600 A ENERGY EXTRACTION SYSTEMS 600 A Energy Extraction what where how 600 A EE upgrade what Intervention statistics LS1 actions and some details Findings Resources To do Planning ID: 779565
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Slide1
Long Shutdown 1
The upgrade of
600 A
ENERGY EXTRACTION SYSTEMS
Slide2600 A Energy Extraction ; what, where, how ?
600 A EE upgrade; what ?Intervention statisticsLS1 actions and some detailsFindingsResourcesTo doPlanning
Overview
Slide3Energy
Extraction 600 A circuit
Slide4600A Energy
Extraction Systems202 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.
Slide5600A Energy
Extraction Systems
Slide6Slide7Intervention Statistics
21 interventions stopped (or delayed startup of) LHC
Total intervention time approx. 775 hours
- analysis, intervention and follow up
- often more persons involved
Between 2010 – 2013: 143 interventions
113 Preventive Maintenance (Technical stops)
30 Corrective Maintenance (Piquet Service)
Slide8Intervention Statistics
ctnd.36 breakers were changed (plus ~25 in period before)90 %: holding-coil issues10 %: 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..
Slide9LS1 Actions
Breakers - Regular maintenance and ConsolidationEqualizing Resistors – Installation & wiring of ThermostatsVoltage
measurement channel
improvement
Visual inspection of main axles – Endoscope
Individual
System
Test (IST)
Hard-Ware Commissioning (HWC)
Slide10LS1 actions LIST
1 New Voltage divider board2 New voltage measurement wires + Vtap3 Thermostats on equalizing Resistors4 New Thermostat connection PCB5 Wiring Thermostat PCB to connector SK246 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) upgrade13 New measurement PCB14 Replacement of transformer (- overheated zener)15 Dump Resistor modification RQTL9Added activities - unscheduled at start of LS1
Slide11LS1 Flow Chart
Slide12LS1 Actions details CHASSIS:
DQAMS
(firmware)
upgrade
Voltage
measurement Gain adjustment
Interface Firmware Upgrade
New Measurement card
Slide13LS1 actions LIST
1 New Voltage divider board2 New voltage measurement wires + Vtap3 Thermostats on equalizing Resistors4 New Thermostat connection PCB5 Wiring Thermostat PCB to SK246 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
Slide14LS1 Actions details Power Part:
Remove orange measurement wire
Replace orange wire by new V-tap
Replace
imbus
screws by hexagonal
Slide15LS1 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
Slide16LS1 actions LIST
1 New Voltage divider board2 New voltage measurement wires + Vtap3 Thermostats on equalizing Resistors4 New Thermostat connection PCB5 Wiring Thermostat PCB to SK246 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
Slide17LS1 Actions details Power Part:
PCB for thermostat series connection
Thermostats on all 606 Req. Prepared at
surface in 281
LS1 actions LIST
1 New Voltage divider board2 New voltage measurement wires + Vtap3 Thermostats on equalizing Resistors4 New Thermostat connection PCB5 Wiring Thermostat PCB to SK246 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
Slide19Performed by Dr. Alexandre
Erokhin (with support from Mariusz Blaszczyk)Budker Institute for Nuclear Physics Project leader on Power Converters and Magnets Protection Design, Now attached to Krakow University (AGH)
Breaker consolidation
Collaborating with CERN since 1997 on Energy Extraction Systems – Modeling and Design
Slide20Loosening of holding coil mechanism
Weak design of U-shape and dimensional tolerancesBreaker consolidation
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
Slide21Solutions
Slide22Tuning gaps and forces
=>
Decreasing number of switch closing failures
Maintenance
Slide23Main axe problem
Slide24- Visual inspection by endoscope
- Several images per breaker
- > 2700 pictures for 606 breakers
Visual inspection
Slide25- Data base of the pictures for each breaker & system with the names of the circuit
– Traceability for each breaker
Visual inspection
cntd
.
Slide26Findings during maintenance
Zener diode overheated – patch from 2008 to lower DC voltage on holding coilDecided to change transformer ; costs 8 kCHFSeveral loosened screws were reported – randomly locatedVisual inspection show one suspect breaker – with possible weak main axle fixationRSF1.A23B1 B Breaker
Slide27Completed
Slide28Completed
600 A EE UPGRADEHardware : 99.5% COMPLETED
Slide29Alexandre Erokhin (All subjects)
Mariusz Blaszczyk – assistance with breakers maintenance and part of Marek’s teamBozhidar Panev – electronics upgrade voltage measurement, heat-run, preparationTatyana Erokhina – PCBs: replacing the components, endoscope database, transformer replacementPolish team under Marek Ciechanowski’s supervision – manufacturing of cables and mounting of thermostats, screws, transformers:
Mariusz
Blaszczyk
,
Pawel
Baran
,
Tadeusz
Jeziorek
,
Maciej
KosikPawel Dubert – preparation and general helpSpecial thanks to:
Slide30TO DO B4&OLS1
Interface board: Firmware upgradeMeasurement board: Replacement UA67: replacement of 16 systems in 8 racksIndividual System Tests HardWare CommissioningAcquisition and monitoring card: Hardware and software upgrade to complete voltage measurement transfer with high resolution
Slide31Planning 2014
Replacement of 8 racks (16 systems) in UA67Individual System Tests - IST February – June 20141wk / sector for 2 teams of 2 test-engineersHardWare Commissioning tests - HWCJune – December 2014
1wk / HWC step (PLI.b1?) & PNO.b1 for 2 teams of 2 test-engineers
Slide32Thank you for your attention!