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Consolidation activities for TE-CRG

12 th September 2013 Accelerator Consolidation Workshop. Consolidation activities for TE-CRG. L. Tavian, TE-CRG. Content. Status of the present approved consolidation program Additional consolidation proposals for: LHC machine AD North Area (NA) (Test areas including HIE- Isolde )

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Consolidation activities for TE-CRG

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  1. 12th September 2013 Accelerator Consolidation Workshop Consolidation activities for TE-CRG L. Tavian, TE-CRG

  2. Content • Status of the present approved consolidation program • Additional consolidation proposals for: • LHC machine • AD • North Area (NA) • (Test areas including HIE-Isolde) • (General cryogenic services)

  3. Status of present consolidation program To be reconsidered w/r to the probability of massive magnet quenches (> half sector) Cancelled (CSAP, LSC, LMC) (Saving of 150 kCHF) New CtC estimate: 225 kCHF (saving of 180 kCHF) + on the LHC detector side, the consolidation of compressor stations: Hot spares for a MTTR < 1 day ! New CtC estimate: 510 kCHF (Extra cost: 50 kCHF in 2013)

  4. Additional proposals for LHC (I) • Continuation of the compressor station consolidation (Chamonix’2012 proposal): • Present situation: • Critical spare available to guarantee a MTTRestore of about 1 week in case of compressor failures at Point 18 and P2. • Proposal: • MTTR of 1 day possible by adding new compressor skids (6 skids: 3 MCHF + EN-EL, EN-ICE, EN-HE support) • Stock availability > 90-95 % by increasing the spare number (4 new spares: 1.2 MCHF)

  5. Additional proposals for LHC (II) • IT cryogenics: • Identified as HW limitation before HL-LHC • Present limitation following 2005-2006 consolidation: Lmax < 1.75 Lnom (considered acceptable at the time) • New consolidation to be studied in collaboration with the equipment owner (TE-MSC) for a consolidation work during the LS2  could be an expensive consolidation. (+ EN-MME, EN-HE support)

  6. Additional proposals for LHC (III) • Consolidation of the LHe storage during LS • During LS1, about 90 t of helium (~2/3 of the LHC inventory) have been send back to the market via “virtual” storage contracts with gas vendors ~ 0.7 MCHF/LS • This helium has to come back at CERN in 2014: return rate compatible with the LS1 schedule  but could be a limiting factor if higher rates are required for future LS. • The possibility to keep a large fraction (~60 tons) of the 90 tons has to be studied: • A small second-hand TCF20 liquefier is under procurement to consolidate 30 t of LHe to be operational for the LS2 (100 kCHFrequired for installation (EN-EL, EN-HE support) • Another liquefier is required to consolidate an additional inventory of 30 t (1.2 MCHF + EN-EL, EN-HE support)

  7. Additional proposals for LHC (IV) • Electricity & instrumentation consolidation • Deported Siemens electronics for control valves in the tunnel: only 1 spare crate available for 150 operating units (10 year old) proposal to increase the spare to ~10 % (300 kCHF).

  8. Additional proposals for AD • AD new cryogenic distribution & recovery infrastructure: • Present situation: • Heavy logistics: up to ~20 dewars (500 l) per week • Clients not familiar nor trained with helium transfer (1 recent accident during summer). Safety (handling and cryogenics) is the concern. • In addition, 20 % of the delivered helium is lost (generally 10 %)  200 kCHF of extra losses per year • Proposal: • Add a new cryogenic distribution and recovery infrastructure  800 kCHF + EN-HE support

  9. Additional proposals for NA (I) • NA62 • Very old LN2 transfer line without redundancy  loss of Krypton inventory (10 MCHF). • Proposal: add a second transfer line and use the old one as redundancy  50 kCHF

  10. Additional proposals for NA (II) • Unicos Controls migration • Controls of cryogenic infrastructure is based on obsolete hardware (ABB) and SCADA (PCvue, ABB): • ATLAS H8 & CMS RD5 • NA62 cool-down & warm-up unit • (SM18 compressor station, SM18 magnet test station) • (B163 and cryolab pumping unit) • (CAST) • No CERN support: Hotline with ABB (10 kCHF per year) and old spare are existing  up to 1 to 2 weeks of downtime in case of major problems. • 650 kCHFneeded for the migration to the UNICOS/PVSS controls system (50 to 150 kCHF per infrastructure)

  11. Additional proposals for test areas (I) • SM18 infrastructure: • Problem with impurities: downtime of 1 week per year for cold box cleaning. New full flow purifier  1 MCHF • Compressor station consolidation: • 2 critical compressors (Stal S93 & S73)  3 to 6 months of downtime • S93 machine recently available in the present LHC spare • S73 machine available following the ATLAS consolidation (but ATLAS property ?)  common ATLAS/SM18 spare with ATLAS priority in case of a low-probable dual need or new spare procurement (0.3 MCHF)

  12. Additional proposals for test areas (II) • HIE Isolde compressor station: • HIE Isolde will reuse in 2014 the ex-ALEPH refrigerator. • No spare are existing for the two cycle compressors (Aerzen VMY236 and VMY436) i.e. 3 to 9 months of downtime in case of major failure. Cannibalization of the CAST refrigerator (ex-DELPHI plant identical) •  or procurement of two new spares (valid for HIE Isolde and CAST) : 0.4 MCHF  MTTRestore of 1 week.

  13. Additional proposals for general cryogenic services (I) • LN2 storage for CERN infrastructure: • Present situation: 3 x 50000 l (NA, Central liquefier and SM18) rented 20 kCHF each per year, for more than 10 years, i.e. more 600 kCHF already spent. • Cost of a storage vessel: 200 kCHF • Proposal: Purchase 3 units (600 kCHF + EN-HE support) • LN2 storage for CERN experiment: • Present situation: 2 x 20000 l (Compass and NA61) rented 12 kCHF each per year, for more than 10 years, i.e. more than 240 kCHF already spent. • Cost of a storage vessel: 120 kCHF • Proposal: Purchase 2 units (240 kCHF + EN-HE suppport)

  14. Additional proposals for general cryogenic services (II) • Recovery compressors (Helium, 200 bar) • Present situation: 3 compressors • 1 Burckhard compressor 400 m3/h very reliable • 2 Bauer compressor 100 m3/h requiring heavy corrective maintenance (20 kCHF/year over 5 years) and with low running hours (1500 h/y in average instead of 4000 h/y), i.e. the large Burckhard compressor is running often at reduced capacity to compensate the unavailability of the Bauer machines  Efficiency issue and additional wear (number of stop and go). • Proposal: Replace the 2 Bauer compressors by a new Burckhard 200 m3/h  350 kCHF

  15. Summary table *: According to TE-CRG

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