A technical proposal for the consolidation of the LHCA cryogenic elec/control system for the HL-LHC era. 07/10/2017 Simon MARTIN Marco PEZZETTI Simon MARTIN

Technical status Electrical part 07/10/2017 Process Instrument Connection Field Box Electrical Cabinets Cabling Simon MARTIN

QSCA Upgrade Reflection Input Output 07/10/2017 Input Output Equipment: ▫ Cabinet ▫ Field Box ▫ Link Cabling ▫ Field cabling ▫ Plant Instrumentation Component selection Technical Choice +Functionality +Availability +Safety -Maintenance Technical subset : ▫ Safety chain ▫ Protection chain ▫ EMC ▫ Elec Distribution ▫ Hardware Interface ▫…. Technical optimisation ratio: Maximum technical result Minor resources/cost Technical requirements : ▫ Standards ▫ Electrical Spec ▫ EMC rules Simon MARTIN

SUMMARY of technical solution presented : QSCA Upgrade SOLUTION 07/10/2017 SUMMARY of technical solution presented : ▫ Push button Safety chain ▫ 3.3kv motor rotation test ▫ 3.3kv Cellule signal exchange ▫ Elec Distribution ▫ Hardware Interface ▫ Field box ▫ Field Cabling & Cable tray ▫ Instrumentation connection Simon MARTIN

Push-Button Safety Chain QSCA- Cabinet-Zoom Push-Button Safety Chain 07/10/2017 Goals -SIL level increased -Hardware simplified  unique safety relay -No relay forced Simon MARTIN

Rotation Test PROTOCOL QSCA- Cabinet-Zoom Rotation Test PROTOCOL 07/10/2017 Status During the test of electric motors, an operator has to force a relay. There is the risk that he makes a mistake and he activates another motor under maintenance. This is a risk for the operator who does the maintenance because he could be involved in a serious accident. ! No TEST Goals -Make safe and error free 3.3kv motor rotation test. -Motor test with remote control. -Simplified and standardized operation. -No manual relay forced, no human mistake ! -TEST MODE introduced in the UNICOS Control system. Simon MARTIN

3.3kV Cellule Order and Status QSCA- Cabinet-Zoom 3.3kV Cellule Order and Status 07/10/2017 NEW Circuit Breaker position status Goals -Make safe 3.3kv cellule orders (Unlock & Start) with SIL1 relay No possibility of forcing -Increase information of 3.3kv cellule status with “circuit breaker position status” Warning if 3.3kv cellule padlocked Simon MARTIN

QSCA- Cabinet-Zoom Distribution BT (400V) 07/10/2017 Goals -Distribution & Protection simplified (new design, new component…) -Main maintenance switch positioned on front doors. -Easy and faster operation recovery: In case of failure, “spare maintenance switch” have been added Simon MARTIN

QSCA- Cabinet-Zoom Distribution TBT 24V 07/10/2017 Old 24V distribution “Serial Loop” New 24V distribution with “Parallel BusBar” NEW 24V Bus Bar Goals Each device is supply from bus bar: -More flexibility to add or remove device - Easier diagnostic - Easier component disconnection & isolation - Better availability in case of failure of a component (degraded mode) Simon MARTIN

Interface connexion from field QSCA- Cabinet-Zoom Interface connexion from field 07/10/2017 Goals -Remove as possible Burndy Connector to reduce quantity of connexion -Field interface clearly defined Unique bloc terminal on bottom of cabinet. -Easy upgrade and modification (more flexible with accessible spare) Simon MARTIN

Overview of new CE standard cabinet Cabinet conclusion Overview of new CE standard cabinet 07/10/2017 Simon MARTIN

QSCA- Field Box-Zoom Cable Gland 07/10/2017 Status - Oil infiltration - Cable gland plate damaged Goal -Prevent infiltration by gravity Drilling only on bottom plate -Index Protection increased -Easy upgrade and modification Simon MARTIN

QSCA- Field Box-Zoom Removal of electronic 07/10/2017 Goal -Reducing equipment failure Active component removal -Reducing connection problem Screw less terminal bloc Problematic Field box bad environment: Vibration Aggressive oil Heating Screw terminal bloc Simon MARTIN

QSCA- Cabling & Instrumentation Cable tray & Protection 07/10/2017 Status Light cable tray & damaged cable clamp in bad environment (UV, Aggressive oil, Heating).  Cabling unprotected and damaged Goal -Cable protection increased Cable tray cover added  Cable sheath Simon MARTIN

QSCA- Cabling & Instrumentation Connector M12 Moulded as much as possible 07/10/2017 Status Lot of failures (Short circuit with ground) are caused by bad connection inside EV connector. Maintenance human mistake (re-assembly). Goal Reducing equipment failure  as possible welded and moulted connector  adaptor M12 connector to EV connector Industrial component following standard must be preferred than a special part developed at CERN Simon MARTIN

CONCLUSION 07/10/2017 The technical upgrade methodology/solution come out from CE section, other laboratory and industry experiences…Several technical solutions presented have been already installed in the various TE-CRG projects with very good results. Safety : functionalities have been upgraded to the actual international norms. Functionalities : technical installation present the same level of operation functionality. Availability : technical installation have been design to have better availability (to be confirmed by time..) (i.e. degraded mode operation have been installed: separation of electrical and instrumentation circuit) Maintenance : is easier by design : cabinet layout low density, better distribution, new terminal block… Simon MARTIN