT

e.g. quench:- cryogenics- energy extraction conditions- quench heater supplies recharged- PM buffers sent- etc…

This pattern is repeated foreach test at a given current level


refined estimate of the times required for the test (2/2)refined estimate of the times required for the test (2/2)

Circuit type First method[days/circuit]

Refined method

w/o anal.[days/circuit]

Time estimated for

analysis[days/circuit]

Total refined method

[days/circuit]

# ofcircuits

RB 11.0 6.0 1.6 7.6 8

RQRQX

5.55.5

4.45.0

1.61.4

6.06.4

1616

Ind. Powered quadsand dipoles

1.7 1.8 0.5 2.3 78

600 A average 0.8 0.6 0.4 1.0 436

80 A, 120 A 0.3 0.1 0 0.1 274

60 A 0 0.1 0 0.1 752

Reference for theGeneral Schedule

require battery tests


tools absolutely required for day 1…tools absolutely required for day 1…

supervisions of the different equipment (PC, PIC, QPS, Cryo, Vac, cooling & ventilation, …)

control applications to drive and monitor the equipment (see Markus’ talk) Logging, LASER, Post-Mortem standard tools for manual analysis using data from Post-Mortem (in general,

nothing different from individual magnet benches or String 2): view data (y=f(t), engineering units) several curves from different systems on same plot zooming, cursors, etc

tools absolutely required to gain timetools absolutely required to gain time automated procedures for simultaneous commissioning of multiple

circuits the sequencer shown by Markus is an excellent tool for this purpose once validated, they will be very useful to gain time in the case of the

commissioning of the corrector circuits safety of equipment does not rely on them (as requested by AB-CO) high energy circuits (RB, RQX, …not many) will be done one by one

tools for automated analysis these tools will be commissioned themselves during the commissioning of the

first two sectors still to be agreed upon what information to integrate within this

automated analysis (sequence of events, data integrity, time constants, etc)


how to improve and save time? (1/2)how to improve and save time? (1/2)

training as much as possible using LSS L8 tests being organized and ready from day 1

respecting procedures applying the quality assurance programme obtaining support from the MTF and database team

optimization of the MTF configuration for hardware commissioning

exchange of data between the central database and the specialist owned databases

support from the Controls/Operation Groups programmed procedures for battery tests to be

commissioned as soon as possible dry runs well in advance

PM tools ready reliable analysis is a must

procedures after failure scenarios … to be done


how to improve and save time? (2/2)how to improve and save time? (2/2)

Being protection systems, functionalities of the interfaces of PIC and QPS must always be checked at 100%

All bus bar connections (cold and also warm) have to be checked with high current

Quenching of magnets is required also to verify the performance of the cryogenic system

Risks of skipping some tests there where it pays off: 600 A and 60 A circuits if one of the 202 energy extraction systems does

not operate properly, the impact will be severe 60 A circuits are high inductance, high specific

energy

Streamlining of tests with experience


failure scenariosfailure scenarios

discussed at EEWG and HCWG at requests from MARIC and MAC see Karl Hubert’s talk for most severe cases

some other which are included in a document in preparation are:

PC: Fire Cables: Massive water leak S.c. elements:

Bad splice overheating in a sc circuit: detect, open and repair Bad splice resistance in the normal state (String-2 case) => very difficult

diagnostics Energy extraction failure scenarios All instrumentation lost for s.c. magnet, lead or circuit Redundancy lost for the instrumentation of magnet, leads or circuit =>

recovery procedure Impossible to power a circuit due to either dead short to ground inside the

cold masses or open circuit (?) list of circuits which are critical for first beam in 2007 (O. Bruening)

reactivity: who, what, when? are defined in advance (within possible)

… anyway, the worst failures will be the ones we did not think about (KHM)

take advantage of Tevatron, HERA, RHIC


special tests on the first sector(s) 1/2special tests on the first sector(s) 1/2

Cryogenics AT-ACR would validate the quench recovery and subsequent

cooldown procedure and control logic therefore various tests at progressively increasing energy per sector

are required, including quenching more than the expected full cell PIC

Reaction times of interlock (especially RB circuit with EE on either side)

BIC interface (although commissioned at a later stage) Endurance tests -Post Mortem Interface -Validation of automated

procedures in ML8 and XL8 (in parallel with manual commissioning) -Training of personnel

QPS Validation of digital quench detector firmware

Adjustment of digital filters and inductance tables Test of selected heater firing @ injection current

General Mains failure EMC tests (AB-CO, AB-PO, AT-MEL)


special tests on the first sector(s) 2/2special tests on the first sector(s) 2/2

Also in the first sector Commissioning of automatic test procedures

Preparation of automatic powering procedures and battery tests

Interfaces to Post-Mortem Analysis tools …

will be used for the first time.


Outlook to LSS L8Outlook to LSS L8

Unique occasion for the: Validation of powering procedures Early identification of errors, shortcomings

and possible corrections Training of the teams

The perfect dress rehearsal


A few words on the role of the coordination …A few words on the role of the coordination …


Ensures that the hardware commissioning procedure validates the circuit for nominal operation as defined in the Design Report/LHC Reference Database.

Ensures that all the Individual System Tests related to equipment connected to the circuit have been carried-out, the data has been stored and interpreted by the responsible person

Ensures that each step of the test procedure is carried-out as described in the hardware commissioning procedure document

Ensures that the data associated to each step of the test procedure is recorded and adequately stored in the MTF

Interprets the data and depending on it allows/refuses the execution of the following step of the test procedure

Answers for the data and history of the commissioning of each circuit throughout the IST and the Hardware Commissioning

OK

Measurements

IST

OK

Measurements

IST

OK

Measurements

IST

MTF

OK

Measurements

HCProcedure

MTF

Coordinator for the LHC magnet circuitsCoordinator for the LHC magnet circuits


Coordination for the warm part of the sc circuitsCoordination for the warm part of the sc circuits

Interfaces: Power cables – DFB (in particular current leads, but

also all the other equipment to be connected studies and integration)

Power cables – power converters Power cables – water cooling Power converters – water cooling

Phases: (Validation of individual systems) Installation and first connection Hardware Commissioning Operation & Maintenance

Groups involved: AB-PO, AT-MEL, AT-ACR, TS-CV, TS-EL, TS-HDO, TS-IC,

SC-GS


Goals for the Coordination for the warm part of the sc circuitsGoals for the Coordination for the warm part of the sc circuits

Clarify interfaces Coordinate the definition of sequences and

the write-up of procedures Assessment on the feasibility

Define responsibilities over the different phases

…with special attention to: Planning Co-activities Safety


Thanks


powering profiles

time 1time

step 1

step 2

time 2

nominal Icurr

ent

First power

One of thesubsequentpower runs

This was the procedure applied to String-2 circuits

With the implementation of adapted quench detection thresholds(1/10 for the plateaux, see Reiner’s talk) this procedure will relaxthe specification for the control application


power tests foreseen for MB circuitspower tests foreseen for MB circuits

current tests verifications

760 A Set up current loop current loop parameters

760 A Fast PA from PIC partial protection chain

760 A Slow PA from PIC partial protection chain

760 A Open EE switches with global (or bus bar) QD trip full protection chain

760 A Fire quench heaters in two dipoles (two tests) full protection chain, partial energy dissipation

2000 A Check current loop stability current loop parameters

2000 A Slow PA from PIC partial protection chain

2000 A Open EE switches from PIC EE parameters OK; magnets don’t quench

2000 A Fire quench heaters in at least one magnet full protection chain, partial energy dissipation

6000 A Check current loop stability current loop parameters

6000 A Fast power abort from PIC EE parameters OK; magnets don’t quench

6000 A Fire quench heaters in one magnet full protection chain, partial energy dissipation


11850 A Check current loop stability up, down, powering failure in PC

11850 A DCCT calibrations calibrations for beam operation


11850 A Fire quench heaters in one magnet full protection chain, full energy dissipation


Analysis of provoked eventsAnalysis of provoked events

right equipment number of data blocks and their integrity sequence of actions (PIC, PC, QPS, cryo?) QD:

fixed pattern for QS during provoked quenches threshold verification

EE: voltage across dump resistor Flags:

QD Coherency flag, QD0, ST_Magnet_OK EE to be defined in detail

PC: decay time constant signals from quench heater power supplies:

U levels time constant