cryogeniques a u CERN Frédéric Ferrand CERN Geneva Switzerland On behalf of CERN Cryogenics Group LHC machine c ryogenics CERN LHC cryogenics 8 x 18 kW 45 K 8 x 24 kW 18 K ID: 1042773
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1. Maintenance et methodes pour les installations cryogeniques au CERNFrédéric FerrandCERN, Geneva, SwitzerlandOn behalf of CERN Cryogenics Group
2. LHC machine cryogenics@CERN LHC cryogenics8 x 18 kW @ 4.5 K8 x 2.4 kW @ 1.8 Khelium inventory of 130 tonsLHC acceleratorcircumference of ~ 27 kmconstructed at ~100 m undergroundSURFACECompressor Stations 4.5K Cold Boxes Liquid & Gas storagesUNDERGOUND4.5K & 1.8K Cold Boxes Distribution Valve Boxes Distribution System@CERN @CERN @CERN @CERN @CERN @CERN
3. LHC Machine Cryogenics Maintenance Windows+1Yr+1YrCryogenics M&O contract inital 5-year period
4. Maintenance shutdown managementPreparation and scheduling before interventionCryoplant transfer from operation to maintenance with work authorizationLocal coordination of maintenance work to handle co-activitiesCryoplant return from maintenance to operation team Reviewing and closing of work orders and reportsMaintenance results
5. Delegation of Condition Based MaintenanceContractor is in charge of measurements or samples taking on the field, together with a first level of expertise for task oriented facilitiesExpertise remains within the cryogenics group for LHC and detectorsFor result oriented cryoplants contract the contractor shall apply the recommended CERN cryogenics maintenance policy and is liable to undertake necessary action to ensure availability of the cryoplant Maintenance results
6. Cryogenic test and experimental facilitiesTASK ORIENTED OPERATIONOperation support under CERN’s supervisionRESULT ORIENTED OPERATIONFull delegation of responsibility to the contractor MAINTENANCEMETHODOLOGY
7. Result Oriented Operation for non-LHCDistribution downtime responsibility over the last 3 years is shared between CERN with 62%Utility fault User eventsObsolescenceContractor with 38%Compressor breakdownInstrumentation issuesTurbine breakdownsClogging of water circuit or Recovery time too long after user eventsOperational achievementsTask Oriented Operation for LHCA third of LHC and detectors operation resources working daytime Two operation stand by duty services with 50 to 80 interventions per yearAvailability of the LHC cryogenics from April 2015 to December 2018 amount to 97.2% (excl. planned shutdowns)
8. RO 45%ME 17%TO 20%MA 14%ROV 4%Cryogenics Actual M&O 2018Year of RUN RO – Result Oriented operationROV – Result Oriented VariableTO – Task Oriented operationCryogenics Budget M&O 2019Year of LS RO 33%TO 12%MA 32%ME 20%ROV 3%Cryogenics M&O contract frameworkME – MethodologyMA – Maintenance
9. CERN Cryogenics group Industrial PartnershipWork Organization implementation Maintenance support TeamCoordinationPlanning CMMSSpare partsMaintenance ManagementField Mechanical TeamField E&I TeamOperation support or Fully delegated with performance obligationField Vacuum Team
10. Work Organization implementationComputerized Maintenance Management SystemAll Maintenance Plans are review by: Maintenance experts by fieldMethod & Logistic support section Contractor Maintenance Support teamReference matrix is updated and shared with the teamUpdate of the of the CMMS is done by the contractor
11. Work Organization implementationComputerized Maintenance Management SystemTechnical Stop 3-4d 30-80woYETS 2-3wk 1’000-1’200woLong Shutdown 1yr 3’000-4’000wo Workflow is in place and each WO is check and validated by CERN technical expert in the field and quality controller
12. Development of methodologiesMaintenance ProceduresTechnical content of all work instructions for mechanical and vacuum tasks have been reviewed and updated before Long Shutdown 2Technicians can now fill checklists directly on digital tablets Implementation of industrial instrumentation calibrators and database
13. Operation electronic LogbookCaptures and tracks all activities occurring on cryoplants Migrated to the same database as the CMMS in March 2018Different use between LHC and other cryoplantsDevelopment of methodologies
14. Operation electronic LogbookCaptures and tracks all activities occurring on cryoplants Migrated to the same database as the CMMS in March 2018Different use between LHC and other cryoplantsDevelopment of methodologies
15. LS2 Maintenance activities - Week 37-2019@CERN39.2%
16. LS2 activities
17. Maintenance - Major overhauling Compressors logistics at contractor premises
18. Maintenance - Major overhauling HV motors logisticsat contractor premises
19. Charbons stations QSCA/B-2/8Réaménagement atelier vide P2Calibrations avec outil BeamexNettoyage chimique et mécanique de la station QSCA du point 2Remplacements coalesceursLS2 activities
20. QSVQSDNQSDHLS2 activities
21. Conclusions and perspectivesOver the last three years the M&O contract has:Provided support to sustain continuous improvement of LHC availability, Maintained a good level of availability for a significant number of cryoplants Adapted to the requirements between run and shutdown periodsDeveloped M&O methodologies together with CERN teamIn the next two years the contract shall: Deliver the maintenance scope of work for Long Shutdown 2 Resume LHC operation at nominal capacity for the third run
22. @CERN – BA6 Mobile Cold BoxQuestions ?
23. Back-up slides
24. LS2 cryogenics general frame F.FerrandTE-CRG1013111211101210
25. Compressor station & Oil Removal System Courtesy of TE-CRG Mechanical SectionPREDICTIVE Maintenance program – Condition Based Monitoring Checked CriteriaVibration analysis Monthly Multiple : spectrum analysis, RMSOil analysis program Yearly Multiple : oxidation, particlesElectrical cabinets thermography Yearly Over heating temperatureCritical instrumentation checks 4-Yr Deviating valuePREVENTIVE Maintenance programOil pumps Revision 8’000(minor) & 24’000(major) running hours Activated charcoal load replacement 24’000 running hoursCoalescing filters replacement None or 24’000 running hoursScrew compressor Major Overhauling 40’000 running hoursHigh Voltage Motors 30’000(bearings) & 40’000(sleeve bearings) running hoursVacuum pumps revisions 8’000 to 40’000 running hoursSafety chain check YearlySafety valves test bench test 2-Yr, 4Yr, 5-YrWater Heat Exchangers chemical cleaning 4-YrCritical instrumentation & valves check 4-Yr
26. Cold Boxes@CERN@CERNPREDICTIVE Maintenance program – Condition Based Monitoring Checked CriteriaElectrical cabinets thermography Yearly Over heating temperature Critical instrumentation checks 4-Yr Deviating valueCold Compressors 4-Yr Mechanical clearanceHeat exchangers 4-Yr Tightness testTurbine filters Yearly Delta PPREVENTIVE Maintenance programSafety valves test bench or local test 2-Yr, 4Yr, 5-Yr Safety chain check YearlyWater Heat Exchangers chemical cleaning 4-YrVacuum pumps revisions 8’000 to 24’000 running hoursCritical valves & instrumentation check 4-YrTurbine filters 4-Yr (when vacuum break required) RUN to FAILTurbines
27. Storage, Distribution & Cryostat@CERN@CERNPREDICTIVE Maintenance program – Condition Based Monitoring Checked CriteriaLine integrity test during warm-up 4-Yr Pressure and vacuum testsCritical instrumentation checks 4-Yr Deviating valueCritical valves check 4-Yr Leak tightnessCapacity legal pressure check 10-Yr Pressure test according to EU PREVENTIVE Maintenance programSafety valves 2-Yr, 4Yr, 5-Yr Safety chain check YearlyVacuum pumps revisions 8’000 to 24’000 running hoursCritical valves check 4-YrCritical instrumentation check 1 to 4-Yr@CERN – LHC Point 2 Distribution Valve Box @CERN – LHC Nitrogen tank during LHC pre cooling
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