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LS1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS

LS1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS. Overview. 600 A EE; what, where, how ? Reliability Hardware Failures to be cured Why upgrade? Failure causes Solutions LS1 actions Resources Planning Showstoppers Non LHC activities during LS1. Energy Extraction 600 A circuit.

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LS1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS

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  1. LS1The upgrade of 600 AENERGY EXTRACTION SYSTEMS

  2. Overview • 600 A EE; what, where, how ? • Reliability • Hardware Failures to be cured • Why upgrade? • Failure causes • Solutions • LS1 actions • Resources • Planning • Showstoppers • Non LHC activities during LS1

  3. Energy Extraction 600 A circuit

  4. 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.

  5. Reliability • Systems reliability from protection point of view: No opening failures during Fast Power Abort events or tests (> 100.000 openings since 2005) • 2 independent opening mechanisms/circuits per breaker; guaranteeing 6-fold redundancy • Calculated by Antonio Vergara in December 2003: • System Failure probability in 20 years of operation < 0.01% (Preventive maintenance!!)

  6. Reliability (2) • Systems reliability from hardware failure point of view: • 6 hardware failures in 2010 • 1 hardware failure in 2011 • 3+1* hardware failures in 2012 • Changes with respect to 2010 operational year : • Preventive maintenance • with help of automatic analysis and tracking software tool. • For operation: 2 failures per year – not in shadow • Mean Time To Recovery : 4 hours • (including preparation, access and travel) • All failures were “fail-safe” for the s.c. circuits • reducing the availability of the system.

  7. Hardware Failures treated during LS1 • 5-10/year - 95% of all failures: Breaker refuses to close • Loosening of holding coil mechanism – LHC re-start delayed • 1/year - Breaker is physically open but indicates “CLOSED” • micro-switch not actuated / main axle – LHC re-start delayed • 1/year - Breaker main contact re-bounces on micro-switch • main axle – LHC re-start delayed

  8. Why do we upgrade? • Correcting measures are relatively easy • < 100 kCHF • This upgrade will improve the availability of 600 A EE systems for LHC operation by 4-8 hours per year…. • Less preventive maintenance

  9. Failure causes • 1- Loosening of holding coil mechanism • Weak design of U-shape • 2- Micro-switch not actuated • Tolerances in dimensions of housing • 3- Main axle fixation • Weakness during production– not an increasing fault

  10. Solutions • 1- 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 – Once open: 2-3 minutes per breaker

  11. Solutionscntd. • 2- Micro-switch not actuated (temporarily) • Tolerances in dimensions of housing • Already tracked by automatic analysis software tool • Leading to an unscheduled but still preventive maintenance intervention (in the shadow) • On-going but to be extended with advice in form of logbook entries (MPE-MS)

  12. Solutionscntd. • 3- Main axle fixation • A loose main axle means no current in 2 oo 3 phases in the CB leading (> 200A circuit current) to overheating of the 3rd phase. • Weakness during production – no increasing numbers • Manufacturer has improved this process for new breakers • For existing breakers no solution.. But.. • We can track it because of known early symptoms • Already tracked by the same automatic analysis software tool but with very few cycles left – we can measure the System Resistance! • Leading to an unscheduled corrective or preventive maintenance intervention

  13. Solutionscntd. • 3- Main axle fixation tracking improvement - Measurement • Needs to achieve • Improvement of existing Voltage Measurement Channel • Replacement of Voltage Divider by low impedance divider and noise reduction components (270 pcs MPE-EM) • Replacement of Measurement Board by low noise separation amplifier (270 pcs: MPE-EM) • Replacement of DQAMS by 12 bit to 24 bit ADC (MPE-EP & EM: 220 pcs) • Voltage measurement taps to be improved • Hi-level SW for on-line analysis (MPE-MS)

  14. Solutionscntd. • 3- Main axle fixation (and loose bolts) • Save the EE system • in case we don’t track (or too late) it with software tools • Overcurrent in one or two phases of the breakers will lead to over-temperature on the Equalizing Resistor and eventually destroy all breakers in one system • Installation of a Thermostat on each Equalizing Resistor will trip the system early before hardware damage is done • A spare internal interlock channel is available and wired up to the power board. • Needs to achieve • Installation of Thermostats • Reprogramming of Firmware in all 404 interface cards (MPE-EP) • Allow trip on over temperature of Equalizing Resistor • Profit to limit cycles of the breakers

  15. LS1 Actions

  16. Resources

  17. Planning (not incl. SCT and HWC) • ANYTIME – “ANYWHERE” • April 2013 – April 2014 – 6 man-months – • Team of 3 persons could come 2 x 1 month But .. • Man-power Calculations based on one team of Specialistsfrom BINP • Perfect preparation before start of activity • One Engineer or TE as team leader plus two Technicians • Working in a “train” Start – to – Finish one point, including IST

  18. Planning SCT & HWC • SCT & HWC – 2014 • SCT was presented as not needed for 600 A EE but … latest tests show.. Yes, if we could we should  • 1 day per UA or RR – 2 TE or E • 15 working-days - NO recourses allocated yet • HWC like SOF test PLI3.b1 – remotely from CCC – • Automatic Analysis of PM • PNO.b1 – 1 day per UA or RR – 2 TE or E • 15 working-days - NO recourses allocated yet

  19. “Showstoppers” • Preparation for LS1 • Planning – Tests – Tooling – Purchasing (thermostat-study still to be finished) • A LONG WAY TO GO!!! • No reference contract with Russia • If done by non-experts • More CERN staff needed for training, the actual job, follow up, debugging of collateral damage etc. Might delay re-start after LS1. • Spare Circuit Breakers: • DZNVA – Visit in March 2012 - Manufacturer’s premises in very bad state and only 20% occupied - might stop delivering (special) breakers • Currently: 28 spares (13 operational – 15 to be qualified before TS4) • Consumption average: 8-10 per year (including preventive changes)

  20. Non LHC activities during LS1 • Currently low in spare systems (<1%) and spare breakers (3-4%) • In order: 20 spare systems – ATA Autumn 2013 – to be mounted and tested in ISR test building • Urgent: to order 120-150 spare breakers in order to exclude the regular need of Russian Specialists and cover mid-term needs. Long term strategy for 600 A EE systems: • Switch partially (UA areas) to solid state breakers • R&D necessary: • 2012 development of Lab version (Bi-polar) • 2013/2014 development of prototype – 0.5 day/week • 2015 Market Survey/Tender What about the study to prevent Quench-Back on RQTF/D the installation of lower dump resistances in 600A circuits

  21. Thank you for your attention.. So far..!

  22. Questions before continuing with Cable Activities?

  23. Planning activities GJC • Preparation 600 A EE activities to start LS1: • 70% • Installation/Maintenance – 2013 • Coordination – during the activity 50% • IST – 2013 • Coordination – during the activity 50% • SCT – 2014 • Coordination/installation/Analysis: 70% during activity • HWC – 2014 • PLI3.b1 – remotely from CCC – Automatic Analysis of PM • Activities if automatic analysis fails • PNO.b1 – 1 day per UA or RR – 2 TE or E • Coordination/installation/Analysis: 70% during activity

  24. Solutions • 1- Loosening of holding coil mechanism • Weak design of U-shape and dimensional tolerances • Vibrations causing the closing failures – if starting increasing with cycles • To prevent vibrations the manufacturer proposed decreasing of gaps on the side of the U-Shape by gluing small plates between the U-shape and the housing • Several cycling tests have proven the efficiency of this method. Number of closing failures reduces from typically 4% to less than 0.5 % during lifetime of breaker • Needs to achieve • Plate Glue Action in all 606 breakers • Open all breakers (anyway foreseen for regular maintenance) • Plate gluing – Once open: 3-4 minutes per breaker • Glue = Silicon paste (Dow Corning Mil. Standard) approved by breaker manufacturer

  25. Solutions

  26. Solutionscntd. • 3- Main axle fixation tracking improvement • Weakness during production • If this occurs there’s an increase from 0.5 mΩ to max 1.25 m Ω of system impedance due to decrease of contact pressure in the breaker. • By improving the existing voltage (drop) measurement, correlating it to the circuit current, can lead to an early warning, preventing the circuit to trip • An intervention can be planned in the shadow • Needs to achieve • Improvement of existing Voltage Measurement Channel • Replacement of Voltage Divider by low impedance divider and noise reduction components (MPE-EM) • Replacement of Measurement Board by low noise separation amplifier (MPE-EM) • Replacement of DQAMS by 12 bit to 24 bit ADC (MPE-EP & EM) • Voltage measurement taps to be improved • Hi-level SW for on-line analysis (MPE-MS)

  27. Solutionscntd. • 3- Main axle fixation (and loose bolts) • Overcurrent in one or two phases of the breakers will lead to over-temperature on the Equalizing Resistor and destructing all 3 breakers in one system • Installation of a Thermostat on each Equalizing Resistor will trip the system early before hardware damage is done • A spare internal interlock channel is available and wired up to the power board. • Needs to achieve • Installation of Thermostats and Wiring up to the spare channel • Dismounting, drilling, threading of all 606 Equalizing Resistors • Mounting of pre-cabled Thermostats and a connector PCB • Wire installation from connector PCB to Burndy connector SK24 • Reprogramming of Firmware in all 404 interface cards (MPE-EP)

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