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CRYOGENICS OPERATIONS 2008 Organized by CERN

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  1. CRYOGENICS OPERATIONS 2008Organized by CERN Industrial contributions to the maintenance of CERN helium cryoplants F. FERRAND & F. BARACCO On behalf of ALLS maintenance team Cryogenics Operations 2008, CERN, Geneva, Switzerland 22th-26th September 2008

  2. Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection Cryogenics Operations 2008, CERN, Geneva, Switzerland 2 22th-26th September 2008

  3. Cryogenic maintenance overview:Scope of work 5 Local Control rooms + 1 Central Control Centre 23 main cryogenic installations @4.5K 12 Magnet Test Bench 81 screw compressors and high voltage motors (160kW to 1,8MW) 22 medium and high pressure compressors (45 to 600kW) 300 vacuum pumps 100 gas turbines & cold compressors 1’000 cryogenic valves for refrigeration units 120 large GHe vessels 30 large LN2 vessels 65’000 I/O signals treated by industrial control 5’000 instrumentation materials 3’000 pressure safety valves Cryogenics Operations 2008, CERN, Geneva, Switzerland 3 22th-26th September 2008

  4. Cryogenic maintenance overview :Yearly schedule Warm up Winter Maintenance Shut Down Cool down Standard Operation LHC cryogenicsBeam & Experiments -LHC Preventive plan -Curative maintenance intervention: Work Orders -Store management -CMMS deployment -Preparation of LHC Shut Down Operation Warm up Spring/Summer Maintenance Shut Down Cool down Operation Cryogenic labs &none LHC Experiments Result Orientated O& M contract -Preventive plan Cryogenics Operations 2008, CERN, Geneva, Switzerland 4 22th-26th September 2008

  5. Cryogenic maintenance overview :Internal Vs External External contractor CERN Departments • INSTRUMENTATION • Measurement calibration • Control valves calibration • Gas analysers calibration • Electrical maintenance • MECHANICAL • Preventive maintenance plan • Predictive vibration & oil analysis • Safety valves follow-up & repair • VACUUM • Preventive maintenance plan • Gauge calibration • Pumps maintenance • Leak detection • Vacuum pumping & conditioning • METHODOLOGY • CMMS deployment • Spare parts procurement • Store management • Continuous improvement Utilities • Water cooling • Power supply Mechanical Support • Re-engineering • Retrofit Instrumentation - Tunnel instrumentation Maintenance interface & coordination CERN safety • Pressurized vessels • Safety Valves control Control • Supervision • Automation CERN TS - CMMS administration Cryogenics Operations 2008, CERN, Geneva, Switzerland 5 22th-26th September 2008

  6. Cryogenic maintenance overview :Contractor team organization Management Process orientated staff organised by equipment or plant section Maintenance Team leader Operation Team leader Technical specialists organised by field Day + Standby duty Shift + Standby duty Helium cryogenics Mechanical Equipment 1 Corporate Technical Support Vacuum Equipment 2 Instruments Equipment 3 External contractors Spare part Procurement & storage Cryogenics Operations 2008, CERN, Geneva, Switzerland 6 22th-26th September 2008

  7. Cryogenic maintenance overview :Industrial contributions Not so far away Present Future… Equipment list consolidation CMMS Arborescence Criticity study Create maintenance DB Organization Spare parts selection Spare parts selection Develop Reporting tools Develop Reporting tools Spare parts Spare parts procurement Deploy CMMS Store centralization project Improve practices Methods Erection & Commissioning Cryogenic test RUN Large scale cryogenic operation for LHC and Experiments Work Orders system Develop maintenance plan Preventive maintenance Develop predictive methods Develop predictive methods Field work Curative maintenance Implement KPI Expertise Increase reliability Support major Overhauling Increase availability Develop plant follow up Cost optimization Cryogenics Operations 2008, CERN, Geneva, Switzerland 7 22th-26th September 2008

  8. Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection Cryogenics Operations 2008, CERN, Geneva, Switzerland 8 22th-26th September 2008

  9. Focus 1: vibration analysis Scope of work Screw compressors  Power above 250kW LHC accelerator: 63 compressors all considered as critical LHC Experiments: 10 compressors all considered as critical Labs & testing areas: 8 compressors Proximity piping vibration level measurement Measurement methodology Manual measurement with mobile spectrometer Monthly measurement basis Specific campaigns for oil pumps and large vacuum equipments Cryogenics Operations 2008, CERN, Geneva, Switzerland 9 22th-26th September 2008

  10. Focus 1: vibration analysis V A H 4 3 2 1 12 physical points / 14 effective points (« multiplexing ») Cryogenics Operations 2008, CERN, Geneva, Switzerland 10 22th-26th September 2008

  11. Focus 1: vibration analysis Level measurement  Indicators according to ISO 10816-3  81 machines x 12 points = 972 indicators per month !!! Cryogenics Operations 2008, CERN, Geneva, Switzerland 11 22th-26th September 2008

  12. Focus 1: vibration analysis General Key Point indicators KPI under construction Cryogenics Operations 2008, CERN, Geneva, Switzerland 12 22th-26th September 2008

  13. Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection Cryogenics Operations 2008, CERN, Geneva, Switzerland 13 22th-26th September 2008

  14. Focus 2: mobile devices for instrumentation Field technician on site Operators in control Rooms Température, pressure, 4-20mAmps signal… Relevé des données sur la supervision Cell Phone to get information from supervision Liaison téléphonique avec le technicien de terrain Cryogenics Operations 2008, CERN, Geneva, Switzerland 14 22th-26th September 2008

  15. Focus 2: mobile devices for instrumentation Cryogenics Operations 2008, CERN, Geneva, Switzerland 15 22th-26th September 2008

  16. Focus 2: mobile devices for instrumentation Real Time data available through supervision network  Online Signal 4-20mA Unicos Read only Read only SCAN SimulatedPressure Automatic copy Memory Card 8Go Field technician Read/write Manual typing signal 4-20mA Read/write - Synchro MaintenanceDB Calibration history available inmobile device  Batch Cryogenics Operations 2008, CERN, Geneva, Switzerland 16 F. FERRAND & F. BARACCO, 22th-26th September 2008

  17. Focus 2: mobile devices for instrumentation Cryogenics Operations 2008, CERN, Geneva, Switzerland 17 22th-26th September 2008

  18. Focus 2: mobile devices for instrumentation Duration of shut down Data availability in maintenance DB, almost real time Processus Efficience Reliability of information, real time value checking by the data base Device adapted to field work Good feedback from field technicians and customer Cryogenics Operations 2008, CERN, Geneva, Switzerland 18 F. FERRAND & F. BARACCO, 22th-26th September 2008

  19. Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection Cryogenics Operations 2008, CERN, Geneva, Switzerland 19 22th-26th September 2008

  20. Focus 3:Spare parts selection Create homogeneous equipment listings, built from various suppliers worldwide  CMMS template Criticity study  failure frequency, detection, impact Cryogenics Operations 2008, CERN, Geneva, Switzerland 20 22th-26th September 2008

  21. Focus 3:Spare parts selection Installations similarities, cross checking of 8000 references Budget sizing  Cost of spares Vs Cost of equipment • Approach excludes capital spare parts: compressor and turbines • Ration in between 2 and 4% as a first basis Cryogenics Operations 2008, CERN, Geneva, Switzerland 21 22th-26th September 2008

  22. Focus 3:Spare parts selection Management of spare parts Specification and procurement Centralised warehouse project for cryogenics cryoplants spare parts  Ongoing project to be finalized end of 2008 Cryogenics Operations 2008, CERN, Geneva, Switzerland 22 22th-26th September 2008

  23. Q&A Thank you for your attention F. FERRAND & F. BARACCO Cryogenics Operations 2008, CERN, Geneva, Switzerland 23 22th-26th September 2008