Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS

TE-MPE TM January 16, 2014 G.J. Coelingh, A. Erokhin TE-MPE-EE

Long Shutdown 1The upgrade of

600 AENERGY 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

Overview


Energy Extraction 600 A circuit


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 Systems


SnubberCapacitor

0.8 mF

Fuse32 A

SwitchA

SwitchB

SwitchZ

Equalizing Resistors

each

600 A Energy Extraction Facility

600 A warm cables 400mm2

600 A warm cables 400mm2


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)


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 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 LIST1 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. Screws7 Screwed connections "torque" check8 Breaker maintenance general and Breaker plate gluing 9 Visual inspection main axle10 Interlock PCB resistor change11 Interface card firmware upgrade12 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


LS1 Flow Chart


LS1 Actions details CHASSIS:D

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LS1 actions LIST1 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. Screws7 Screwed connections "torque" check8 Breaker maintenance general and Breaker plate gluing 9 Visual inspection main axle10 Interlock PCB resistor change11 Interface card firmware upgrade12 DQAMS (firmware) upgrade13 New measurement PCB14 Replace transformer (- overheated zener)15 Dump Resistor modification RQTL9


LS1 Actions details Power Part:

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Replace orange wire by new V-tap

Replace imbus screws by hexagonal



Dismount Burndy 48 pin-and 28 pin-support And Insert 2 wires /pins in correct empty placesInside 60x90 cm rack without side space


LS1 actions LIST1 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. Screws7 Screwed connections "torque" check8 Breaker maintenance general and Breaker plate gluing 9 Visual inspection main axle10 Interlock PCB resistor change11 Interface card firmware upgrade12 DQAMS (firmware) upgrade13 New measurement PCB14 Replace transformer (- overheated zener)15 Dump Resistor modification RQTL9



PCB for thermostat series connection

Thermostats on all 606 Req. Prepared at surface in 281


LS1 actions LIST1 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. Screws7 Screwed connections "torque" check8 Breaker maintenance - general and Breaker plate gluing 9 Visual inspection main axle10 Interlock PCB resistor change11 Interface card firmware upgrade12 DQAMS (firmware) upgrade13 New measurement PCB14 Replace transformer (- overheated zener)15 Dump Resistor modification RQTL9

> 27.000 screws checked


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


Loosening of holding coil mechanism Weak design of U-shape and

dimensional tolerances

Breaker 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


Solutions


Tuning gaps and forces

=> Decreasing number of switch closing failures

Maintenance


Main axe problem


- Visual inspection by endoscope - Several images per breaker

- > 2700 pictures for 606 breakers

Visual inspection


- Data base of the pictures for each breaker & system with the names of the circuit – Traceability for each breaker

Visual inspection cntd.


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


Completed

ARC Location

Number of Systems to be installed

Number of Racks

Date Name Date Name Date Name Date Name Date Name Date Name Date Name Date Name Date NameRR17 7 4 28/11/13 AE 12/07/13 MB 12/07/13 MB 12/07/13 MB 15/08/13 AE 27/11/13 AE 27/11/13 AE 12/07/13 MB 12/07/13 MBUA23 16 8 29/11/13 AE 18/07/13 MB 18/07/13 MB 18/07/13 MB 20/08/13 AE 30/08/13 MB 28/08/13 AE 18/07/13 MB 18/07/13 MBUA27 16 8 29/11/13 AE 16/07/13 MB 16/07/13 MB 16/07/13 MB 23/08/13 AE 28/08/13 MB 29/08/13 AE 16/07/13 MB 16/07/13 MB

UJ33+R34 11 6 28/11/13 AE 05/07/13 MC 05/07/13 MC 05/07/13 MC 19/07/13 AE 29/11/13 AE 29/11/13 AE 05/07/13 MC 05/07/13 MCUJ33+R36 11 6 28/11/13 AE 05/07/13 MC 05/07/13 MC 05/07/13 MC 26/07/13 AE 29/11/13 AE 29/11/13 AE 05/07/13 MC 05/07/13 MC

UA43 17 9 18/09/13 AE 15/08/13 MB 15/08/13 MB 15/08/13 MB 13/09/13 AE 04/09/13 AE 13/09/13 AE 15/08/13 MB 15/08/13 MBUA47 17 9 18/09/13 AE 13/08/13 MB 13/08/13 MB 13/08/13 MB 20/09/13 AE 03/09/13 AE 18/09/13 AE 13/08/13 MB 14/08/13 MBRR53 7 4 24/09/13 AE 23/07/13 KB 23/07/13 KB 23/07/13 KB 24/09/13 AE 29/11/13 AE 24/09/13 AE 23/07/13 KB 23/07/13 KBRR57 7 4 24/09/13 AE 24/07/13 MB 24/07/13 MB 24/07/13 MB 24/09/13 AE 29/11/13 AE 24/09/13 AE 24/07/13 MB 24/07/13 MBUA63 16 8 10/10/13 AE 25/07/13 MC 25/07/13 KB 25/07/13 KB 10/10/13 AE 10/10/13 AE 10/10/13 AE 25/07/13 MC 25/07/13 MCUA67 16 8 removed AE 30/07/13 MC 30/07/13 MC 30/07/13 KB water damage AE New systems AE New systems AE New systems MC New systems MCRR73 11 6 10/10/13 AE 06/08/13 TJ 06/08/13 TJ 06/08/13 TJ 25/10/13 AE 25/10/13 AE 25/10/13 AE 08/08/13 PB 08/08/13 PBRR77 11 6 30/10/13 AE 26/08/13 MB 26/08/13 MB 26/08/13 MB 07/11/13 AE 07/11/13 MB 07/11/13 AE 26/08/13 MB 26/08/13 MBUA83 16 8 11/11/13 AE 18/07/13 MB 08/07/13 MC 09/07/13 MB 01/08/13 AE 12/11/13 AE 12/11/13 AE 09/07/13 PB 09/07/13 PBUA87 16 8 11/11/13 AE 10/07/13 MB 10/07/13 MB 11/07/13 MB 08/08/13 AE 14/11/13 AE 14/11/13 AE 10/07/13 MB 10/07/13 MBRR13 7 4 28/11/13 AE 12/07/13 MB 12/07/13 MB 12/07/13 MB 15/08/13 AE 27/11/13 AE 27/11/13 AE 12/07/13 MB 12/07/13 MB

6-7

7-8

8-1

1-2

2-3

3-4

4-5

5-6

Screwed connections

"torque" checkThermostats on

ReqNew Thermostat connection PCB

Wiring Thermostat PCB to SK24

Change transformer (- overheated

zener)Interlock PCB

resistor change

Breaker maintanance general and

Breaker plate glueing

visual inpection main axle

Replacement of A and Z imbus to hexag. Screws


Completed

600 A EE UPGRADEHardware : 99.5% COMPLETED


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’s supervision –

manufacturing of cables and mounting of thermostats, screws, transformers:

Mariusz Blaszczyk, Pawel Baran, Tadeusz Jeziorek, Maciej Kosik

Pawel Dubert – preparation and general help

Special thanks to:


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 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


Thank you for your attention!

Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS

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Transcript of Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS