Long shutdown 1 the upgrade of 600 a energy extraction systems
This presentation is the property of its rightful owner.
Sponsored Links
1 / 32

Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS PowerPoint PPT Presentation


  • 79 Views
  • Uploaded on
  • Presentation posted in: General

Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS. Overview. 600 A Energy Extraction ; what, where, how ? 600 A EE upgrade; what ? Intervention statistics LS1 actions and some details Findings Resources To do Planning. Energy Extraction 600 A circuit .

Download Presentation

Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS

An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -

Presentation Transcript


Long shutdown 1 the upgrade of 600 a energy extraction systems

Long Shutdown 1The upgrade of 600 AENERGY EXTRACTION SYSTEMS


Overview

Overview

  • 600 A Energy Extraction ; what, where, how ?

  • 600 A EE upgrade; what ?

  • Intervention statistics

  • LS1 actions and some details

  • Findings

  • Resources

  • To do

  • Planning


Energy extraction 600 a circuit

Energy Extraction 600 A circuit


600a energy extraction systems

600A Energy Extraction Systems

  • 202 systems installed in the LHC tunnel in corrector circuits with stored energy between 2.2 and 150 kJ

  • In 15 different locations;

    • 8 x UA parallel service tunnel and 6 x RR and 1 x UJ tunnel caverns

  • Systems developed in close collaboration between CERN and the Budker Institute of Nuclear Physics (BINP), Novosibirsk, Russia.


600a energy extraction systems1

600A Energy Extraction Systems


Intervention statistics

Intervention Statistics

  • Between 2010 – 2013: 143 interventions

    • 113 Preventive Maintenance (Technical stops)

    • 30 Corrective Maintenance (Piquet Service)

  • 21 interventions stopped (or delayed startup of) LHC

  • Total intervention time approx. 775 hours

    - analysis, intervention and follow up

    - often more persons involved


Intervention statistics ctnd

Intervention Statistics ctnd.

  • 36 breakers were changed (plus ~25 in period before)

    • 90 %: holding-coil issues

    • 10 %: main axle, micro switch, thread, unknown

  • 40 interventions only for Preventive Breaker maintenance during TS

  • 10 interventions for Electronics

  • 19 interventions for Rest: Software, HWC steps, connections..


Ls1 actions

LS1 Actions

  • Breakers - Regular maintenance and Consolidation

  • Equalizing Resistors – Installation & wiring of Thermostats

  • Voltage measurement channel improvement

  • Visual inspection of main axles – Endoscope

  • Individual System Test (IST)

  • Hard-Ware Commissioning (HWC)


Ls1 actions list

LS1 actions LIST

1New Voltage divider board

2New voltage measurement wires + Vtap

3Thermostats on equalizing Resistors

4New Thermostat connection PCB

5Wiring Thermostat PCB to connector SK24

6Replacement of A and Z imbus to hexag. Screws

7Screwed connections "torque" check

8Breaker maintenance general and Breaker plate gluing

9Visual inspection main axle

10Interlock PCB resistor change

11Interface card firmware upgrade

12Acquisition and Monitoring board (firmware) upgrade

13New measurement PCB

14Replacement of transformer (- overheated zener)

15Dump Resistor modification RQTL9

Added activities - unscheduled at start of LS1


Ls1 flow chart

LS1 Flow Chart


Ls1 actions details chassis

LS1 Actions details CHASSIS:

New Measurement card

Interface Firmware Upgrade

DQAMS (firmware) upgrade

Voltage measurement Gain adjustment


Ls1 actions list1

LS1 actions LIST

1New Voltage divider board

2New voltage measurement wires + Vtap

3Thermostats on equalizing Resistors

4New Thermostat connection PCB

5Wiring Thermostat PCB to SK24

6Replacement of A and Z imbus to hexag. Screws

7Screwed connections "torque" check

8Breaker maintenance general and Breaker plate gluing

9Visual inspection main axle

10Interlock PCB resistor change

11Interface card firmware upgrade

12DQAMS (firmware) upgrade

13New measurement PCB

14Replace transformer (- overheated zener)

15Dump Resistor modification RQTL9


Ls1 actions details power part

LS1 Actions details Power Part:

Replace orange wire by new V-tap

Remove orange measurement wire

Replace imbus screws by hexagonal


Ls1 actions details power part1

LS1 Actions details Power Part:

Dismount Burndy 48 pin-and 28 pin-support

And

Insert 2 wires /pins in correct empty places

Inside 60x90 cm rack without side space


Ls1 actions list2

LS1 actions LIST

1New Voltage divider board

2New voltage measurement wires + Vtap

3Thermostats on equalizing Resistors

4New Thermostat connection PCB

5Wiring Thermostat PCB to SK24

6Replacement of A and Z imbus to hexag. Screws

7Screwed connections "torque" check

8Breaker maintenance general and Breaker plate gluing

9Visual inspection main axle

10Interlock PCB resistor change

11Interface card firmware upgrade

12DQAMS (firmware) upgrade

13New measurement PCB

14Replace transformer (- overheated zener)

15Dump Resistor modification RQTL9


Ls1 actions details power part2

LS1 Actions details Power Part:

Thermostats on all 606 Req. Prepared at surface in 281

PCB for thermostat series connection


Ls1 actions list3

LS1 actions LIST

1New Voltage divider board

2New voltage measurement wires + Vtap

3Thermostats on equalizing Resistors

4New Thermostat connection PCB

5Wiring Thermostat PCB to SK24

6Replacement of A and Z imbus to hexag. Screws

7Screwed connections "torque" check

8Breaker maintenance - general and Breaker plate gluing

9Visual inspection main axle

10Interlock PCB resistor change

11Interface card firmware upgrade

12DQAMS (firmware) upgrade

13New measurement PCB

14Replace transformer (- overheated zener)

15Dump Resistor modification RQTL9

> 27.000 screws checked


Breaker consolidation

Breaker consolidation

  • Performed by Dr. Alexandre Erokhin (with support from MariuszBlaszczyk)

    • Budker Institute for Nuclear Physics

      • Project leader on Power Converters and Magnets Protection Design,

    • Now attached to Krakow University (AGH)

  • Collaborating with CERN since 1997 on Energy Extraction Systems – Modeling and Design


Breaker consolidation1

Breaker consolidation

  • Loosening of holding coil mechanism

    • Weak design of U-shape and dimensional tolerances

  • Needs to achieve

    • Plate Glue Action in all 606 breakers

      • Open all breakers (anyway foreseen for regular maintenance)

      • Plate gluing

  • Tuning gaps and forces

  • Cleaning main contacts


Solutions

Solutions


Maintenance

Maintenance

  • Tuning gaps and forces

=> Decreasing number of switch closing failures


Main axe problem

Main axe problem


Visual inspection

Visual inspection

- Visual inspection by endoscope

- Several images per breaker

- > 2700 pictures for 606 breakers


Visual inspection cntd

Visual inspection cntd.

- Data base of the pictures for each breaker & system with the names of the circuit

– Traceability for each breaker


Findings during maintenance

Findings during maintenance

  • Zener diode overheated – patch from 2008 to lower DC voltage on holding coil

    • Decided to change transformer ; costs 8 kCHF

  • Several loosened screws were reported – randomly located

  • Visual inspection show one suspect breaker – with possible weak main axle fixation

    • RSF1.A23B1 B Breaker


Completed

Completed


Completed1

Completed

600 A EE UPGRADE

Hardware : 99.5% COMPLETED


Special thanks to

Special thanks to:

  • Alexandre Erokhin (All subjects)

  • Mariusz Blaszczyk – assistance with breakers maintenance and part of Marek’s team

  • Bozhidar Panev – electronics upgrade voltage measurement, heat-run, preparation

  • Tatyana Erokhina – PCBs: replacing the components, endoscope database, transformer replacement

  • Polish team under Marek Ciechanowski’ssupervision – manufacturing of cables and mounting of thermostats, screws, transformers:

    • MariuszBlaszczyk,

    • PawelBaran,

    • Tadeusz Jeziorek,

    • MaciejKosik

  • PawelDubert – preparation and general help


To do b4 ols1

TO DO B4&OLS1

  • Interface board: Firmware upgrade

  • Measurement board: Replacement

  • UA67: replacement of 16 systems in 8 racks

  • Individual System Tests

  • HardWare Commissioning

  • Acquisition and monitoring card: Hardware and software upgrade to complete voltage measurement transfer with high resolution


Planning 2014

Planning 2014

  • Replacement of 8 racks (16 systems) in UA67

  • Individual System Tests - IST

    • February – June 2014

    • 1wk / sector for 2 teams of 2 test-engineers

  • HardWare Commissioning tests - HWC

    • June – December 2014

    • 1wk / HWC step (PLI.b1?) & PNO.b1 for 2 teams of 2 test-engineers


Thank you for your attention

Thank you for your attention!


  • Login