cabling activities in the lhc-injectors during ls1

Cabling activities in the LHC-injectors during LS1

Daniel RICCI, on behalf of EN-EL-CF

LS1 : Cabling activities

The consolidation and maintenance of the accelerator infrastructure (cabling and fibres)

A large amount of requests from equipment groups

D. Ricci – Cabling activities during LS1 – IEFC workshop2

Priority 2

Priority 1 & Priority 2but also Priority 3 & 4

Reliable Operation of LHC

Operation of LHC @ 7 TeV

9 March 2012

The goal of LS1 is to implement everything needed for a safe and a reliable operation of LHC @ 7

TeV/beam

Priority

Definition

0 safety1 Beam to 6.5 - 7 TeV2 Reliable operation3 CERN approved

projects4 Not approved

projects

3 D. Ricci – Cabling activities during LS1 – IEFC workshop

Outline Part1: status of the accelerator infrastructure

(why we need to consolidate) Overloaded cabling areas Irradiated cabling areas

Part 2: activities foreseen for LS1 Consolidation projects Requests from equipment groups

Part 3: resources and priorities Summary and conclusions

Cabling activities:- Installation of copper cables- Installation of optical fibres- procurement of cables/connectors

9 March 2012



Part1: status of the accelerator infrastructure (why we need to consolidate) Overloaded cabling areas Irradiated cabling areas

9 March 2012


Status of the accelerator infrastructure

SPS was put in service in 1976 (36 years old) So far, cables for new systems were just “added” Irradiated cable replacement campaigns carried on

regularly since 20 years PS was put in service in 1959 (53 years old)

Only one cleaning campaign carried on in 1995-2000 600 km of cables removed in PS and PSB No irradiated cable replacement

Rest of PS-complex and Meyrin technical galleries Till now, cables were just “added” for new machine

systems and general CERN infrastructure All cables installed before ’80s are with halogens (risk

in case of fire accidents)

9 March 2012

6

Overloaded areas: SPS

9 March 2012

BA3 false floor

TS5 et ECX5


Overloaded areas: SPS

9 March 2012

Galleries

Shafts

Overloaded cable trays do not allow pulling cables in the proper technical way

This situation is general for SPS

In some cases, cables cannot be installed anymore


Overloaded areas: PS-complex and Meyrin site

9 March 2012

PS ring centre

Gallery TP9Intersection Linac2-

Linac4-PSB

Tunnel TT2



9 March 2012

Bld.361 (under the Booster), room BCER


Overloaded cable areas (ordered by critical state)SPS machine

Critical state 1: Point 5 surface, shafts and

underground Point 4 surface, shafts and


underground

Critical state 3: Point 6 surface, shafts and




underground

Critical state 5: TT60, TT70

Shafts are the most critical areas for all points.

9 March 2012

PS-Complex and Meyrin site Critical state 2: Bld.360-361 (under the Booster),

rooms BCER, BOR, BAT Bld.354, room CCR et MNR, gallery

815 Gallery TP9 between Bld.354 and

Bld.361 Bld.353 (ring centre) and tunnel of PS

Bld.350 accelerator TT2 entire tunnel (from Build. 269 to

TT2A towards nTOF)

Critical state 4: Bld.2001 (upstairs), cable

connections from Build.2008

Critical state: severity of overload (1=highest)


9 March 2012


Gallery TP9

Tunnel TT2

Bld. 2001

B354

B361


Maintenance of the accelerator infrastructure

Consolidation (clean-up) activities: With the help of users’ groups:List of unused cables Identify unused cables on site Disconnect unused cables from their equipment

Remove unused cables

9 March 2012


BA1: TS1

BA2: TS2

BA6: TS6, TCC6, TT60, TT61, TNC

BA4: TS4

North Area: TCC2, TDC2

Maintenance of the accelerator infrastructure: replacement of

SPS irradiated cables

9 March 2012

Total cables concerned: 6300Total length: 630 km (~12% of the total)

TS2: 1400TS1: 1200BA6: 2100TDC2-TCC2: 800TS4: 800



irradiated cables SPS: regular replacement carried on until 2009

9 March 2012

Areas 1990 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05 06 07 08 09

TS1 All

TS2 ZS/MST/MSE All ZS/MST/V

acExc TCT Exc TCT

TCC2 All AA R

TDC2 All All

TS4 Part

TS6 ZS/MST/MSE

Exc TCT TCT Exc TCTVac exc

TCT TCT

TT60 All

TCC6 All

TNC All

TCT

Rem. ZS, Inst MKE

All

Cable volume

0

500

1000

1500

2000

2500

1992 93 94 95 96 97 98 99

2000 01 02 03 04 05 06 07 08

2009

Years

Cabl

e qu

antit

ies

0

50

100

150

200

Cable quantitiesTot length (km)

1 complete SPS point every shutdownReplacement foreseen every 5/6 years is today every ~10 years

TCT: Top cable tray, AA: Almost All, R: Rest, Part: Partial.

15



9 March 2012

SPS TS1, TS6




9 March 2012

Cable ageing + radiation can cause failure of SPS equipment and could stop the machine

Replacement is organized by campaigns. Not possible selective replacement of one/few cables: Cables entangled Risk of damaging the other cables High dose level taken by workers

Irradiated cable areas are also overloaded the consolidation (clean-up) benefits also the irradiated areas and viceversa


Affected area: ~200 m


radiation-sensitive fibres

9 March 2012

July 2011 @ LHC-P7 found rad-sensitive optical cable contingent problem solved (new cable installation) started measurement campaign in all LHC & SPS radiation areas

Measurement and replacement campaigns Rad-sensitive fibres found so far in P1, P5, P7 Strategy:

install new spare cables (in Xmas break + LS1) replace rad-sensitive cables (LSI) continue monitoring + fiber database (2012 + LS1)

New procedure = Quality Control



Part 2: activities foreseen for LS1 Consolidation projects Requests from equipment groups

9 March 2012

19

Consolidation: replacement of irradiated cables: TS1+, TCC2-

TDC2, RAL

2000 cables concerned incl. replacement of kickers cables in TS1+ (requested by TE-ABT)

2.8 MCHF 6 FTE 2013-2014

9 March 2012D. Ricci – Cabling activities during LS1 – IEFC workshop

SPS racks RAL

No. Zones Descr. Areas Duration* Remarks

1 SPS-P1 Repl. Irradiated cables TS1+ 14W 2 shifts, not // to (2), mid LS1

2 SPS-North Area

Repl. Irradiated cables TCC2, TDC2 14W 2 shifts, not // to (1), end LS1

3 SPS P1,P2,P4,P6,NA

Cons. Irradiated and aged rack RAL

P1, P2 8+12 W P1 // to (1), P2 after (2), mid-LS1

* Not including zone preparation (only cabling)

20

Consolidation: replacement of irradiated cables: Radio

Protection


Very high dose levels foreseen for EL activities during LS1 Increasing efforts in preparatory activities (dose estimation,

ALARA, etc.) and in contract management (training, rotation of personnel, etc.)

We will need help from our RP colleagues: Estimated doses available well before the end of 2012 “Hot” equipment shall be removed in the areas of

intervention Place the shielding in a way to not obstruct the access to the

cable trays Identify clearly for which areas the waste shall be treated as

radioactive RP operator field support during contractor working hours

21

Consolidation: clean-up unused cables in SPS-P5

Concerned areas: BA5, BB5, TS5, ECA5,…

Number of cables currently installed: ~6000

Total estimated cable length: 600 km 3.2 MCHF (to be confirmed) 2 FTE 2013

With the help of users’ groups: Started to establish cleaning list of

unused cables Identify and disconnect (all) unused

cables on-site during 2012


https://edms.cern.ch/document/1149428/3


Clean-up unused cables in SPS-P5: status of feedback

from users (05/3/12)

9 March 2012

Systems (group) Feedback status Missing actions EN-CV List in progress On-site researchEN-STI Replied on xls list + on-site research NoneEN-EL Work in progressTE-ABT Replied on xls list + on-site research NoneTE-MPE Replied on xls list On-site researchTE-VSC Replied on xls list End of on-site researchTE-EPC Replied on xls list On-site researchTE-MSC No reply ReplyTE-CRG No cables BE-CO Replied on xls list + on-site research NoneBE-RF Replied on xls list + on-site research None

BE-BIReplied on xls list + on-site research (in progress) End of on-site research

BE-ABP Replied on xls list + on-site research NoneGS-ASE Replied on xls list End of on-site researchPH-ADO Replied + on-site research NoneIT-CS Replied for the intercom syst. Reply for the other systemsDGS-RP Replied on xls list On site research


Clean-up unused cables in SPS-P5: summary

Results of activities during the last Xbreak (feedback from users + EN-EL inspection):

Found 1515 cables registered in the cable DB; total length 220 km This includes:

Abandoned cables (oxidated connectors, old patches, etc…): identified by EN-EL Unused cables: identified by the users Unused cables in the racks: identified by the users in collaboration with EN-EL

Found 1400 cables not registered in the cable DB; total length 50 km This are abandoned (cut, etc.) cables to be removed by default (in agreement

with technical coordination)

Total amount of cables to remove: ~2900; total length ~270 km~40% of total installed cables enough to organize a cleaning

campaign!…however we still need the users to complete their actions

(thanks!)9 March 2012


Clean-up unused cables in SPS-P5: follow-up

9 March 2012

Schedule proposal

Price estimation

Ressources definition

Identification of thestarting points

Identification of the cable ladders or passages concerned

Accessibilities to the cable ladders - schaffoldings, lifting equipment, etc…

Estimation of the waste of irradiated cables.

Estimation of the total length

Volume estimationof the unused cables

Storage of the irradiated cable waste: containers and storage area.

Work Supervisor, transport, RP, safety process, etc…

t

0

Dose level estimation:ALARA comitee

Process definition to reduce the dose level taken by the workers.

Technical and adm.preparation

6-9

mon

ths

Upon the receipt of the list of the unused cables established by the users. (See EDMS 1149428)

See IEFC presentation of 21/10/11 for more details on the challenges related to organize cabling campaigns

March 2012

Volume estimatio

n

Preparation

of the campaign

Study of technical constrains

Study of access conditions


Consolidation: replacement of radiation-sensitive fibres

9 March 2012

Monitoring activities to be continued in 2012

New contract for rad-resistant fibres 1.2 MCHF (to be confirmed) 5.5 FTE 2013-2014


Consolidation: replacement of WCC hoses in 3 LHC sectors

9 March 2012

Risk of “leakage” due to hoses not conforming to the technical specifications (presence of chlorine and cracks)

Hose of WCC to be replaced in 3 LHC points (4 right, 6 and 8)

Length: 3120 m Commissioning and tests 2 MCHF 5 FTE 2013-2014


Requests from equipment groups

9 March 2012

A large amount of user requests have already been made filling much more than 100% of our capacity during LS1. Moreover based on the last shutdown, we estimate that only 50% of the requests for LS1 are currently known.Some examples: R2E; relocation of EL equipment and re-cabling in 4 LHC

points PS Access system (PSS) Linac4 and Transfer line to Linac2 RF upgrade project in SPS BA3 the BE/BI upgrade projects, IT upgrade projects, HIE

Isolde, Elena, Video SPS, RF fire brigade, GSM-BTS, DAQ system for CMS and LHCb, etc.


Requests from equipment groups: relocation of EL equipment and

re-cabling in 4 LHC points.

R2E Huge amount of cabling

relocation activities Work in 2 shifts New WCC for P5 and P1 5 MCHF 10 FTE 2013-2014

9 March 2012

29

Requests from equipment groups: PS-PSS (Personnel

Safety System)

9 March 2012

Sas Material

NTOFAD

PSBPS

CTF

HALL EST

TT2

ISOLDE

LINAC’s

Sas Personnel

28 new access points to integrate and equip

GS/ASE project (P. Ninin)

3,2 MCHF Cables & Fibres 3.5 FTE 2012-2013 Includes a portion of

consolidation in Meyrin

CABLE DISTRIBUTION ON SITE


The day-to-day business

Roughly 2200 cables/year are installed on the three main sites: LHC, SPS, PS (~80 cabling requests per site)

This includes: Treatment of DIC and DIF (Demandes Installation Cables et Fibres) Technical study (cable trays, routing, termination, planning, cost,

etc.) Material procurement (price enquiries, invitation to tenders, etc.) Installation works (managing contractors, etc.) Work surveillance Acceptance and quantity check

Day-to-day business includes also: Section and coordination Contract management People training Etc.

9 March 2012



Part 3: resources and priorities

9 March 2012


Strategy & workload In order to cope with the huge program of work

during LS1, all CF projects have been organised so that they could start during the technical stops in 2011/2012

and ideally, only those activities which must take place during

a full shutdown are carried out during LS1. Therefore the CF program for the shutdown has

already commenced (2011) EL-CF had already doubled its staff in the last 3

years. This substantial increase of has now reached the limit of the training and supervision capacity of the CF core staff Projects have to be prioritized

9 March 2012


Projects & Priorities

9 March 2012


Summary & conclusions Huge amount of work for CF before and during LS1 Project preparation started already (works are anticipated during TSs) Cabling and fibre activities are strongly dependent from other groups We need your help to cope with everything:

Users: continue helping with the identification of unused cables present your cabling/fibres requests now (for organizing the activity: resources,

plannning, purchase of material) Planning coordination:

SPS, PS: anticipate as much as possible the communication of the access constraints, drive and organize activities with other services/groups

Machine coordination: what do we do with old systems (e.g. Intercom Public Access in SPS)?

RP: estimate doses, remove “hot” equipment, etc. (see slide 21)

Management: help us to set priorities (now…)

Project leaders: start to take into account the cable removal in the new projects in order to avoid

these situation to repeat in the future9 March 2012


Thank you for your attention

…and have a nice weekend!

9 March 2012

36

LS1 Cabling activities


Extra slides


Requests received for LS1(Nov. 2011)SPS machine

Critical state 1: Point 5 : clean-up campaign (EN-EL) Point 4 : - Point 3 : BE-RF cavities/new bld.

Critical state 3: Point 6 : - Point 1 : repl. irr. cables + cons. RAL

(EN-EL) Point 2 : cons. RAL (EN-EL) Point 7 : -

Critical state 5: TT60, TT70 : -

All SPS: BE-BI instr. (BCT, BTV, BPM, BLM, etc.)

+ other cabling requests of various types9 March 2012

PS-Complex and Meyrin site Critical state 2: Bld.361 (Booster) : BE-BI instr. (BCT, BPM,

BLM, etc.) + PSS (GS-ASE) + cons. Multipole (TE-EPC) + Interlock (TE-MPE) + L4-PSB connection

Bld.354 : - Gallery TP9 : - Bld.353, PS tunnel Bld.350 : BE-BI instr. (BCT,

BWS, BBQ, BLM, etc.) + PSS (GS-ASE) TT2 tunnel : BE-BI instr. (SEM) + PSS (GS-ASE)

Critical state 4: Bld.2001-2008 : -+ other cabling requests of various types

From IEFC meeting 27th Jan 2012

38 9 March 2012

How is it possible to arrive to this situation in pt5?

3: The duration of the Shutdownsdoesn’t preview the huge removal of the old system.

Now is not possible to pull (install) new cables in the

tunnel of Point 5.Now is the time to foreseen a cleaning cable

campaign !

1: No huge campaign for removal of old cables since the SPS’ installation in the BA5 and in the tunnel.

2: The installation of a new system doesn’t includes the removing of the previous one.

D. Ricci – Cabling activities during LS1 – IEFC workshop

Cleaning up SPS-P5

39

Cleaning up SPS-P5


Summary: For some users we are still missing a reply For other important users we strongly recommend a research in the

field It seems many cables are very old and not known by the users.

However, it is clear to which system they belongs requires system owners to understand “what it is”

In the great majority of cases the users think “What are the cables which I do not need anymore in the existing system?”, they should instead think “I have a system with a lot of cables. How could I improve my system in order to reduce the number of cables? Which cables can I remove then considering these improvements?”

Example: a lot of cables affected to “Intercom Public Address” (Intercom station only). Do we need to keep it in use like it is? Can it be replaced by portable telephones like in LHC?

From IEFC meeting 27th Jan 2012

Cas pratique : Plan de travail

• Fournir les listes de câblages aux utilisateurs :

• Réponse des utilisateurs :

• Relevé des câbles abandonnés:

• Evaluation du volume et de la stratégie (manpower + coûts) :

• Mise en œuvre (préparation) :

• TRAVAUX (durée de 6-9mois) :

Octobre 2011

Janvier 2012

Janvier 2012

Juin 2012

Octobre 2012

Janvier 2013 (LS1)

Action EN/EL

Action utilisateurs

Action coordination

Action EN/EL Action utilisateurs+

Action EN/EL

Action EN/EL +

Action coordinationAction EN/EL +

EDMS n°1154423

https://edms.cern.ch/document/1154423/1

cabling activities in the lhc-injectors during ls1

Documents

ricci cabling activities

cabling activities4part1

ls1 iefc workshopls1

ls1 iefc workshopstatus

ls1 iefc workshop2priority

conclusionscabling activities

ls1 iefc workshoppscomplex

goal of ls1