Accelerator Consolidation Workshop TEEPC consolidation plan JeanPaul Burnet

Accelerator Consolidation Workshop TE/EPC consolidation plan Jean-Paul Burnet ACC consolidation day, 12/09/2013 2

Status of EPC equipment & control Ø Present consolidation plan (Simon’s file) Ø Update of the consolidation plan with present MPP Ø Remaining issues & proposals Ø ACC consolidation day, 12/09/2013 3

Status of EPC equipment TE-EPC is managing all the power converters for magnets and some for RF systems. 40% of the equipment are less than 10 years old 50% of the equipment are more than 30 years old Older ones are close to 50. EPC has already 43 MCHF in the Simon’s file (until 2020) which represents 50% of the EPC project budget. The EPC consolidation items are only for replacement of old equipment. No item can be considered as maintenance (recurrent process) or infrastructure upgrade or tools. ACC consolidation day, 12/09/2013 4

Why is it so difficult to consolidate ? the 5300 power converters in operation are from 460 different types ! LHC is done with 10 types, so the difficulty is in the injector and experimental areas. All power converters are custom equipment designed mainly by CERN. No industrial product in our domain. ACC consolidation day, 12/09/2013 5

Status of EPC control After more than 40 years there is a zoo of 8 different types of controls electronics in use with power converters: 1. CAMAC 2. MIL 1553/G 64 3. PLC 4. RS 422 5. Junction Crate 6. MUGEF 7. FGC 2 8. FGC 3 An important goal for the future is to the reduce the number of different types of controls to make support easier. PS LHC Total ~5200 SPS Huge effort to maintain all these obsolete hardware and Software, costly in manpower! ACC consolidation day, 12/09/2013 6

Status of big power system PSB main power converter will be replaced in the framework of LIU. New SVC is needed with the new sub-station ME 59, requested for LS 2. PS main power converter was replaced by POPS. SPS main power converters are fully consolidated during LS 1. Spare SVC (new BEQ 1) is requested for LS 2. ACC consolidation day, 12/09/2013 7

Present consolidation plan Up to 2013, only injector chain equipment were considered for consolidation. Only most critical equipment were upgraded or replaced (example, POPS). No full consolidation were done per machine. For experimental areas, nothing was done. First proposal for the North area consolidation dates from 2001! New facilities (HIE-ISOLDE, ELENA, …) get the priority which always postpones the experimental area consolidation. A status board of the consolidation need per machine is shown afterward with its evolution over the years. ACC consolidation day, 12/09/2013 8

EPC Consolidation status board after LS 1 LHC program ACC consolidation day, 12/09/2013 9

Update of the consolidation plan In the present plan, the north area should have start in 2015, but with the present MPP, it will not be possible for EPC. Idem for EAST Withdraw of 23 MCHF over the 43! Here are the main objectives for EPC with our present MPP for the coming years including all projects : ACC consolidation day, 12/09/2013 10

EPC main objectives before LS 2 Machine End of Project total cost Status LINAC 4 LT-LTB-BI 2014 2017 ACC 10 MCHF 800 k. CHF Commissioning New request RD 1 replacement (LHC) SM 16 -26, PS-RF, QKECT (PS) CANADA (PSB) SPS extraction 2016 2017 2016 ACC ACC 1 MCHF 2. 4 MCHF 1. 2 MCHF 1 MCHF Approved New proposal HIE-ISOLDE TSR (ISOLDE) ELENA AD consolidation AWAKE SESAME S-FRS 2015 2018? 2016 2019 2018 2016 ACC 2. 2 MCHF 3. 5 MCHF 890 k. CHF 3 MCHF 240 k. CHF 1 MCHF 800 k. CHF Approved Not approved Approved LHC program ACC consolidation day, 12/09/2013 11

EPC main objectives for LS 2 Machine End of Project total cost Status LIU PSB LS 2 21 MCHF Approved LIU PS LS 2 2. 6 MCHF Approved TT 2 consolidation LS 2 ACC 3. 8 MCHF Approved SVC SPS (new BEQ 1) LS 2 ACC 10 MCHF Approved SVC Meyrin ME 59 LS 2 ACC 7 MCHF New request LHCCONS (R 2 E) LS 2 ACC 20 MCHF Approved LHC 11 T (Nb 3 Sn) LS 2 ? Approved? All LHC program ACC consolidation day, 12/09/2013 12

EPC Consolidation status board after LS 2 ACC consolidation day, 12/09/2013 13

EPC main objectives for LS 3 Machine End of Project total cost Status New Inner-triplet LS 3 10 MCHF? Approved SPS aux & COD LS 3 ACC 6 MCHF EPC tentative EAST LS 3 ACC 5 MCHF EPC tentative TT 20 LS 3 or LS 4 ACC 3 MCHF EPC tentative NORTH LS 3 or LS 4 ACC 30 MCHF EPC tentative LHC program The consolidation of the experimental areas is postponed to LS 3 but depending of new approved projects, it could be postponed to LSXX !!! ACC consolidation day, 12/09/2013 14

EPC Consolidation status board after LS 3 Best case, East – North done in LS 3 Most likely situation with present MTP. For EPC, the NORTH consolidation is a 5 year project before installation. For LS 3, EPC has to start working on it from 2017 ! Seems very difficult with LIU workload for LS 2. ACC consolidation day, 12/09/2013 15

Coordinate the consolidation of the experimental areas For Experimental Areas, the powering of these facilities should be reviewed to reduce energy consumption. For EAST, reduction of 95%, saving 500 k. CHF/year, 30 magnets to be replaced. For NORTH, reduction of 30%, saving 800 k. CHF/year, 120 magnets to be replaced. This requires : v to have laminated magnets v to operate the magnets in pulse mode The consequences are: v Replace of solid yoke of magnets v Change of power converter types and ratings v Change of the electrical distribution (less transformers, different sockets) v Reduce water cooling needs The consolidation shall be planned for the same LS for all groups (EL, CV, MSC, MPE, EPC). ACC consolidation day, 12/09/2013 16

Remaining control issue Even with this plan, the control issue will not be solved. Here you can see the evolution of the converter controls: After LS 1 After LS 2 After LS 3 Still 1000 MIL 1553 devices after LS 3 ! Still 300 MUGEF devices after LS 3 ! FGC based control systems will be in all machines but mixed with older control system ACC consolidation day, 12/09/2013 17

Solving control issue To solve the control issue, a plan could be added with 2 milestones: v LS 2: migrate all converter control to FGC from LINAC 4 to PS v LS 3: migrate all converter control to FGC for SPS and all experimental areas This could be possible with additional resource as requested in our MPP and a dedicated ACC budget for the upgrade of the converter control. Expected situation after LS 3 FGC based control systems + Industrial controls ACC consolidation day, 12/09/2013 18

Additional objective for LS 2 With the present plan, we replace equipment for LIU and we consolidate critical equipment with the ACC. The result will be a mix of new and old equipment with different control system. EPC would recommend to upgrade all equipment to get an unified machine. from LN 4 to PS. Estimation to be done. ACC consolidation day, 12/09/2013 19

Summary • EPC has many equipment to consolidate • With the present MPP, the experimental areas can’t be consolidated before many years • An increase of 10% of EPC manpower is needed to launch consolidation of the experimental areas • The consolidation of experimental areas has to be coordinated between all the groups and plan for a same LS • Availability of NORTH, EAST, AD will decrease up to …? • The zoo of converter controls should be addressed, risk analysis is not enough • The EPC item on the Simon’s file has to be updated with new objectives defined after this review ACC consolidation day, 12/09/2013 20