Long shutdown 1 the upgrade of 600 a energy extraction systems
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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 .

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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

1 New Voltage divider board

2 New voltage measurement wires + Vtap

3 Thermostats on equalizing Resistors

4 New Thermostat connection PCB

5 Wiring Thermostat PCB to connector SK24

6 Replacement of A and Z imbus to hexag. Screws

7 Screwed connections "torque" check

8 Breaker maintenance general and Breaker plate gluing

9 Visual inspection main axle

10 Interlock PCB resistor change

11 Interface card firmware upgrade

12 Acquisition and Monitoring board (firmware) upgrade

13 New measurement PCB

14 Replacement of transformer (- overheated zener)

15 Dump Resistor modification RQTL9

Added activities - unscheduled at start of LS1



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

1 New Voltage divider board

2 New voltage measurement wires + Vtap

3 Thermostats on equalizing Resistors

4 New Thermostat connection PCB

5 Wiring Thermostat PCB to SK24

6 Replacement of A and Z imbus to hexag. Screws

7 Screwed connections "torque" check

8 Breaker maintenance general and Breaker plate gluing

9 Visual inspection main axle

10 Interlock PCB resistor change

11 Interface card firmware upgrade

12 DQAMS (firmware) upgrade

13 New measurement PCB

14 Replace transformer (- overheated zener)

15 Dump 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

1 New Voltage divider board

2 New voltage measurement wires + Vtap

3 Thermostats on equalizing Resistors

4 New Thermostat connection PCB

5 Wiring Thermostat PCB to SK24

6 Replacement of A and Z imbus to hexag. Screws

7 Screwed connections "torque" check

8 Breaker maintenance general and Breaker plate gluing

9 Visual inspection main axle

10 Interlock PCB resistor change

11 Interface card firmware upgrade

12 DQAMS (firmware) upgrade

13 New measurement PCB

14 Replace transformer (- overheated zener)

15 Dump 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

1 New Voltage divider board

2 New voltage measurement wires + Vtap

3 Thermostats on equalizing Resistors

4 New Thermostat connection PCB

5 Wiring Thermostat PCB to SK24

6 Replacement of A and Z imbus to hexag. Screws

7 Screwed connections "torque" check

8 Breaker maintenance - general and Breaker plate gluing

9 Visual inspection main axle

10 Interlock PCB resistor change

11 Interface card firmware upgrade

12 DQAMS (firmware) upgrade

13 New measurement PCB

14 Replace transformer (- overheated zener)

15 Dump 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



Maintenance
Maintenance

  • Tuning gaps and forces

=> Decreasing number of switch closing failures



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



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



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