1. ELQA Electrical Quality Assurance
Introduction
When ELQA?
How is ELQA performed?
Resources
Organization
Practical example: ELQA during Long Shutdown 1 (LS1)
Conclusion

2. ELQA: Introduction
The electrical quality assurance concerns all superconducting circuits of the LHC machine (more than 1600 circuits).
The objectives of the ELQA tests are:
Electrical qualification of each superconducting electrical circuit, including the current leads and the active systems connected to the circuit.
Measurement of electrical parameters of each superconducting electrical circuit in order to verify reference values for the initial operation of the power converters and for the machine operation.
Verification of the integrity of the instrumentation used for the protection of the superconducting magnets and current leads.
All the ELQA tests are documented, based on approved procedure, with predefined conditions and safety aspects
The parameters of the circuits are stored in DB (Electrical Layout DB)
The ELQA test results are recorded in ELQA DB
The follow-up of a circuit is ensure via Manufacturing and Test Folder (MTF) as a part of EDMS
Non Conformities are reported and stored in MTF

3. ELQA: When ? Machine assembly: Hardware Commissioning of the machine:
ELQA tests were present during machine assembly to ensure the circuit correctness (Arc Interconnection Verification or AIV procedure, Partial Arc Qualification or PAQ procedure).
Hardware Commissioning of the machine:
ELQA tests are performed at warm to detect any major defect before cool down in order to intervene in case of need.
During the cool down of the machine, some of the circuits have an insulation to ground monitoring. If a fault is detected due to thermal contraction, the cool down might be stop and dedicated diagnostics could be launched.
Finally, ELQA tests are performed at cold in order to ensure the readiness and parameters of the circuits before powering test can start.
Machine Operation:
According to procedure, whenever a cold mass or part of the circuit being cold reaches 80 K, an ELQA test is required.
On request, after a powering fault that requires an electrical diagnostic on superconducting circuits.

4. ELQA: How ?
The ELQA tests are performed by trained Engineers and Technicians that have specific knowledge on the electrical measurement and circuit topology.
The parameters of the circuits and the criterion applied are predefined and stored in the database.
The software allows online validation of the tests. However, engineers are looking at the data and giving furthers analysis or performing additional diagnostics when a fault is detected.
The main goal of ELQA is to ensure qualitative work. Therefore, the ELQA team is focusing on the precision and the quality of the measurements rather than the duration of it. Nevertheless a great effort is put in place in order to stick to the schedule.
At the end of the test campaign, the ELQA project engineer validates the test results and finally gives the green light to proceed with powering tests.

5. ELQA: Follow-up webpage

6. ELQA: Resources Hardware and Software:
Hardware and Software have been developed according to ELQA needs, using components from the industry and adapted to our specificities. The development of the hardware and software is being shared between CERN staff and HNINP (Poland) collaborators. Several application based on LabVIEW have been developed to ensure the quality of the tests.
We are using 8 TP4 measuring systems (Test Protocol), 2 AIV measuring systems, more than 12 High Voltage measuring systems, and many other measuring equipment from the shelf.
In order to further develop and maintain our measuring systems to a high level, several contract have been signed with our collaborators from HNINP to support CERN staff.

7. ELQA: Resources Manpower:
The ELQA team is made of experienced and trained electrical engineers or technicians.
The core of the activity is based on 5 CERN staff (3 engineers and 2 technicians) with the support of Project Associates and fellow
During ELQA campaign, there is a peak of activity. In this period, experienced personnel is hired via our Polish collaboration for a defined duration. For example, during LS1, in average about 25 external collaborators were assigned to ELQA activities.
During long periods, as LS1, there was a rotation of personnel from the collaboration. The training of the personnel was done among the external collaborators.

8. ELQA: Organization
The planning of resources, the activity lists and the preparation work starts well in advance.
Dedicated internal meetings, general planning meetings , etc. are organized regularly. In case of LS1, the preparation started more than one year in advance.
On site, the work is planned and organised in advance by the ELQA project leader in agreement with the general planning of LHC.
A daily planning is organised for the ELQA team, for a maximum of 4 teams of 2 people, working in 2 shifts per day.
Reporting of the ELQA activity is assured by weekly report.

9. ELQA: typical example during LS1
ELQA tests during LS1 SMACC (Superconducting Magnets And Circuits Consolidation Project) Standard Campaign Magnet replacement: AIV Splices consolidations: PAQ_LS1

10. Summary of planned activities during LS1
before SMACC
DC Cables disconnection
Galvanic insulation installation
TP4-E
MIC-C
DOC-C
NCs solving
Warm-up
TP4C: Monitoring system of spool and 13kA circuits
before SMACC
TP4-A & B
MIC-W
DOC-W
Elqa during SMACC
ELQA for SMACC train: LS1-PAQ
Magnet replacement: AIV & PAQ.
Diagnostics and Follow-up of NCs.
Relocation and validation of C.L. heating system for DFBXs in IP1 and IP5. (R2E)
Upgrade and validation of temperature sensor electronics for 13kA circuits:TT891 & TT893(EN/EL, TE/CRG and TE/MPE).
Upgrade of instrumentation for 120A DCF powered via DFBs (TE/MSC and TE/MPE)
before cool-down
Elqa during cool-down
TP4-C: Monitoring system of spool and 13kA circuits
before powering
Galvanic insulation removal
DC Cables connection with new silver coated screws
10 days
3 weeks
3 – 4 months
3-4 weeks
2 teams
2 shifts
monitoring
1 team of 3 pers

11. Preparation for ELQA campaigns (1/2)
In order to perform ELQA campaigns, the circuit and the associated Power Converter must be “consigné” (TE/EPC & EN/MEF) and the DQHDS turned OFF (TE/MPE).
A galvanic insulation must be installed decoupling from the PowerConverter and allowing fast, easy and reliable connection to the circuit via the current leads:
Mainly 4 types of current leads (13kA, 8kA, 6kA and 600A) are spread around the LHC for a total of 1174 DC cable connections:

12. Preparation for ELQA campaigns (2/2)
In order to complete one entire sector, it required 2 days with 2 shifts/day of for 1 team of 2 persons
 One sector: 4 pers/day, for 2 days
Part of this job could be done in // with the start of ELQA campaign
Work organization:
The material (galvanic insulation, cables, banana plugs, screws, etc…) was prepared in advance (6 months before LS1).
The material was organized into container (plastic boxes), with their proper label for each DFBs.
A dedicated procedure was prepared with photos and used on place by all teams involved into it.
Detailed planning according to constraints.

13. Elqa @ cold (1.9K) before warm-up (1/2)
The ELQA campaign at cold, consist of verifying the integrity of a circuit, including its instrumentation and protective equipment (quench heaters).
The electrical tests can be grouped in:
local test (performed along the magnet itself): MIC-C and DOC-C. These test required the transport of the measuring equipment, TP4 system among the ARC.
global test (TP4-E) performed from the DFBs, even if the circuit goes across the ARC.

14. ELQA@ cold (1.9K) before warm-up (2/2)
The ELQA campaign is known from the past. The work was planned one year in advance (need of signing agreement with HNINP), and we tried to have trained people, especially at the beginning. Hardware and Software development were prepared one year before the start, with the goal of delivery 8 upgraded TP4 measuring systems (initially 4, and was limiting).
Time window required and allocated for this campaign: 10 days/ sectors, 2 shifts/day with 2 teams of 2 persons
 8 pers / day
 10 days / sectors
 maximum 2 sectors in parallel, exceptionally 3.
ELQA during warm-up / cool down:
At the end of the standard ELQA cold campaign, the monitoring system of some circuits was installed.
During the warm-up phase of a sector, this system allowed the monitoring of insulation to ground for 13kA and Spools circuits.

15. ELQA@ warm(300K) before SMACC
The ELQA campaign at warm is very similar to the previous one at cold, with different parameters. It consist of verifying the integrity of a circuit, including its instrumentation and protective equipment (quench heaters).
The goal of this campaign was to detect any weaknesses before SMACC in order to intervene on the circuits, if needed.
It also served as reference for the next campaign after SMACC
The same time window was required and allocated for this campaign: 10 days/ sectors, 2 shifts/day with 2 teams of 2 persons
 8 pers/day, 10 days with a maximum of 2 sectors in parallel

16. ELQA during SMACC List of planed activities during SMACC:
LS1-PAQ on all 8 Sectors during SMACC! Up to 5 in parallel.
19 Magnet replacements: AIV & PAQ 15 MBs, 2 SSSs, 1 IPQ.
Relocation of current lead heating system for DFBXs in IP1 (Left and Right) and IP5 (Right).
Upgrade of the measuring chain of temperature sensor for 13kA circuits.
Upgrade of the cabling regarding 120A circuit powered via DFBs: exchange of cabling and connector in order to fulfill High Voltage specifications. Validation of the measuring chain.
Follow-up of Non Conformities.

17. ELQA during SMACC: LS1-PAQ
this test was applied to the circuits that were sensitive to SMACC activities: 13 kA and distributed correctors (EDMS )
The goal is to ensure the continuity and the insulation to ground of the circuit.
The baseline was to have up to 4 Sectors in //, and the test performed on a daily basis (evening hours).
Daily basis test, changed to twice a week per sector, from 17:00
Field team performing the test
Message on Safety Panel to be changed
WISH tool to be signed when test is “PASSED” or block SMACC!
The test procedure was prepared in advance, but the hardware and software were finalized on site, once HNINP collaborator were trained.
Because of the safety aspects and the length of the circuits under test, a field team of minimum 3 persons was needed (use of electrical bike).

18. ELQA during SMACC: Magnet replacement.
A.I.V. test for Magnet replacement:
This test procedure was applied when a magnet was replaced
The goal is to ensure the correct connectivity of the magnet including all the circuits passing through it (Line N, etc…)
19 Magnets were planed to be replaced: up to 5 Sectors in parallel
A.I.V. test was strictly linked with Special Intervention Team and the collaboration was efficient and fruitful
AIV field team of minimum 3 persons performing the test, Reporting, Updating AIV DB

19. ELQA during SMACC: 13kA TT sensors
Upgrade of the measuring chain of temperature sensor for 13kA circuits:
Cannon connector (300V)
Redel connector (3,2kV)

20. ELQA after SMACC: Standard ELQA campaigns
warm, after SMACC (TP4 A&B):
similar to warm, before SMACC
ELQA during cool down, after SMACC (TP4-C):
similar to ELQA during warm-up, before SMACC
cold (1.9K) after SMACC, before powering (TP4-E):
similar to cold (1.9K) before warm-up
Preparation for powering (DC cable connection)

21. ELQA: Example of Non Conformity
RB.A12 fault to GND: EDMS

22. ELQA manpower during LS1
5 CERN Staff + 1 Fellow + 1 FSUs + 25 HNINP

23. ELQA manpower during LS1
Personnel was trained in advanced
Safety aspect (safety courses, personnel equipment, rescue mask, “habilitation éléctrique”, etc) were organized in advance.
Quantity and quality of personnel was appropriate
The personnel was working outside normal working hours, usually from 7:00 to 21:00
The rotation of the personnel was organised in advance in order to allow overlap and training time.
Real Team spirit was shared among all ELQA team members!
Priority given to ELQA team, as for CERN:
SAFETY : 1st, QUALITY: 2nd , SCHEDULE 3rd

24. Conclusions
ELQA test is mandatory to run and operate a safe complex machine.
The success of ELQA is the results of several components:
Huge effort all year long to maintain high level of knowledge and experience among the team members.
Organization and quality of the work is crucial for the success
Fruitful collaboration with our experienced colleagues from the institute in term of hardware and software.
Logistics to have all the material, components ready on time
Support of other CERN groups and departments
Respect of safety rules

25. Thank you for your attention !