Cryogenic Instrumentation and Controls Cryogenic Instrumentation and - - PowerPoint PPT Presentation

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Cryogenic Instrumentation and Controls Cryogenic Instrumentation and - - PowerPoint PPT Presentation

Sep 15, 2022 239 likes •392 views

experience with the experience with the Cryogenic Instrumentation and Controls Cryogenic Instrumentation and Controls of String 2 of String 2 Paulo Gomes for the ACR-IN team with the precious contributions of D. Bozzini, L. Serio, his

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SLIDE 1

LHC / ACR / IN / PGomes

  • pg. 1

LHC - CP 3rd Workshop , 21-22 March 2002

experience with the

Cryogenic Instrumentation and Controls

  • f String 2

experience with the

Cryogenic Instrumentation and Controls

  • f String 2

Paulo Gomes for the ACR-IN team with the precious contributions of

  • D. Bozzini, L. Serio, his Operators team, IAS, BARC, and many others…

MQ1 MQ2 MB 1 MB 2 MB 3 MB 4 MB 5 MB 6 DFB QBV MRB QRL

QRLSA QRLSI

  • String2 layout
  • LHC regular cell
  • commissioning check points
  • the commissioning
  • the thermometers issue
  • ther instruments
  • LHC
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SLIDE 2

LHC / ACR / IN / PGomes

  • pg. 2

LHC - CP 3rd Workshop , 21-22 March 2002

DP STRING PA QLISR PA QLISF DP LHCa DP LHCb DP DFB PA DFB

MQ1 MQ2 MB 1 MB 2 MB 3 MB 4 MB 5 MB 6 DFB QBV MRB QRL

QRLSA QRLSI

PLC1 PLC2

  • n the machine

distributed racks central rack control room

full String 2 full String 2

3 2 7 Profibus 40 350 300 620 80 OWS Ethernet PLC fieldbus segments remote I/O stations signal conditioners signal cables sensors actuators

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SLIDE 3

LHC / ACR / IN / PGomes

  • pg. 3

LHC - CP 3rd Workshop , 21-22 March 2002

DP LHCa DP LHCb

MB 1 MB 2 MB 3 MB 4 MB 5 MB 6

  • n the machine

distributed racks central rack control room

  • one order of magnitude less instruments
  • more regular topology

Siemens S7-400 UNICOS - Schneider PCVue32 UNICOS - PVSS industrial + custom + Siemens ET200M custom ACR/IN rad-tol intelligent instruments dumb rad-tol instruments

  • custom rad-tol front-end
  • UNICOS, Schneider, WorldFip

NEED to be validated

  • n the String in 2003

LHC regular cell LHC regular cell

2 WorldFip 6 18 30 23 16 3 2 7 Profibus 40 350 300 620 80 OWS Ethernet PLC fieldbus segments remote I/O stations signal conditioners signal cables sensors actuators

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SLIDE 4

LHC / ACR / IN / PGomes

  • pg. 4

LHC - CP 3rd Workshop , 21-22 March 2002

  • n the machine

distributed racks central rack control room

PLC

Profibus addresses I/O-mem mapping addresses communication with ABB logic of interlocks, alarms, process sensor calibration functions correspondence SN --Tag mathematical function integrity

OWS

synoptic layout mapping of PLC addresses interlocks, alarms, process

signal conditioners

choice of conditioner type / range calibration of conditioner pin-out

sensors

choice of sensor type / range wrong info on TT type (CX, Pt100, CRT) correspondence SN --Tag swapped SN unknown SN unreported change of SN late info on SN mechanical mounting wire/ block thermalisation electrical mounting electromagnetic noise sensor / wire damaged pin-out

remote I/O stations

Profibus address I/O module type pin-out

Profibus networks

bus terminations contacts inside connectors

signal cables

wire damaged swapped sensors pin-out

Ethernet

IP addresses, routers

ACR / IN IAS

  • thers

commissioning checkpoints commissioning checkpoints

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SLIDE 5

LHC / ACR / IN / PGomes

  • pg. 5

LHC - CP 3rd Workshop , 21-22 March 2002

  • 1. Ethernet

2 PLC / EWS / OWS

  • 2. Profibus

all remote I/O stations accessible (cable continuity, Profibus address) all I/O modules well configured, in each station

  • 3. databases PLC & OWS synchronised (by forcing values on PLC)

all parameters & values for sensors / actuators all parameters & thresholds for interlocks / alarms / process

  • 4. once SPV application on the OWS is reliable,

qualitative inspection of sensor values (@ room T, P) identification of completely wrong values wrong pinout / broken sensor, wire, conditioner CX / Pt100 identification error wrong range settings

  • instrumentation commissioning needs PLC / OWS / ethernet running
  • 5. first set of simple/obvious corrections
  • 6. quantitative/fine inspection of values (@ nominal T, P, dT_gradients)

swapped, inaccurate, non-identified sensors

  • 7. if problem

follow signal chain (hardware + software) connector on machine / connector on rack / connector on I/O module PLC physical value / PLC engineering value / OWS database

the commissioning the commissioning

NEED access to LAN in LHC tunnel

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SLIDE 6

LHC / ACR / IN / PGomes

  • pg. 6

LHC - CP 3rd Workshop , 21-22 March 2002

TT with SAME transfer function 300 Pt100 TT with INDIVIDUAL transfer function 140 Cernox NEED much more DISCIPLINE from the TT users

the thermometers issue - identification the thermometers issue - identification

each and every Cernox must be : UNAMBIGUOUSLY identified IN TIME for producing the corresponding PLC interpolation table enormous effort to get IDs from the responsibles of every system not always correct at the first iteration !!! (440 TT)

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SLIDE 7

LHC / ACR / IN / PGomes

  • pg. 7

LHC - CP 3rd Workshop , 21-22 March 2002

wires not protected against sharp edge cooper wires instead of manganin wires point welding of support the specs were not respected (materials, mounting, wiring) dangling and stretched wires

SOME have been repaired

the thermometers issue - installation the thermometers issue - installation

  • thers … nobody has a clue on how they are mounted !!!

MUST users take photos of every TT ?

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SLIDE 8

LHC / ACR / IN / PGomes

  • pg. 8

LHC - CP 3rd Workshop , 21-22 March 2002

>10 TT lost >10 TT broken wires

the thermometers issue - Current Leads the thermometers issue - Current Leads (200 TT)

100% >10% bad documentation quality assurance ? all 38 CL numbered in reverse order in every CL circular permutation of the 6 TT TT type some changed from CX to Pt100

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SLIDE 9

LHC / ACR / IN / PGomes

  • pg. 9

LHC - CP 3rd Workshop , 21-22 March 2002

the thermometers issue - accuracy the thermometers issue - accuracy

0.1 1. 10. 100. 1 000. 10 000. L Q O A T _ T T 2 1 1 L Q O A T _ T T 2 1 2 L Q O A T _ T T 2 1 4 L Q O A T _ T T 2 2 1 L Q O A T _ T T 2 2 2 M B 1 _ T T 3 4 1 M B 1 _ T T 3 4 2 M B 1 _ T T 3 6 1 M B 1 _ T T 3 6 2 M B 1 _ T T 4 4 1 M B 1 _ T T 4 6 1 M B 2 _ T T 3 4 1 M B 2 _ T T 3 4 2 M B 2 _ T T 3 6 1 M B 2 _ T T 3 6 2 M B 2 _ T T 4 4 1 M B 2 _ T T 4 6 1 M B 3 _ T T 3 4 1 M B 3 _ T T 3 4 2 M B 3 _ T T 3 6 1 M B 3 _ T T 3 6 2 M B 3 _ T T 4 4 1 . M B 3 _ T T 4 6 1 L Q O A G _ T T 2 1 1 L Q O A G _ T T 2 1 2 L Q O A G _ T T 2 1 4 L Q O A G _ T T 2 2 1 L Q O A G _ T T 2 2 2

DT [mK]

1.798 1.798 1.790 1.869 1.898 1.8 PLC 1.9 PLC

SSS3 SSS4 MBP201 MB2PA2 MBP2N1.V3 5mK <-> 0.25%

in the MAGNETS @ nominal T=1.8K, expected accuracy is better than 10mK all errors understood, thermometers calibs OK no re-calibration needed ! (28 TT)

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SLIDE 10

LHC / ACR / IN / PGomes

  • pg. 10

LHC - CP 3rd Workshop , 21-22 March 2002

MB1 / MBP2O1:

2 TTcm lost on the Bench X 1 TTcm replaced

  • 1 TTvac

broken wires ~

MB2 / MBP2A2:

2 TTvac not perfect mounting 40 mK

MB3 / MBP2A1s:

2 TTcm damaged on the Bench ~ 1 TTvac not perfect mounting 50 mK 1 TT broken wires ~ 1 TT reversed wires ~

MQ1 / SSS3:

1 TTcm bad calib of unknown origin 100 mK 1 TTvac not perfect mounting 30 mK 1 TTvac Cu wires + 10cm inox 1 000 mK 1 TT to gnd ~

MQ2 / SSS4:

2 TTcm swapped

  • 1 TTvac

not perfect mounting 30 mK 1 TTvac 10cm inox 300 mK 3 TT broken wires ~ 2 TT reversed wires ~ 1 TT grounded wires ~

the thermometers issue - magnets the thermometers issue - magnets (28 TT)

1/3 2/2 2/2 1/4 2/4 2/2 1/4 2/3 2/2

MB4 / A001_2:

1 TTcm damaged ~ 100%

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SLIDE 11

LHC / ACR / IN / PGomes

  • pg. 11

LHC - CP 3rd Workshop , 21-22 March 2002

too many broken / grounded wires swapped sensors / wires re-installed sensors lost sensors (during Bench tests ?)

the thermometers issue - let’s be serious! the thermometers issue - let’s be serious!

most of them repaired (but degraded accuracy) too long time to identify repair high risk of blindness for LHC !! ( series magnets have only 1 TT )

ACR/IN should not supply TT without knowing their exact destination users must strictly follow installation guide users should produce accurate documentation on location, pin-out, follow-up users should check integrity at all phases of assembly (traveler doc) ACR/IN has no resources to inspect all systems before closure ! should users take photos of every TT ?

  • therwise

risk of damage

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SLIDE 12

LHC / ACR / IN / PGomes

  • pg. 12

LHC - CP 3rd Workshop , 21-22 March 2002

1 PT lost in MB1 / MBP2O1 3 LT (LHe wetting indicators) grounded wires

  • ther instruments
  • ther instruments

1 EH lost in MB1 / MBP2O1 3/10 intelligent valve positioners lost firmware config card replacement not LHC

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LHC / ACR / IN / PGomes

  • pg. 13

LHC - CP 3rd Workshop , 21-22 March 2002

many unexpected problems 3 months to commission only the cooldown related instruments Operator and Engineering WS next to the plant

commissioning summary commissioning summary

NEED access to LAN in LHC tunnel 2 more months commissioning instruments & control for nominal conditions ( T, P, I ) 2.5 more months still hunting for bad TT (not yet finished !) commissioning time MUST not be neglected !! the positive note: we managed to always be on time for the milestones (also thanks to mechanical assembly delays …)

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SLIDE 14

LHC / ACR / IN / PGomes

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LHC - CP 3rd Workshop , 21-22 March 2002

and for the LHC ? and for the LHC ?

commissioning time MUST not be neglected !! NEED access to LAN in LHC tunnel for commissioning & maintenance custom rad-tol front-end, WorldFip, Schneider, UNICOS NEED to be validated on the String in 2003 let’s be more serious about the expensive instruments we stuff into the machine !!