US Participation in the LHC Hardware Commissioning

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US Participation in the LHC Hardware Commissioning
US LHC Accelerator Research Program
bnl - fnal - lbnl - slac

• Michael Lamm for the HC group
• 19 October 2004

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Hardware Commissioning Task
.to paraphrase the LARP Proposal. 2.1.1.
Hardware Commissioning

• HC not included in USLHC construction project
• US component builders most knowledgeable about
  operation and integration of US deliverables
  (best to help, have most to benefit from
  experience)
• Modest effort will significantly speed up
  commissioning
• Important feedback (to designer and builders)on
  effectiveness of component designs (..e.g. 2nd
  Generation IR)
• Effort should continue into beam operation to
  study issues such as component performance under
  dynamic loads

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Components to be Commissioned in 5 IRs
In IR1,2,5, 8 Cryo, Powering, Vacuum etc. tied
into the sector

Other important components Hadron and neutral
absorber for IR1, 5(LBNL) Other separation
dipoles in IR 1,2,4,5,8 (BNL)
IR 2,8 only
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Hardware Commissioning History

• 2002 HC part of LARP baseline
• Summer 2003 HC part of approved LARP
• Effort 2 FTE/year
• Sept 2003 Port Jefferson LARP meeting
• Establish LARP HC group
• November 2003 Discussion with CERN about
  Structure of US participation
• Defining job types, length of stays, role in
  commission
• February 2004 Refine participation, begin to
  recruit LARP participants, budget for 2004-6
• Present Understand time scale and scope of
  participation in light of the emerging LHC HC
  time line.

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CERN Installation and Hardware Commissioning
Milestones

• Major schedule revision is in the works
• Compressed installation and commissioning with
  beam in 2007
• The LHC is committed to make every effort
  require to provide colliding beams in the LHC in
  the summer of 2007
• -Update on the situation of the QRL 20
  September 2004
• Milestones
• Hardware Fitup (January-March 2005)
• First Inner Triplet Installation (Sept-December
  2005)
• Begin Hardware Commissioning (TBA)
• Sector Test (CANCELLED)
• Finish Commissioning (Summer 2007)
• First Circulating Beam (Summer of 2007)

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CERN Installation and Commissioning Org

• In the construction project US responsibility
  ends with acceptance of deliverables.
• LARP HC participation is through the CERN
  Organization
• Installation
• Installation is the responsibility of the CERN
  project engineer Ranko Ostojic
• Hardware Commissioning
• Coordinated by Roberto Saban through the hardware
  commissioning team
• Types of People needed
• Mechanical Engineers for Installation
• Cryogenic Engineers for Cryo Commissioning
• Magnet Physicists for Electrical and Powering

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How LARP Personnel Would Fit Into LHC

• Duration of Stays
• Short duration (2 weeks to 2 months) especially
  during fitup and installation
• Longer duration (at least 6 months but up to a
  year or more) during commissioning

• Person would be part of the installation or
  integrated into an equipment group participating
  in the hardware commissioning

Note Scope of LARP has been focused on US
deliverables. Recently CERN has identified a
shortage of qualified engineers and physicist to
complete the formidable global HC. e.g.
global cryogenic system, power systems, quench
protection, controls They are requesting our
help!
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LARP Hardware Commissioning Tasks

• Participation can be summarized by 4 general
  areas
• Above Ground Fitup
• First and only chance to assemble prior to tunnel
• Installation
• Provide technical assistance to CERN installers
• Commissioning
• Active members, particularly in the cryo,
  electrical, powering and protection
• Oversight
• Planning is essential in shortened installation
  and commissioning time frame

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(1) Mechanical Fitup

• Above Ground Mechanical Fitup
• Inner Triplet (D1,DFBX,Q3-Q1) does not include
  TAS fitup
• Time Frame January-March 2005 (approximate
  duration 8 weeks)
• Purpose of Test
• Assemble all pieces for one complete IR
• Mechanical fitup of interconnects
• Pipes adjustments to install length, dry fit
• Vacuum tests
• Shields, interconnect kits
• Magnets on alignment jacks
• Electrical continuity
• Exercise alignment (SSW?)
• Build DFBX Cable trays as per final installation

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Fitup Part II

• How are we preparing for this
• Developing detailed plan for interconnect
• 3-D model, drawings, parts list, procedures
• Generating parts and widgets for assembly
• Work with CERN to develop run plan for
  installation
• Level of effort
• 0.4 FTEs spread over the 3 labs.
• Mostly mechanical engineers

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(2) Installation

• Time Frame First sector TBA, sometime in late
  2005?, Continuous throughout FY2006, 07?
• Check mechanical/vacuum/cryo connections
• Check installation procedures
• Participate in electrical connections
• Review electrical and alignment data
• How we are preparing for this
• Writing interconnect assembly procedures etc.
• Through active participation in the Above Ground
  Fitups
• Level of Effort FY05-6-7
• 1 FTE spread over 3 labs
• 1/3 FTE on First sector
• Time distribution depends on on details of
  installation schedule

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(3) Commissioning

• Time Frame Mid 2006? through end of 2007
• Purpose
• Once installation complete, all aspects of
  bringing system to full operation.
• How we are preparing for this
• Through reviewing CERN documentation on
  Commissioning Test Procedures
• By remotely following the HC planning progress
  through the HC working group
• By defining with CERN our roles in HC
• Level of Effort (mostly starts in FY06)
• Full time FTE physicist
• Cryo engineer (s) for IR cryo system and DFBX/HTS
  .
• 3.5 FTEs in FY06-07, probably one FTE in FY08?

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(4) Oversight

• Oversight
• Time Frame Now through Spring 2007
• Discussion with CERN on defining participation
  both IR and new requests
• Review installation and commissioning plans
• Recruit participants for long range stays
• Prepare budgets and schedule including Long Term
  Living Arrangements
• Level of Effort
• Mostly .1/institution/year
• Increase FTE in FY05 to insure hit the ground
  running for Installation/commissioning in FY06

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Proposed FTE by Task

• Original Plan Calls for 0.5 FTE in FY04, 2 FTEs
  in FY05-6-7, 1 FTE in FY08
• Total of 7. 5 FTEs

• Distribution Depends on CERN Schedule
• Late Start to Installation shifts Effort to
  FY06-7
• Effort total slightly increases

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Proposed FTE by Institution

• Distribution in FY06-7 depends on home
  institution of long term participants
• Short term visitors are from all labs, local
  experts in mechanical aspects of installation,
  cryo engineering and magnet scientist
• We have identified Fermilab Magnet Physicist for
  FY06, Fermilab Cryo Engineer for FY06-7. Still
  working on Physicist and Cryo engineers,
  particularly in FY07, from all institutions.

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Proposed

• Again, effort shifted towards FY06-7 (relative to
  original plans)

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Hardware Commissioning Conclusion

• HC is an important way for the US to contribute
  to the LHC project
• Inner triplet HC contribution is established
• Recent new requests in global commissioning could
  greatly expand our role
• We have presented our best estimate of required
  costs for HC of inner triplet based on CERN
  schedule
• Plan for success (i.e funding and participation
  is minimal and without contingency)
• Does not include cost of participation in global
  HC
• Taking responsibilities in Inner Triplet Region
  (an area in which the US has a large and unique
  expertise) will help in the global HC (free up
  CERN personnel, LARP IR personnel can take on
  global jobs).
• Major uncertainties
• Uncertainty in CERN schedule
• Cost of living in Geneva (addressed at LAPAC)
• Lining up the appropriate people at the right
  time