Consolidation needs for the Electrical Distribution, Control Cables and Optical Fibres Equipment F. Duval

Outline 2 1. Boundary Conditions 2. Methodology 3. Domains of Consolidation  Cables  Fibres  High Voltage Network  Low Voltage Network  Controls  General 4. Conclusion 12 September 2013Consolidation Day - François Duval EN-EL

Why consolidation ? 3  Non compliance to present safety and technical norms  Ageing equipment everywhere  Well beyond manufacturer recommended lifetime (reliability)  Impossibility to find spares  Unsafe to manoeuver  Layered installation of equipment  Evolution through the addition of strata instead of an integrated approach  Radiation damage  Mostly cables and fibers but also emergency stops  Overcrowded passages and tray  Needs beyond the EL 2025 program (including major HV Upgrade & Consolidation projects) 12 September 2013Consolidation Day - François Duval EN-EL

Methodology 4  Study the different domains  Risk analysis for each to determine priority done or in preparation  The costs quoted are based on supply contracts and experience (e.g. cabling)  Systems thinking rather than replacing like with like  Every consolidation item is documented in detail in EDMS 12 September 2013Consolidation Day - François Duval EN-EL

Domains of Consolidation 5 12 September 2013Consolidation Day - François Duval EN-EL SPS machine Critical state 1:  Point 5 surface, shafts and underground  Point 4 surface, shafts and underground  Point 3 surface, shafts and underground Critical state 3:  Point 6 surface, shafts and underground  Point 1 surface, shafts and underground  Point 2 surface, shafts and underground  Point 7 surface, shafts and underground Critical state 5:  TT60, TT70 Shafts are the most critical areas for all points. PS-Complex and Meyrin site Critical state 2:  Bld (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 Priorities for Cable Clean Up

Domains of Consolidation 6 ▶ Taking into account the LIU project and the priorities for overcrowded areas, we propose to clean up during LS2: ▶ the booster complex ▶ the SPS-P5 during LS2  Concerns ~10’000 cables  Total estimated cable length: 1500 km  14 MCHF  8 FTE 12 September 2013Consolidation Day - François Duval EN-EL Cable Clean Up Cleanup cables on overcrowded areas Cannot pull cables in the proper technical way This situation is general for SPS In some cases, cables cannot be installed anymore EDMS &

Domains of Consolidation 7  In order to exchange the cables in the irradiated areas of the SPS to ensure operation, two cable replacement campaigns similar to the one which is taking place in SPS TS1+ will have to be organized during LS2  These two areas will be selected after the conclusions of the RIAC and other constraints  The procurement of new cables for these campaigns will start already in  The studies to prepare these campaigns as well as the procurement of cables will take place in advance of LS2 ( ). The budget for these is included in this request. Number of cables to be replaced: ~1200 Total estimated cable length: 600 km  4 MCHF (1.1 MCHF already funded)  5 FTE 12 September 2013Consolidation Day - François Duval EN-EL Irradiated Cables EDMS

Domains of Consolidation 8  Consolidation of the network  the dimensioning of the existing, CERN-wide, infrastructure to cope with new users needs. This was until now mainly paid by the IT/CS Group.  the replacement of radiation sensitive fibres in all radiation areas Total estimated cable length: 600 km  6 MCHF  10 FTE 12 September 2013Consolidation Day - François Duval EN-EL Fibres EDMS

Domains of Consolidation 9  Tools for management and monitoring  Creation and population of of an optical fibre database “Fibrothèque” based on the existing Cablothèque.  Implementation of an on-line transmission quality monitoring system based. Total estimated  0.9 MCHF for the Fibrothèque  0.23 MCHF for the Online Monitoring Tools Both including manpower 12 September 2013Consolidation Day - François Duval EN-EL Fibres EDMS EDMS

Domains of Consolidation September 2013Consolidation Day - François Duval EN-EL High Voltage Network  Consolidation of old protection relays  Necessary upgrade on functionalities after the consolidation of the 66 kV protection system ( communication, differential..)  Poor reliability due to ageing of electronic components (e.g. drift of time constants)  200 relays to be replaced,  4 MCHF  Consolidation of the 400 kV protection system  RTE now requires an additional breaker (incomer) in order to comply with the French regulations  Consolidation of the protection system:  Necessary upgrade on functionalities after the consolidation of the 66 kV protection system (communication, differential..)  Separation from 18 kV pulsed system (room, 48Vdc, etc.)  1,5 MCHF CERN RTE EDMS EDMS

Domains of Consolidation September 2013Consolidation Day - François Duval EN-EL High Voltage Network  Consolidation of the PS and administrative areas in Meyrin: Necessary to withstand increasing short circuit current and necessary to extend switchboards not anymore available on the market.  Consolidation of two substations (ME16 & ME49)  Operation problems  Old cubicles will be reused as spares  Consolidation of HV power cables  Larger section  External insulation in very bad shape  Consolidation of distribution transformers  Cope with present power demand  Continuous effort to eliminate non compliant transformers  Switch from oil transformers to dry type  Oil transformer pits not compliant with CERN safety rules  2 MCHF EDMS

Domains of Consolidation September 2013Consolidation Day - François Duval EN-EL High Voltage Network  Consolidation of Meyrin Diesel Generators  No more spares for the generator sets  The cooling system and various mechanical components are at the end of their lifetime  3MCHF  Consolidation LHC Diesel control  Diesel system reliability decreasing (see monthly test reports)  Control system needs upgrade (com, safe connection, etc.)  0.5 MCHF  SPS and Meyrin Safety network  Following the upgrades and consolidations in the SPS and in Prevessin, install power cables, reorganize the BKs, modify control system accordingly  1 MCHF EDMS EDMS

Domains of Consolidation September 2013Consolidation Day - François Duval EN-EL Low Voltage Network  Consolidation of the Distribution networks  Consolidation based on risk analysis and fleet assessment  Consolidation of the whole distribution system according to present and future needs  208 switchboards to be replaced until 2020  30 MCHF  Consolidation of the 48 Vdc distribution systems  Consolidation based on risk analysis and fleet assessment  Redesign of the complete system (redundancy, LED based safety lighting)  Upgrade of functionalities (double supply, separate battery pack, by-pass functionalities, etc.)  27 systems will be replaced  4.5 MCHF EDMS , & EDMS

Domains of Consolidation September 2013Consolidation Day - François Duval EN-EL Controls  Consolidation of the PLC system  The evolution of the network requires modifications of some of the PLC functionalities  No spares for ageing PLC systems  5 PLC systems will be consolidated (ATLAS Diesels, Autotransfert, Normal/Secours at LHC1)  0.42 MCHF  Consolidation of the local SCADA infrastructure  Replacement of the RTUs by a local SCADA,  33 substations (or group of substation) will be consolidated  2 MCHF EDMS EDMS

Domains of Consolidation September 2013Consolidation Day - François Duval EN-EL General  North area consolidation  Inside the global North Area Consolidation project  23 switchboards and 9 UPSs will be replaced and adapted to the new power, space, etc. requirements  5.9 MCHF  Consolidation of the AUG chains  Replacement of 20 racks and 1800 buttons,  Redesign of AUG chains (1’500 buttons)  Suppression of 400 superfluous buttons mainly in LHC surface buildings.  Replacement of ~400 membranes  1.6 MCHF EDMS EDMS

… in summary 16 DomainBudget [MCHF] Cables 18 Fibres 7.13 High Voltage Network 12 Low Voltage Network 34.5 Controls 2.42 General September 2013Consolidation Day - François Duval EN-EL  The Consolidation Programme addresses the items which are urgent to ensure safe and reliable operation of the Electrical Distribution Network as well as the control cable and optical fibre infrastructures  Resources for LS2 is an issue…..