Preparations for Installation, Testing and Commissioning

Preparations for Installation, Testing and Commissioning based on Experience at

CERN, SNS and Siemens

Eugène Tanke

FRIB / MSU

ESS Seminar, Lund, 6 March 2013

E.Tanke, Seminar at ESS, Lund, 6 March 2013 2

Outline

Project Goal for the Accelerator Path towards the Goal Technical obstructions on the Path and some Remedies pertaining to installation,

testing and commissioning Summary and conclusion


Project Goal and typical path towards it

For the accelerator the Project Goal translates as: Deliver a (fully) integrated and (fully) functional

accelerator on time and within budget Reach specified beam performance at the output

Given the design, reaching the goal will require Scheduling each of the installation, testing and

commissioning phases and doing the actual installation, testing and

commissioning and tracking that scope is implemented on schedule and

within budget and success is guaranteed...


Questionable Path towards the Goal


Preparations for Installation

Receiving, Assembly, Testing and Storage area is crucial SNS had RATS facility of more than 5500 m2

Installation will be further aided by Installing tested equipment (FAT*) Service Building: Detailed rack layout and rack

installation plan Tunnel: Lattice file, containing names and locations

in global coordinates of beam line devices Good estimate and coordination of work involved

SNS "Field Coordination" 119 FTEy

*Factory Acceptance Test


Obstructions on the Path towards the Goal (1)

Ultimately during beam commissioning (if not sooner) lack of performance may show up

Examples of root causes for lack of performance are poor documentation, poor design, poor quality materials, lack of integration, machining errors, cabling errors, software errors, alignment errors, inadequate testing etc

Such deficiencies are not uncommon (most if not all labs have their examples) and...

…can be very costly and time consuming to fix


Obstructions on the Path towards the GoalDesign phase: LHC magnets from FNAL* (2)

* http://fnal.gov/directorate/OQBP/index/oqbp_misc/Final_LHC_Root_Cause_Analysis_Report_Rev2_19Sep07.pdf

http://fnal.gov/directorate/OQBP/index/oqbp_misc/Final_LHC_Root_Cause_Analysis_Report_Rev2_19Sep07.pdf


Obstructions on the Path towards the GoalConstruction/assembly phase: SNS DTL (3)

Shortly before mounting drift tubes in the first SNS DTL tank (#3), vacuum leaks were detected on the drift tubes

Leaks were traced to e-beam weld (water/vacuum)

E-beam was deflected due to insufficient shunting of the PMQ field, missing the intended joint

E-beam penetrated the Cu body and damaged the PMQs


Obstructions on the Path towards the GoalTesting phase: CERN RFQ2a (4)

Performance of the CERN RFQ2a was hampered by oil pollution from a roughing pump due to an improperly functioning vacuum interlock system

An additional RFQ (RFQ2b) had to be built

CERN RFQ2b (200 mA p)

with pulsed ion source on the

right and linac2 on the left


Can one reduce the risk of such Obstructions ?

Proper testing and Q/A procedures combined with full integration will reduce or even eliminate such risk But what exactly should one test and how?

In industry the so-called V-model is widely used (see next slide)

How can one improve systems integration?


V-model as defined in industry

DVM=Design Verification MethodDVP=Design Verification Plan


V-model applied in an accelerator: Requirements Definition

Define and document System Requirements, and the Sub-System, Device requirements and specifications driven by these, e.g. Magnet requirements (45 deg dipole, 5 cm aperture

1T , 1 m, dB<0.1%) drive specifications (e.g. RT, n windings of diameter x, 100 A, yoke shape etc)

Avoid requirements/specifications that cannot be tested

Do not list the same requirements in multiple documents

Once device/system built, test against these requirements


Now we may have a handle on this problem


Define and document test plans Define appropriate and comprehensive tests e.g.

Leak test a water cooling system with water or with helium?

Verify in/out control of diagnostics

Test against requirements/specifications and document results

Use a Design Verification Matrix (DVM) to track which requirements have been verified

V-model applied in an accelerator:Requirements Verification


V-model applied in an accelerator:Siemens Particle Therapy systems

Synchrotron and Linac

Layout for Kiel facility (now dismantled)Raster scan


Test at vendor where appropriate

Test equipment before installation and where appropriate, have as much tested as possible at the vendor (FAT) Avoids time loss due to shipping equipment back Witness construction and tests at vendor

Due to schedule pressure, one may be tempted to skimp on testing because after installation and/or during beam commissioning proper functioning of equipment will be confirmed, but.....


Consequences of insufficient / delayed testing (as apposed to thorough / early)

If proper functioning of equipment is not confirmed after installation and/or during commissioning, one may suffer substantial delays

Commissioning is typically on the critical path

increased costs Example: how much does it cost to run the cryoplant during

4 hours of debugging and repair of a magnet problem? (additional) rework "standing army"


Can one reduce the risk of such Obstructions (to reaching the Goal) ?

Proper testing and Q/A procedures combined with full integration will reduce or even eliminate such risk But what exactly should one test and how?

In industry the so-called V-model is widely used

How can one improve systems integration? Preparation: Set up a framework for integration, that allows

for tracking of requirements. Industry uses tools such as DOORS or Caliber to assist in the DVM function

Preparation: Sign off on interface definition by system owners on both sides of each interface during design

Clearly define installation, testing and commissioning phases (see following slide)


Typical installation, testing and commissioning sequence

Given the accelerator design, reaching this sequence will consist of the following phases Building/buying accelerator equipment Equipment testing prior to installation (FAT) Equipment installation (phase A) Equipment testing (stand alone) (phase B) Equipment integration or V test (phase C) Equipment testing with beam (phase pre-D) Equipment beam commissioning (phase D)

Project is helped by clearly defining handover points from one phase to the next


Systems Integration on Site (V tests)

"Vertical" Tests (Phase C) are end to end tests across multiple systems When planning these, take installation and

commissioning into account To be performed after successful FATs/stand alone

tests of all systems concerned Cables should also undergo stand alone testing

(Phase B in preparation for C) The cables used to test a device in the FAT are usually not

the same cables as installed on the facility Cables may be hooked up to the wrong device/terminals


The goal of Beam Commissioning (Phase D) is to achieve the required beam parameters at the output under required conditions

In preparation for beam commissioning, beam diagnostics should be tested with a (pilot) beam (Phase pre-D)

Testing should include a full V test Subsequently, the beam itself can be

commissioned

Preparations for Beam Commissioning (1)


Beam Commissioning is aided by a Beam Commissioning plan, delineating

Commissioning team Commissioning sequences, e.g.

Source to RFQ input, Source to DTL input

Commissioning sequence details Detailed description of measurements to be made and their

durations, backed up by beam dynamics simulations, including those

away from the nominal setting

Preparations for Beam Commissioning (2)


Preparations for Beam Commissioning (3)SNS example of commissioning sequence

TASKDuration (shifts)

Peak Current

(mA)

Pulse Width (usec)

Rep Rate (Hz)

Beam Power (kW)

Beam stop Priority

1 Ion Source and RFQ Startup 4.5 20 50 3 0.0075 MEBT high

2 Beam transport to MEBT beam stop 10 20 50 3 0.0075 MEBT high

3 Beam transport through DTL 1 to Energy Degrader/Faraday Cup 6 5 20 2 0.0005 ED/FC high4 Beam transport through DTL to D-plate Beamstop 7 20 10 2 0.003 D-plate high5 Commission D-plate Diagnostics and MPS 17 20 50 2 0.015 D-plate high6 Perform Fault Studies 4 10 20 2 0.003 D-plate high7 RF System Checkout/Verification with Beam 4 20 100 3 0.045 D-plate high8 Establish Phase and Amplitude Set-point 23 20 50 3 0.0225 D-plate high9 Establish Transverse Matching Conditions 14 20 50 3 0.0225 D-plate high10 Establish Long-Pulse Operation 8 20 680 3 0.306 D-plate high11 Perform Aperture Scan 7 5 10 2 0.00075 D-plate low12 Establish Nominal 38 mA beam conditions at DTL output 13 38 50 3 0.04275 D-plate high13 Characterize DTL 1 nominal output beam 16 38 50 3 0.04275 D-plate high14 Commission Chopper Systems 15 38 50 3 0.04275 MEBT med15 Characterize DTL 1 chopped output beam 9 38 50 3 0.04275 D-plate med16 High Duty Factor Measurements 18 38 680 30 5.814 D-plate high17 Other Measurements low

Example for SNS DTL Tank 1


Preparations for Beam Commissioning (4)SNS example of commissioning form

Have "sanity check" alternatives In this case, check RF tank amplitude on cavity


Commissioning is aided by support from beam dynamics tools

Various tools: Off-line model(s) On-line model(s) Virtual accelerator

RFQ (foto) and linac originally foreseen for SSC being used for production of medical isotopes

Loss in beam transport to target was found Debugged with off-line code DYNAC


Use of multiple beam dynamics codes aids understanding of measured beam

During the MEBT commissioning of CERN Linac3, measured and simulated beam emittances and Twiss parameters seemed to be similar, but...

double checking with another emittance measurement gear and with another code (DYNAC*) demonstrated flaws in both the simulation and measurement

*DYNAC source code available at: http://dynac.web.cern.ch/dynac/dynac.html

http://dynac.web.cern.ch/dynac/dynac.html


Success of Commissioning helped by well planned use of temporary diagnostics

Apart from using "inline" diagnostics, use strategically placed temporary ones

Use emittance scanner to measure beam at the input plane of the RFQ

Explore other settings than the nominal one Could condition RFQ in parallel "parking" position

Use bunch length, energy and energy dispersion measurements as well as an emittance scanner to characterize the beam at the input plane of the linac

Compare measurement results from inline and temporary diagnostics with each other and with beam dynamics code(s) results

E.Tanke, Seminar at ESS, Lund, 6 March 2013 28© Siemens AG 2011, Healthcare Sector, Particle Therapy. All rights reserved.

Temporary diagnostics used at the RFQ input and the IH DTL input at Siemens

RFQ and IH placed in "parking position", allowing for simultaneous beam commissioning and RF conditioning


Examples of temporary Diagnostics

"D-Plate" used behind SNS DTL tank 1

Emittance scanner with fast Faraday cup and end cup at location of

Siemens RFQX and Y grids can be read out simultaneously

for real time isometric profile plot


Optimize sequence duration by planning simultaneous installation, testing and commissioning (macroscopic scale)

Base durations on bottom-up estimates from system/task owners

Have on-site day to day planning (microscopic scale)

Define clear handover from one phase to the next

e.g. final alignment is part of installation include handover parameters as needed

Managing Installation, Testing and Commissioning


SNS CCL during installation and....

8 CCL segments linked by bridge couplers; awaiting installation of inter-segment quadrupoles

Photo courtesy of Oak Ridge National Laboratory


…..simultaneous DTL1 Commissioning

Towards remainder of DTL and CCL

PPS Access

Ion source & LEBTRFQ

MEBTDTL tank 1

D-plate

D-plate


Installation, testing and beam commissioning will profit from

well defined scope and plans for each of these as well as durations (based on bottom-up estimates from system/task owners)

well defined handover from one phase to the next

Equipment/system tests are crucial to successful and timely project completion

There are methods to reduce the risk and impact of "system failures"

Summary highlights


….successfully aid in reaching the end goal

Conclusion

There are methods that will.....

and will help avoid undesirable outcome(s)


Thank you for your attention !

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Preparations for Installation, Testing and Commissioning