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Long Shutdown 1 The upgrade of Long Shutdown 1 The upgrade of

Long Shutdown 1 The upgrade of - PowerPoint Presentation

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Long Shutdown 1 The upgrade of - PPT Presentation

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

measurement breaker pcb upgrade breaker measurement upgrade pcb voltage maintenance firmware ls1 actions inspection thermostat main screws resistor replacement

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Presentation Transcript

Slide1

Long Shutdown 1

The upgrade of

600 A

ENERGY EXTRACTION SYSTEMS

Slide2

600 A Energy Extraction ; what, where, how ?

600 A EE upgrade; what ?Intervention statisticsLS1 actions and some detailsFindingsResourcesTo doPlanning

Overview

Slide3

Energy

Extraction 600 A circuit

Slide4

600A 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.

Slide5

600A Energy

Extraction Systems

Slide6

Slide7

Intervention 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)

Slide8

Intervention 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..

Slide9

LS1 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)

Slide10

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 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

Slide11

LS1 Flow Chart

Slide12

LS1 Actions details CHASSIS:

DQAMS

(firmware)

upgrade

Voltage

measurement Gain adjustment

Interface Firmware Upgrade

New Measurement card

Slide13

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

Slide14

LS1 Actions details Power Part:

Remove orange measurement wire

Replace orange wire by new V-tap

Replace

imbus

screws by hexagonal

Slide15

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

Slide16

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

Slide17

LS1 Actions details Power Part:

PCB for thermostat series connection

Thermostats on all 606 Req. Prepared at

surface in 281

Slide18

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

Slide19

Performed 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

Slide20

Loosening 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

Slide21

Solutions

Slide22

Tuning gaps and forces

=>

Decreasing number of switch closing failures

Maintenance

Slide23

Main 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

.

Slide26

Findings 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

Slide27

Completed

Slide28

Completed

600 A EE UPGRADEHardware : 99.5% COMPLETED

Slide29

Alexandre 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:

Slide30

TO 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

Slide31

Planning 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

Slide32

Thank you for your attention!