Upload
vanhuong
View
225
Download
3
Embed Size (px)
Citation preview
Page 2 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Maintenance of the LHC cryogenic system during the first
long shutdown
O. Pirotte on behalf of the CERN cryogenic group 6th International Workshop on Cryogenics Operations
STFC Daresbury Laboratory, United Kingdom November 10-12, 2014
Page 3 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Content
• Introduction and context
• Preparation : planning, organisation, maintenance tasks
• Major overhauling
• Compressors, motors, oil pumps
• Statistics
• Filtering elements
• Requalification of pressure vessels
• Conclusion
Page 4 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
INTRODUCTION LHC physics run 1 started end of 2009 (cryo installations from 2008)
Change of operation/maintenance sequence : • LEP : 9 months operation + 3 months shutdown • LHC : 3-4 years continuous operation (incl. 4 or 5 technical
stops of 1 week + one month Xmas stop per year) + 18 months Long Shutdown
Stop = no beams for physics, but cryogenic installations must remain in full operational mode (He inventory)
First long shutdown was expected in 2012 -> postponed mid 2013
Long Shutdown 1 (LS1)
Page 5 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
PLANNING
Master planning defined by LS1 general coordination Planning based on the main consolidation works in the LHC tunnel (magnet splices): sequence of tasks starting from sector 5-6 and running clockwise
LS1 Master Planning : sequence of sectors
18 months for maintenance tasks
Page 6 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
ORGANISATION & SCHEDULING
Basic principle for the schedule of the maintenance for a cryogenic plant
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Lock outDismountingTransportMajor overhaulingTransportRe-installationCommissioningCryo TuningFlushingCooling
Equipment available
Major overhauling Max 12 weeks
8 weeks Maintenance tasks
Identification of windows where cryogenic plants can be stopped and maintained
Page 7 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MAINTENANCE TASK LIST Identification of maintenance tasks and maintenance plans • Compressors (warm / cold) • Oil pumps • Motors • Filtering components (adsorbers, separators, coalescers, gas/oil/water filters) • Heat exchangers • Instrumentation (sensors, transmitters, …) • Valves, safety valves, bursting disks • Vacuum system components • Requalification of pressure equipment • Repairs (corrective: QRL, HX in cold box, …) CMMS, generation of
maintenance plans / category of equipment
> 5000 work orders MS Project planning
Major overhauling of (warm) rotating machines
Page 8 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Major overhauling
15734
24198 22642
29896
44104
33846 38983
52000
Jun-2009QSCB-8-CP3
Roller bearing(failure)
VMY536aH
Dec-2010QSCB-4-CP6
Roller bearing(breakdown)VMY536aH
Feb-2011QSCA-2-CP8 /
M08Balancing piston/ plain bearing
S93
Jun-2011QSCB-8-CP7
Roller bearing(breakdown)VMY536aH
Dec-2011QSCB-8-CP6
Plain bearings(wear)
VMY536aH
Feb-2012QSCB-4-CP7
Damaged rotorVMY536aH
Nov-2012QSCA-8-M08Plain bearing
(wear)Stal S93
Mai-2013ANRS
Roller bearing(breakdown)
Kaeser
Breakdown of 2 high stage Aerzen compressors (Dec 2010, Jun 2011) ⇒ Set up of an enhanced vibration monitoring system and of a plan to
modify the oil injection pipe to the balancing piston ⇒ Identification of bearings issues ⇒ Xmas stop 2011 : preventive replacement of bearings and balancing
piston for all high stage Aerzen ⇒ Identification of two issues : excessive wear for one plain bearing + one
damaged rotor
Main events during LHC physics run 1
Page 9 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
PREDICTIVE MAINTENANCE DURING RUN 1
QSCB-8-CP6
QSCB-4-CP7
SKF analysis confirmed roller bearing issues detected (vibration monitoring)
Roller bearings of Aerzen high stage compressors
Page 10 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MAJOR OVERHAULING
Criterion for major overhauling :
- End of LHC physics run 2 : 2018 - Compressors : ~40’000 h max - Motors : max according to maintenance plan
LHC screw compressors before LS1
Manufacturer Qty Major overhauling recommendation
Aerzen 20 20'000 h Stal 37 40'000 h Kaeser 9 40'000 h Mycom 4 20'000 h Howden 4 4 years of operation
LHC motors before LS1
Type Voltage Power Qty Maintenance plan Major overhauling
Ball bearings 3.3 kV - 13 61
30'000 h Plain bearings 40'000 h Ball bearings (oil pumps) 400 V > 10 kW 27 30'000 h
≤ 10 kW 29 Replacement (new)
Page 11 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Motor-compressor systems of the LHC cryogenic installations sent for major overhauling
Point 1 Point 1.8 / Point 2 Point 4 Point 5
ATLAS SR
LHCB
LHCA
LHCB
CMS
M
ATLAS ANRS LHCCB
LHCCA LHCCA
LHCCB
ATLAS MR
Legend Total : 77 motor-compressor systems
C
CP1
M
C
CP2
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
M
C
CP1
M
C
CP2
M
C
M
C
CP5
M
C
CP6
CP3
M
C
M
C
CP1
M
C
CP2
M
C
M
C
CP7
M
C
CP8
CP3
M
C
CP4
M
C
M
C
M
C
CP1
CP2
M
C
CP1
M
C
CP2
M
C
CP1
M
C
CP5 CP6
CP4
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP4
M
C
CP7
M
C
CP8
M
C
CP9
M
C
CPA
M
C
CP1-2
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
LHCA
M
C
CP1
M
C
CP3
M
C
CP2
M
C
CP4
Point 6
LHCB
LHCCA
LHCCB
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP4
M
C
CP7
M
C
CP8
M
C
CP9
M
C
CPA
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
LHCA LHCA
M
C
M
C
CP2
M
C
M
C
CP7
M
C
CP8
CP3
M
C
CP4
M
C
M
C
CP5 CP6CP1
Point 8
LHCB
LHCCA
LHCCB
M
C
CP1-2
M
C
CP1
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
CP2
M
C
CP1
M
C
CP2
M
C
CP1
M
C
M
C
CP1-2
New motor-compressor systemsMajor overhaulingNo major overhauling
MAJOR OVERHAULING OF
55 Compressors 63 Motors 3.3kV
Page 12 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
OIL PUMP
400V ELEC. MOTOR
OIL PUMPS
KRAL
MYCOM Oil pump motors (400V) Major overhauling : 26
Replacement (< 10kW): 26
Page 13 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
CriticalityPumpmanufacturer
Compressoror system Maintenance plan In operation Spare
Major overhauled
StalS87S89
Manufacturer :5'000 hStandard : 8'000 hMajor overhaul : 24'000 h
22
11
22
8'000 h /24'000 h
StalS73S75
Manufacturer :5'000 hStandard : 8'000 hMajor overhaul : 24'000 h
98
44
45
24'000 h
No redundancyNext to compressor (electrical motor)
IMOS93 BoosterS93 High stage
Standard : 16'000 hMajor overhaul : 24'000 h
104
44
3 24'000 h
Sytems without redundant pump
Desmi LHCA Booster 1/1Hig stage 1/1
Standard : 8'000 hMajor overhaul : 24'000 h
22
22
24'000 h8'000 h
Kral LHCBBooster : 1 / 3High stage : 2 / 3
Major overhaul : 40'000 h1212
33
3 40'000 h
Kral CMSBooster : 1 / 2High stage : 1 / 2
Major overhaul : 40'000 h22
11
40'000 h
Mayekawa-Mycom
Compressor : 1 / 2 Major overhaul : 40'000 h 2 1 1 40'000 h
Allweiler Compressor : 1 / 3Standard : 16'000 hMajor overhaul : 24'000 h
3 1 2 40'000 h
Sytems withredundant pump(s)
No redundancyIntegrated in compressor
LHC Oil pumps before LS1 Newperiodicity
Oil pumps sorted according to criticality criteria (damage, process) Update of the maintenance taking into account :
• Vibration monitoring for all oil pumps • Spare are available • Results of major overhauling of samples achieved during LS1
*SKF bearing : 40’000 h
*
Page 14 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MAJOR OVERHUAL OF KRAL OIL PUMP
Major overhaul of a KRAL pump (> 40'000 running hours). − Pump generally in good condition; − No sign of wear identified on the screws; − Some significant wear marks on the inlet site,
probably caused by particles.
Page 15 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Preventive Maintenance • Complete cleaning, and dismounting of all the
compressor parts; • Control and measurements of functional clearances
during dismounting and before re-assembly of the compressor;
• Control and measurements of rotor alignment; • Inspection of all parts including rotors, slide valve,
housing, balancing piston, shaft and seats of seals; • Inspection and replacement of all bearings • Inspection and replacement of shaft seals; • Replacement of all gaskets and O-rings; • Re-painting of the compressor and parts; • Helium leak tightness test; • Conditioning with dry nitrogen; • Packing for transport to CERN, including a new set of
assembly gaskets; • Major overhaul report
Corrective Maintenance Polishing and/or grinding • of rotors (profile); • of slide-valve; Reconditioning • of bearing seats; • of shaft seal seat; • of shaft coupling seat; • drive end surface Re-machining • of rotor housing; • of slide valve bore; • of hydraulic cylinder ;
MAINTENANCE TASKS
STATOR: • Polishing the outside of the carcass • Cleaning, sandblasting and painting of interior
mechanical parts • Reconditioning of the terminals and boxes • Polishing all the connections • Replacement of all the seals on the terminals boxes • Spray with a varnish anti flash on the windings and in
the terminal boxes. • Report with pictures
ROTOR: • Control and balancing of the rotor if necessary • Spray with a varnish anti flash COOLER and fans (if existing): • Inspection and verification of the cooler. • Inspection and verification of the fans. • Decalcification, cleaning and rinsing of the water circuits. • Pressure test of the cooler circuits • Drying in a ventilated oven • Painting
Exchange • of piston rod; • of oil pump (Stal); • of balancing sleeve; • of balancing piston; • of slide valve (oversize); • of slide valve support; Consolidation; • of shaft seal holder (S93); • of clamping unit.
Page 16 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
ALLOCATION OF MAINTENANCE COSTS
CP #
Over- hauled
Contractual revision period at contractor’s
premises
Major overhaul time (Average )
Allocation of costs
Preventive maintenance
Corrective maintenance
5 co
ntra
cts
Stal 24 12 weeks per batch of seven/eight compressors
11 weeks per batch of seven/eight compressors 88 % 12 %
Aerzen 17 8 + 4 weeks per batch of five compressor
8 weeks per batch of five compressors 78 % 22 %
Howden 4 6 weeks per compressor 4 weeks per compressor 97% 3%
Kaeser 6 6 weeks per batch of two compressors
12 weeks per batch of two compressors
(corrective maintenance) 86% 14%
Mycom 3 6 weeks per compressor 4 weeks per compressor 96% 4%
MOTOR #
Over- Hauled
% of the contract
Allocation of costs
Preventive maintenance
Corrective maintenance
3.3 kV 63 86 % 73 % 27 %
400 V 26 8 % 72 % 28 %
400 V exchange 26 6 % 100 % -
Total LHC major overhauling Allocation of costs
Motors 13%
Compressors 87%
Page 17 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
ORGANISATION – FOLLOW-UP
~1 year
Page 18 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MAINTENANCE COSTS : STAL S70’s
78%
22%
S73
Preventive maintenance costCorrective maintenance cost
73%
27% S75
Preventive maintenance costCorrective maintenance cost
Model (overhaul) Asset Meter Unit Last overhaul Allocation of
corrective costs
S73-26A (4/9)
QCCV-STAB15 36666 18202 33% QCCV-STAB01 38902 12100 17% QCCV-STAH03 63459 30480 23% QCCV-STAH04 63618 30721 27%
Model (overhaul) Asset Meter Unit Last overhaul Allocation of
corrective costs
S75-26A (6/8)
QCCV-STAB16 42172 21838 16% QCCV-STAB17 45162 21320 12% QCCV-STAB18 47319 20560 14% QCCV-STAB03 58283 18829 24% QCCV-STAB02 59382 12100 22% QCCV-STAB04 62295 21624 13%
Page 19 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Model (overhaul) Asset Meter Unit Last
overhaul Allocation of
corrective costs
S87-26A (2/2)
S89-26A (2/2)
QCCV-STAH10 27522 11512 0,0%
QCCV-STAH09 29202 11958 0,0%
QCCV-STAH06 43635 12016 88%
QCCV-STAH05 45758 13591 12%
Model (overhaul) Asset Meter Unit Last
overhaul Allocation of
corrective costs
S93-26A (10/17)
QCCV-STAB10 30334 12009 13% QCCV-STAB20 43215 12130 5% QCCV-STAB19 44340 12432 5% QCCV-STAH11 48434 19594 15% QCCV-STAB05 53544 12064 12% QCCV-STAB06 54790 11913 10% QCCV-STAB09 57958 21746 13% QCCV-STAB08 62272 31155 1% QCCV-STAH01 64799 30304 22% QCCV-STAB07 65103 31791 9%
MAINTENANCE COSTS : STAL S80’s & S93
98%
2% S87 & S89
Preventive maintenance costCorrective maintenance cost
95%
5% S93
Preventive maintenance costCorrective maintenance cost
Page 20 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MAINTENANCE COSTS : AERZEN
82%
18% VMY536aM
Preventive maintenance cost
Corrective maintenance cost
75%
25% VMY536aH
Preventive maintenance costCorrective maintenance cost
Model (overhaul) Asset Meter Unit Last
overhaul Allocation of
corrective costs
VMY536aM (8/9)
QCCV-AERB05 42163 11% QCCV-AERB08 44575 11% QCCV-AERB07 46286 11% QCCV-AERB04 46769 23% QCCV-AERB11 49444 10% QCCV-AERB10 55208 36812 10% QCCV-AERB01 72868 37907 12% QCCV-AERB02 80920 39354 12%
Model (overhaul) Asset Meter Unit Last
overhaul Allocation of
corrective costs
VMY536aH (9/14)
QCCV-AERH10 17396 4% QCCV-AERB06 38599 14% QCCV-AERB09 41880 6% QCCV-AERH06 42471 28% QCCV-AERB12 44239 4% QCCV-AERH05 46710 6% QCCV-AERB03 78596 39203 4% QCCV-AERH02 81382 39619 6% QCCV-AERH01 83991 40593 6%
Page 21 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MAINTENANCE COSTS
97%
3%
Preventive Corrective
HOWDEN COMPRESSORS
Model Asset Meter Unit Allocation of corrective costs
WLVIH321 QCCV-HOW003 29,502 100%
WLV321 QCCV-HOW001 45,962
WLVIH321 QCCV-HOW004 47,794
WLV204 QCCV-HOW002 48,858
86%
14%
Preventive Corrective
KAESER
96%
4%
Preventive Corrective
MYCOM
Model (overhaul) Model Average
running hours Allocation of
corrective costs
KAESER (6/8) HSDV760 37'000 14 %
MYCOM (3/4)
HE4025SSC-LBL 37'000 4 %
HOWDEN
Page 22 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Maintenance costs vs model of compressor
0%10%20%30%40%50%60%70%80%90%
100%
Average correctivemaintenance costPreventive maintenancecost per compressor
* Double stage compressor type
Page 23 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
COSTS vs TYPE OF CORRECTIVE TASK
STAL
Page 24 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
LS 1 : major overhaul of LHC cryo compressors
HOWDEN : damaged rotor and casing
Wear of slide valve of STAL QCCV-STAB16 (P8) (remachining – oversize)
Scratches on KAESER rotors (QSCCB-4) Coming most probably from insufficient
lubrication -> 6 new rotor pairs
Page 25 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
LS 1 : major overhaul of LHC cryo compressors
Capacity slide valve and support P6
Damaged plain bearing seat (QSCB-4-CP1-VMYaM)
AERZEN
Balancing piston (magnetic particles)
Page 26 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
LS 1 : major overhaul of LHC cryo compressors Mayekawa - MYCOM
Rotor casing is in very good condition
Thrust bearings : normal wear Male rotor has damage on the position from the gear coupling
Damage on gear coupling from high stage
Bearing head is in good condition
Page 27 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
MOTORS : allocation of corrective tasks
020406080
19 13
76
13 12.5 5
52
23 37.5
60
- 19% of QSCA motors with damaged coupling - 60% of QSCB motors with damaged coupling - 13% of shaft needed to be repaired (chroming) - 76% of polishing / grinding (normal wear) - 13% of plain bearing seats exchanged (too much damaged) - 12.5% of brass oil ring were exchanged - 5% of seals were exchanged - 52% of terminals were exchanged - 23% of motor needed a balance task - 37.5% of 400V motors were exchanged
Page 28 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
LS 1 : major overhaul of LHC motors
Damaged terminals
Plain bearing
Shaft & coupling
issues
Page 29 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Recommissioning of motor-compressor systems of the LHC cryogenic installations after LS1 major overhauling. Vibration measurements according to VDI-3836 (compressors) & ISO-10816 (motors)
Point 1 Point 1.8 / Point 2 Point 4 Point 5
ATLAS SR
LHCB
LHCA
LHCB
CMS
M
ATLAS ANRS LHCCB
LHCCA LHCCA
LHCCB
ATLAS MR
Legend Total : 77 motor-compressor systems
C
CP1
M
C
CP2
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
M
C
CP1
M
C
CP2
M
C
M
C
CP5
M
C
CP6
CP3
M
C
M
C
CP1
M
C
CP2
M
C
M
C
CP7
M
C
CP8
CP3
M
C
CP4
M
C
M
C
M
C
CP1
CP2
M
C
CP1
M
C
CP2
M
C
CP1
M
C
CP5 CP6
CP4
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP4
M
C
CP7
M
C
CP8
M
C
CP9
M
C
CPA
M
C
CP1-2
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
LHCA
M
C
CP1
M
C
CP3
M
C
CP2
M
C
CP4
Point 6
LHCB
LHCCA
LHCCB
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP4
M
C
CP7
M
C
CP8
M
C
CP9
M
C
CPA
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
LHCA LHCA
M
C
M
C
CP2
M
C
M
C
CP7
M
C
CP8
CP3
M
C
CP4
M
C
M
C
CP5 CP6CP1
Point 8
LHCB
LHCCA
LHCCB
M
C
CP1-2
M
C
CP1
M
C
CP1
M
C
CP2
M
C
CP3
M
C
CP6
M
C
CP7
CP2
M
C
CP1
M
C
CP2
M
C
CP1
M
C
M
C
CP1-2
Nominal Noncompliant (balancing issues)No major overhaul
Page 30 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
ELEC - INSTRUMENTATION 288 Valves
2000 Sensors 3500 Transmitters
320 Relays
VACUUM
200 Pumps 235 Gauges
29 Gate Valves
METHOD & COORDINATION
> 5000 Work Orders, CMMS,
Spare parts, Maintenance Plans, Plannings
Source: SERCO
LS1 MAINTENANCE OF CRYOGENIC INSTALLATIONS
MECHANICS MAJOR OVERHAULING
55 Screw Compressors 26 Oil Pumps 116 Motors
~75% of LHC
MECHANICS
2000 Safety valves 94 inspections of separator/coalescer
& 613 cartridges replaced 12 adsorbers (22 t of charcoal)
28 chemical cleaning ~ 6700 joints used
Page 31 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
FILTERING ELEMENTS • Adsorbers (# > 50)
• @ room temperature (# > 20) (24’000 h) • LS1 New charcoal (pellets 4 mm – ref 208EA), except MR
ATLAS (PTFE coating) • Update the emptying/filling procedure : pumping out with
addition of water (dust ), manual filling or vacuum method
• @ cryogenic temperature (# > 30) (-) -> inspection of filters
• Coalescers (# >100) (removable or welded) • Oil separator (24’000 h) (with or without cartridge) • Oil separator with cartridges (16’000h) (24'000 if ΔP monitoring)
• Filters (# > 1000) (24’000 h)
• Various fluids : air, water, oil, gas process (He, N, Ar) • room and cryogenic temperatures -> inspection + corrective if necessary, except oil filters (systematic replacement/cleaning)
Page 32 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Coalescers (#100)
QSCA-2-2F167
QSCCB-4-S171
QSCB-4-7F160 QSCA-8-7F167
Page 33 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Filters (# 1000)
QSRB-18-4F210
QSCB-8
QSKA-2 QSRB-6-3F220
Page 34 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
REQUALIFICATION OF PRESSURE VESSELS
• Acoustic Emission Test (AET) is an official and recognized pneumatic requalification method (many EN documents)
• Requalification pressure : "10% above the maximum operating pressure within the last operating period"
• CERN buffers inventory : 58 x 250 m3 + 68 x 80 m3 • Purchase of a piston compressor station (requalification process can be done
independently from operation)
Page 35 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
CONCLUSION • The first shutdown of the LHC was a huge task • First time realized at CERN with 4 years of continuous operation
followed by 18 months shutdown maintenance plans revised accordingly
• Enormous work of inventory, data collection, method and procedure setting up to be recorded now in CMMS (->LS2) !
• Statistics and lessons have been presented, but some analyses are still on going (e.g. oil analyses)
• Preventive maintenance based on integrated running hours • In addition : predictive maintenance based on periodic vibration
monitoring and oil analysis • One year of preparation is a minimum : CMMS configuration,
maintenance plans, planning, contracts, …
Page 36 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Additional slides
Page 37 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Equipment Destination Mode of transport Quatity of transports Mycom Belgium Road 2 Trucks - not full (6500kg/compressor) Stal Sweden Road-Ferry 5 Trucks - 1 full (3500kg/compressor) Howden Scotland Road-Ferry 1 Truck - not full (4000kg/compressor) Kaeser Germany Road 3 Trucks - not full (1500kg/compressor) Aerzen Germany Road 4 Trucks - not full (4000kg/compressor) IHI Japan Road-Air 1 Transport not full (4 wooden boxes) S2M France Road 1 Trucks - not full (100kg/compressor) Motors Italy Road 13 Trucks - 8 full Total : 29 Trucks - 9 full
LS1 Logistics
CRG-ME LS1 : Compressor Remounting – Improvement of the alignment process
CRG-ME GM / 03-Apr-2014
• Configuration of the database (naming, dimensions)
• Taking into account of thermal growth • Taking into account of dynamic tolerances
Alignment at "cold"
Verification at "warm
"
Page 39 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Vibration measurements
Bearing datas stored in analyser settings
M1H Motor FS horizontalM1P Motor FS horizontal PVM1V Motor FS verticalM1A Motor FS axial
M2H Motor DS horizontalM2P Motor DS horizontal PVM2V Motor DS verticalM2A Motor DS axial
E1H Compressor male DS horizontalE1P Compressor male DS horizontal PVE1V Compressor male DS verticalE1A Compressor male DS axial
E2H Compressor male FS horizontalE2P Compressor male FS horizontal PVE2V Compressor male FS verticalE2A Compressor male FS axial
E3H Compressor female DS horizontalE3P Compressor female DS horizont.PVE3V Compressor female DS verticalE3A Compressor female DS axial
E4H Compressor female FS horizontalE4P Compressor female FS horizont.PVE4V Compressor female FS verticalE4A Compressor female FS axial
Measuring points
Tri-Axe Sensor
Machinery Health Analyser
Page 40 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Vibration analysis AMS suite – Machinery Health Manager
CMMS : Reporting & Statistics
Fault statistics for the motor-compressor sets and the oil pumps in operation
CRG-ME & WOs management / 16-May-2014
Page 42 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
Equipment vibration monitoring Key for Equipment condition normal / unproblematic
to be observed
Point 18 to pay attention
LHCB / LHCCB critical / acions recommended
ID Mon
itorin
g Sc
hedu
le
Prov
. mon
i Sc
hedu
le
Janu
ary
Febr
uary
Mar
ch
April
May
June
July
Augu
st
Sept
embe
r
Oct
ober
Nov
embe
r
Dece
mbe
r
WO Description Type
Prio
rity
LHCB
QSCB-18-CP1 60
QSCB-18-CP2 60
QSCB-18-CP3 60 30 Wear - Increased internal play in male & female rotor, decreased
QSCB-18-CP6 60
QSCB-18-CP7 60
Scheduled Measurements 5 5 5 5 5 5 1 5 1
Measured Units 5 5 5 5 5 5 1 5 5 0 0 0
%-Completed 1 1 1 1 1 1 1 1 5 0 0 0
36
113%
32
Measures / Work Orders
LHCB
QSCB-18-CP1
QSCB-18-CP2
QSCB-18-CP3 18874787 Internal play OB M
QSCB-18-CP6
QSCB-18-CP7
WO's created 1 0 0 0 0 0 0 0 0 0 0 01
Page 43 O. Pirotte, Cryo-Ops 2014 Maintenance of the LHC cryogenic system during the first long shutdown
6R3.CV998 (RM S34)
Valves @ cryogenic temperature
QUICC-8-7CV760