ls1 cabling progress ls1 committee (lsc) – 21 june 2013 daniel ricci on behalf of the cabling and...

LS1 Cabling Progress

LS1 Committee (LSC) – 21 June 2013

Daniel RICCI on behalf of the Cabling and Optical Fibre Section (EN-EL-CF)

EDMS 1293605

D. RICCI – CERN, LSC meeting – EDMS 1293605

Outline

The LS1 challenge for cabling Monitoring of cabling activities & current

performance Facing the challenges: where do we stand? Conclusions

21/6/13

Cabling = copper (ctrl & DC) cables AND optical fibres

2 of 25


The LS1 challenge:the important numbers

37 main projects to carry on + day-by-day installation works(Some examples: R2E, LHC cabling campaigns, WCC hose consolidation, SPS campaigns & irradiated cables TS1+, new SPS fibre infrastructure (BI & others), PSS, LINAC4 & Meyrin campaigns, Computer Centre extension B513, LHC-Experiments fibre upgrade)

Overall estimated budget ~12 MCHF

~1000 km of copper and optical cables being installed during LS1

21/6/13

Moreover, activities also include Managing CERN-wide optical fibre infrastructure

(3,000 km installed optical cables) Qualification, procurement and standardisation of

cabling and optical fibre components (3.5 MCHF/year) Managing cable park (4200 drums) and cable tray

infrastructure (350 km) Monitor cable aging and put in action the

replacement campaigns (~1MCHF/machine point)

3 of 25


LS1 challenge:planning and resources

Very « dense » planning Must cope with machine constraints/priorities Delay on one activity can provoke « domino »

effect

~35 people in CF plus ~100 contractor people

Challenging supervision, training and knowledge transfer of new working method

21/6/13

Example CF planning (LHC only)

New

cablin

gR

2E

Conso

lid.

LS1

4 of 25


The cabling strategy(in a snapshot)

see LSC presentation 15/3/2013

21/6/13

Campaign Booster

Campaign SPS-BA1

Campaign LHC-Point1

PROJ 1 Various works TE/ABT

PROJ 2 LIU

PROJ n Various works BE/BI

3) Optimize work organisation and resource distribution by working by geographical

campaigns 5) Project progress and schedule monitoring

1) Enhanced section structure

Simulation

2) Anticipate qualification and procurement of material

4) Boost training & project preparation with contractors

+ fibres…

5 of 25


LS1 progress monitoring

Method developed in agreement with the management request to be able to follow activity progress in ‘real-time’

Objectives Help Project Managers to manage parallel projects and workload Warn timely on activity delay or anticipation Prevent resource bottlenecks Be able to provide detailed status reporting (e.g. for each geographical

campaign) Be a test-bench for LS2

Costs Dedicated FTEs to implement/following (1.5 FTEs for 2013) Enforce new work style with contractors More commitment (mainly time) requested from the Project Managers

21/6/136 of 25


Monitoring method

Challenge: CF field-activities are composite and of different nature, depending on the project Project preparation, ordering of material, documentation and other administrative

activities done by CF are not included

21/6/13

Cabling campaign (core)

Cable pulling (60%)Connectors

(30%)Test

(10%)

ReworksDe-

cabling

Mechanicscable

trays/racks

variablevariable variablevariable

Example of field-activities for copper cables



(30%)Test

(10%)

ReworksDe-cabling Reworks


Cable pulling (50%) Connectors (40%)Test

(10%)

De-cabling

Mechanicscable trays/racks

timet1 t2 t3

7 of 25


Monitoring method

Heterogeneous monitoring tools apply Quick implementation to be ready at the beginning of LS1 campaigns

21/6/13



(30%)Test

(10%)

ReworksDe-

cabling (variable)

Mechanicscable

trays/racks(variable)

Weekly check from each concerned Project Managers Very important to get as accurate feedback as possible

Weekly feedback from Contractors Filling follow-up sheets (for detailed cross checking) Drawback: contractors claiming this is not included in the contract

and produce more work

Cable database (Cablothèque) Filling data is part of the contractor’s obligations Sotware data extraction (EDMS 1245912)

8 of 25


Monitoring: forecast

Forecast curve is extracted from scheduled activities (MS-project planning) Detailed summary of all activities of CF section Updated weekly

21/6/13

2013:Janvier

FevrierMarsAvril

MayJuin

Juillet

Aout

Septembre

Octobre

Novembre

Decembre

2014:Janvier

FevrierMarsAvril

MayJuin

Juillet

2014:Aout

0.0

20.0

40.0

60.0

80.0

100.0

Cabling and Optical Fibre Forecast curve

%Forecast

50% LS1

Beginning of LS1

End of LS1

9 of 25



Simple rules Each activity

Starting date 0% Ending date 100% Linear interpolation

Activity plans weekly updated with the exception of the

campaign already started

21/6/13

Task Name Start Finish w10 w11 w12 w13 w14 w15 w16 w17 w18 w19 w20 w21 w22 w23 w24 w25 w26 w27 w28 w29 w30 w31

BA5 27/3/13 1/7/13 4 10 17 24 31 38 45 52 59 66 72 79 86 93 100 100 100 100 100

BA4 27/5/13 6/8/13 9 18 27 36 45 55 64 73 82 91

CNGS 15/7/13 24/7/13 50 100 100

BA3 27/3/13 9/7/13 3 9 16 22 29 35 42 48 55 61 68 74 80 87 93 100 100 100 100

BA1 29/4/13 7/10/13 4 8 13 17 21 25 29 33 38 42 46 50 54 58

Mars Avril May Juin Juillet

Mars Avril May Juin Juillet0

20

40Cabling Forecast curve - SPS

%Forec...

BA5

BA4

CNGS

BA3

BA1

020406080

100

Campaign Status - SPS

10 of 25



21/6/13

Task Name Start Finish w10 w11 w12 w13 w14 w15 w16 w17 w18 w19 w20 w21 w22 w23 w24 w25 w26 w27 w28 w29 w30 w31

BA5 27/3/13 1/7/13 4 10 17 24 31 38 45 52 59 66 72 79 86 93 100 100 100 100 100

BA4 27/5/13 6/8/13 9 18 27 36 45 55 64 73 82 91

CNGS 15/7/13 24/7/13 50 100 100

BA3 27/3/13 9/7/13 3 9 16 22 29 35 42 48 55 61 68 74 80 87 93 100 100 100 100

BA1 29/4/13 7/10/13 4 8 13 17 21 25 29 33 38 42 46 50 54 58

Mars Avril May Juin Juillet

Mars Avril May Juin Juillet0

20

40Cabling Forecast curve - SPS

%Forec...

BA5

BA4

CNGS

BA3

BA1

020406080

100

Campaign Status - SPS

Simple rules Each activity

Starting date 0% Ending date 100% Linear interpolation

Activity plans weekly updated with the exception of the

campaign already started

11 of 25


Monitoring: progress Progress curve is extracted from heterogeneous monitoring tools

Very large stream of information to process

21/6/13Cabling campaign (core)

Cable pulling (60%) Connectors (30%)Test

(10%)

ReworksDe-cablingMechanics

cable trays/racks

Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase N

Input from

contractors

Computed % of completion

12 of 25


Monitoring plots

21/6/13

CABL. C

AMP.

BA5

(Eq

1)

CABL. C

AMP.

BA4

(Eq

1)

CABL. C

AMP.

CNG

S (E

q 1)

CABL. C

AMP.

BA6

(Eq

1)

CABL. C

AMP.

TI8

(Eq

1)

CABL. C

AMP.

BA3

(Eq

2)

CABL. C

AMP.

BA2

(Eq

2)

CABL. C

AMP.

e BA7

(Eq

2)

CABL. C

AMP.

TI2

(Eq

2)

CABL. C

AMP.

BA1

(Eq

3)

REPL. C

ABL. IR

R. TS1

+

NEW C

ABL. T

S1+ (E

q 3)

CONNEC

TIQUE:

RAL

P2 (E

q 4)

CONNEC

TIQUE:

RAL

P1 (E

q 4)

CONS.

DC C

ABL. S

PS T

DC20

20406080

100

Control & DC Cabling Campaign Status - SPS/Prevessin

Updated: week 21/2013

Actual Forecast Completed

FIB. O

PT. S

PS B

A5: p

uit

FIB. O

PT. S

PS B

A5: T

S5+

FIB. O

PT. S

PS B

A5: T

S5-

FIB. O

PT. S

PS B

A6: p

uit

FIB. O

PT. S

PS B

A6: T

S6+

FIB. O

PT. S

PS B

A6: T

S6-

FIB. O

PT. S

PS B

A1 (p

uit)

FIB. O

PT. S

PS B

A1: T

S1+(tu

nnel

)

FIB. O

PT. S

PS B

A3: p

uit

FIB. O

PT. S

PS B

A4: p

uit

SP

S PO

WER

CABLE

CONS.

CCC u

pgra

de -

BE91

0

20

40

60

80

100

Optical Fibre Project Status - SPS/PrevessinUpdated: week 21/2013

Actual Forecast Completed

13 of 25


Monitoring plots

21/6/13

2013

:Jan.

..Mar

sMay

Decem

bre

Fevr

ier

Juill

et0.0

20.0

40.0

60.0

80.0

100.0

Control & DC Cabling Progress Curve - SPS/Prevessin


%Forecast

%Actual

Pro

gre

ss (

actu

al vs f

ore

cast)

2013

:Jan.

..Mar

sMay

Decem

bre

Fevr

ier

Juill

et0.0

20.0

40.0

60.0

80.0

100.0

Optical Fibre Progress Curve - SPS/Prevessin


%Forecast

%Actual

Pro

gre

ss (

actu

al vs f

ore

cast)

14 of 25


Monitoring plots

21/6/13

2013

:Janv

ier

Mars

May

Decem

bre

Fevr

ier

Juill

et0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

Cabling and Optical Fibre Overall Progress curve


%Forecast

%Actual

Pro

gre

ss (

actu

al vs f

ore

cast)

15 of 25


Current performance

Dashboard: http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/

21/6/13

2013:Janvier

Fevrie

rMars

AvrilMay

JuinJu

illet

Aout

Septembre

Octobre

Novembre

Decembre

2014:Janvier

Fevrie

rMars

AvrilMay

JuinJu

illet

2014:Aout0

10

20

30

40

50

60

70

80

90

100

Cabling and Optical Fibre Overall Progress curve (updated 13/6/2013)

%Baseline (Feb2013)

%Forecast

%Actual

Prog

ress

[%]

0102030405060708090

100

Control & DC Cabling Overall Progress curve (updated 13/6/2013)

%Baseline (Feb2013)%Forecast%Actual

Prog

ress

[%]

2013:Janvie

rMars May

Decembre

Fevri

erJuille

t0

102030405060708090

100

Optical Fibre Overall Progress curve(updated 13/6/2013)

%Baseline (Feb2013)%Forecast%ActualPr

ogre

ss [%

]

16 of 25

http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/

http://lhcdashboard.web.cern.ch/lhcdashboard/ls1/


Monitoring method improvement

Development of a new monitoring procedure based directly on GESMAR All the information concerning the progress of the work is directly filled by

contractors Data extraction from GESMAR + elaboration/plotting by CF (to be included in

GESMAR in the future) First software implementation released to be taken over now by our

contractors

21/6/13



(30%)Test

(10%)

ReworksDe-

cabling (variable)

Mechanicscable

trays/racks(variable)

Integration into GESMAR

Cablothèque (module of GESMAR)

Many thanks to Serge

Oliger! (EN-EL-CD)

17 of 25


Facing the challenges: where do

we stand? The technical challenges

CF working method is solid concerning cabling installations Procurement of material: process well known, largely anticipated not

particular issues so far. Recrudescence of thefts is worrisome. Consider securing more the sites!

Preparation/execution of projects and cabling campaigns is optimised However, still very dependent on users timely feedback on final cabling requests!

Contract orders are issued timely and budget is in line with expectations Coping with more resource needs than initially foreseen for safety

and administrative tasks Procurement and logistics for RP-related material (personal protection

equipment, baskets, waste bags/bins, etc.) Thousands of pieces Find budget (~500 kCHF), manage purchases, deliveries, storage places,

consumption levels, etc. ALARA preparation and follow up

Lot of preparation: multiple iterations required with RP+contractors to achieve acceptable analysis

Workload on RSSOs is much more than estimated

21/6/1318 of 25



we stand? The additional staff

As foreseen, the section management/coordination levels are extremely loaded (even overloaded) Huge efforts to transfer the know-how to the newcomers Huge efforts to train the project managers (aim is “autonomy”) Workload for support functions is demanding taking into account the available

manpower and skills support priority being given to installation activities (e.g. planning, QA, access & safety)

Little and time-limited contingency to recover from (unforeseen) resource loss

21/6/13

Support Function Unit with Support Manager

Structure by project cells

19 of 25

Many thanks to

Fabio Formenti!

(TE-HDO)


JanvierMars

May

Decembre

Fevrier

Juillet

0

20

40

60

80

100

120

140Contractor Load Curve (updated 27/5/2013)

Total CF

Cont

ract

ors

staff

[peo

ple]

Challenge for contractors Four installation contracts currently operational:

C209 (electrical), C210 (electrical), C202 (fibres), B1213 (WCC) Contractors are increasing their staff. However, they need to:

be able to constantly find qualified personnel and to train them cope with CERN planning (peaks and valleys) cope with radiation rules: no temporary contracts + replace/rotate

the personnel achieving the max. allowed dose in radiation areas


we stand?

21/6/1320 of 25


Challenge from contractors One of the main electrical contractor is still

struggling with their internal organisation and expertise level of their personnel CERN has limited control on this (“delit de marchandage”

always behind the corner!) CF is currently working on contingency actions

Increasing at maximum the work supervision Organizing more connector trainings/tests for the

contractors Working on a plan of actions in case of one contractor

resigns (this will not be cost free…) Strongly limited in “contract managers”

Even more overload on section coordination!


we stand?

21/6/1321 of 25



we stand? Planning challenge

Going well so far. Thanks also to joint effort with planning coordinators Managed so far to have certain “agility” to smooth the curve peaks Keep high level of attention to avoid “domino” effects

Attention on how to cope with new (unforeseen) projects Last contingency slot in April 2014 was already filled by R2E-cryo In case of more new projects, set new activity list with priorities!

21/6/13

Many thanks to

Katy Foraz’s team!

0

5

10

15

20

25

30

35 Example of contractor load curve (PS/Meyrin)

05/03/2013

27/05/2013

Cont

ract

or s

taff

[peo

ple]

22 of 25


An eye on the field

21/6/13

Flexwell (coax) cables

in LHC P4

Replacement of WCC

hoses in LHC P8-left

23 of 25


An eye on the field

21/6/13

CTRL cabling in the PSB

Optical fibre cabling SPS &

LHC

24 of 25


Conclusion 27 CF worksites currently ongoing CERN-wide with 4 main installation contractors

A tool for monitoring the LS1 progress for CF is working and available online now developing a new version fully integrated in GESMAR

The working method is proved and work organisation is optimised around geographical campaigns. The forecast schedule is being kept so far

requires a lot of efforts and commitment from CF people!

Main challenges are: the overload of the section work-coordinators, the risks associated to the quality and (especially) the stability of the contractors

cabling activities are under control but still very sensitive to work plan perturbations

It is important to build-up contingency reserve (to cope with unforeseen circumstances) when activities are performed better than in the plan

attention to the new coming projects! Prioritize and schedule wisely…

The success of the LS1 cabling project is a real team effort! Many thanks to all the CF colleagues which are making possible a smooth LS1!

21/6/13…and thanks for everyone’s support!

25 of 25

ls1 cabling progress ls1 committee (lsc) – 21 june 2013 daniel ricci on behalf of the cabling and...

Documents

lsc meeting edms

ricci cern

lhc cabling campaigns

standardisation of cabling

cabling strategy

cf edms

ls1 challenge

cabling campaign core