Upload
asher-ellis
View
218
Download
4
Tags:
Embed Size (px)
Citation preview
prepared by R.A.Barlow (May 2014)
TE-ABT-EC Maintenance methods and policyEdms nb.
TE-ABT-EC
Maintenance methods and policy in EC section
2
Outline EC equipment location Equipment failures EC environment
Hardware Software Maintenance and procedures Repairs Documentation Storage of components Quality control
CONCLUSION
TE-ABT-EC Maintenance methods and policy
3
EC equipment location (expert/piquet equipment)
TE-ABT-EC Maintenance methods and policy
LHCMKI2-Beam1MKI8-Beam2LBDS-MKD-Beam1LBDS-MKB-Beam1LBDS-MKD-Beam2LBDS-MKB-Beam2MKQATCDQ-Beam1TCDQ-Beam2TCDS
PSPI.KFA45PI.KFA28PE.BFA9-21PE.KFA71-79PE.KFA4-9-13-21PE.SMH16PE.SEH23PI.SMH26PE.SEH31PI.SMH42PE.SMH57PE.SMH61PS.SMH61
PSBBI.DISBE.BSWBI.KSWBE.KFABT.KFA10,20BI.SMVBI.SMHBE.SMHBT.SMV10BT.SMV20
LEIRER.KFH31-32-34BI.DFH11-12-21-42SMH11,40ER.SEH10
ADAD.HORNADE/KFE50ADI/KFI55-56NIKHEF 5305-5307
SPSMKPMKDMKQMKE4MKE6ZS2TPSNMST & MSE 2TPSG4MSE4TPSG6MST & MSE 6ZS6
ISOLDEHRS/GPSLINAC4Pre-ChopperCTFCR.KHB550CC.KHC0250CD.SHA110/CD.SHB0120CD.SHB0480/CD.SHA0490TT2FT16.DFA242-254
Equipment Responsible and Deputy
4TE-ABT-EC Maintenance methods and policy
HV genera
tor
Actuato
rs an
d senso
rs
Power su
pply
Power ele
ctronics
Magnet
HV genera
tor elem
ents
Cablin
g
Controls
Hydrau
lics
Timing
Vacuum
0
10
20
30
40
50
60
70
80
Components Kickers + Septa, all facilities
Failu
res b
etw
een
( 200
9-20
13)
HV GENERATOR
IGBT’s/GTO’s/Ignitrons, power triggers
Thyratrons + Heaters
CONTROLS
PLC’s, Fast Controls,
Electronic cards, Software, INTL
ACTUATORS and SENSORS:
Electrovalves, Sensors, Gauges, Temp measurements, etc ...
VACUUM
Failure of vac gauges, Vac levels
HYDRAULICS
Water cooling systems, oil systems
POWER SUPPLY
Large power supplies, Small and Medium type,
5TE-ABT-EC Maintenance methods and policy
BB
ABT EquipmentPS Complex, SPS & LHC
Kickers & Septa
TE/ABT/ECElectronics& Controls
BE/CO & EN/ICEControl Infrastructure
BE/OPOperation
TE/ABTSpecialist
Electronic Modules Power
electronicsHV GeneratorElements
ControlsPLC’s&Pxi systems Power
distribution
Software
Actuators&Sensors Power
suppliesControlchassis
Cabling & associated hardware
6
The EC environment
TE-ABT-EC
Maintenance, methods &
policy
Hardware
modules
Software
Maintenance & procedures
Storage
Documentation
Quality control
TE-ABT-EC Maintenance methods and policy
7
Electronic design data Electronic design is done in-house with the schematics PCB routing with exterior companies or TE-MPE-EM Manufacturing produced outside or by TE-MPE-EM + assembly AED/EDA numbering system for card versioning If done by TE-MPE-EM then all documentation goes into EDMS
under the EDA numbering scheme If done by EC section then documentation is stored in EDMS and
numbered with AED marking Sometimes these are mirrored ! (WE wish to keep OUR ‘AED’
numbering system) Each working manufacturing portfolio contains:
Schematic, layout, gerber files, mechanical drawings, drillings file and serigraphy, BOM’s, test procedures, photo’s...
TE-ABT-EC Maintenance methods and policy
8
Equipment coding of modules
TE-ABT-EC Maintenance methods and policy
Electronic cards labeling with bar code system MTF (Manufacturing and Test Folder) + AED/EDA number + Tested label
The complete MTF system (judged not best suited for our equipment), with LIMITATIONS but...on-going
9
Programmable Logic Controllers
EC has a vast array of industrial automation in its controls park
PLC distributed systems are based around H/W design with associated software
Some chassis design requires custom made electronics coupled to PLC’s H/W
Each PLC chassis is created with technical drawing, cabling scheme, connector scheme (See_electrical) and software code (Step7)
In recent years industrial PXi systems (N.I) are becoming an additional resource to our supervisory control systems
TE-ABT-EC Maintenance methods and policy
10
Power elements/HV elements Many semi-conductor switches type (IGBT,
GTO, Behlke) Trigger systems in the medium power range HV discrete components HV generators (EC/FPS/SE) Electro Mechanical elements
TE-ABT-EC Maintenance methods and policy
11
Power distribution systems EC responsible for the design of system power
distribution These are documented systems and undergo
approval from HSE unit with outside companies such a DEKRA who come along for conformity testing and place approval seals on the systems. This includes Electrical circuit and Electrical protection checks.
We are currently looking at how to produce these elements on the outside using rigorous procedures and guidelines compatible with expected industry standards.
TE-ABT-EC Maintenance methods and policy
12
Software maintainability PLC codes (Ladder, SCL, STL, Graph7) + WinCC
(scada)
Stored onto DFS volume, currently looking at other systems for software maintainability (Autosave product) FPGA ‘s codes (mainly VHDL, sim files, chipscope,
etc....)/SVN C++, Java, other/SVN Hardware drivers/SVN PXI systems software/SVN Fesa equipment classes/SVN
TE-ABT-EC Maintenance methods and policy
13
Preventive maintenance Annual recalibration Annual rotation of DCPS Capacitor exchange (ex: Heater crates) System consolidation Timing system Firmware upgrades Interlock checks Software release Piquet weekly inspections of equipment where possible (ex: oil leaks, HV cable
degradation, flasher not functioning, etc...)
And many more!
Preventive maintenance is difficult in areas with difficult access, no clear evaluation of possible cyclic maintenance, lack of data and analysis for overall systems.
Also MTBF and MTTR are unknown quantities at the present (only LBDS LHC has undergone reliability studies)
TE-ABT-EC Maintenance methods and policy
14
Procedures Magnet conditioning procedures (SPS
MKE4 & 6, MKP, MKD and LHC MKI) ‘Consignation’ procedures Electronic module installation procedures LHC LBDS generator testing + energy scan Test procedures for electronics card Procedures for loading BETS energy tables
et al ...
TE-ABT-EC Maintenance methods and policy
15
Procedures – movies ?
http://www.youtube.com/watch?v=AwugbEjSxAI
The requirements are:
‘To create a multimedia support that shows and demonstrate some typical intervention carried during piquet time and outside of piquet time on TE/ABT equipment (Kickers & Septa)
TE-ABT-EC Maintenance methods and policy
16
Procedures – JIRA“ Plan, track, work – smarter and faster ”
ABT-EC has started to use JIRA as an accomplished work and planning management tool for the following actions:
TE-ABT-EC Maintenance methods and policy
Creating and tracking FSU jobs
Creating and tracking Hardware production jobs
Notification of repairs
Notification of troubleshooting
Notification of general maintenance of equipment related issues
Intervention tracking
17
Interventions/Repairs Daytime requires -> Experts Outside working hours -> Piquet/Experts
These events can last 5mins (ex: Remote solving) up to extreme cases such as 48 hours or more (intervention in-situ involving longsome trouble shooting, special equipment handling, heavy maneuvering. Lots of specialists, etc.,,,)
And occasionally a new spare part will be required !!!
TE-ABT-EC Maintenance methods and policy
18
Anatomy of a typical intervention
TE-ABT-EC Maintenance methods and policy
Logintervention
CCC calls
‘online’ monitoring
of faulty system
Go to systemlocation
Solveproblem
Call CCC
Intervene remotely
Problem solved
IdentifyFault
Stay around
Leavepremises
Logintervention
Controls, Hardware,
Procedural ?
TimeMaterialsPressureHuman factorUnknownsTechnicalexpertise sharingEtc. ...
19
Surface interventions vs tunnel interventions
Surface equipment interventions Items and spares are located in-situ (storage
cupboards, racks, Faraday cages) Missing items have to be fetched from 865 in EC
section AND other storage areas
Tunnel equipment interventions Items are invariably located in 865 or other storage
areas, no spares in UA’s for LHC kicker equipment (except certain power elements)
TE-ABT-EC Maintenance methods and policy
20
Intervention examples LHC LBDS fault: The ratio between DVs1 [v] and DVs2 [v] was out of
specification. A possible GTO failure inside the GTO stack. Decision taken to mask the interlock due to built in redundancy. Clearly a procedural intervention requiring permission from various sources and ultimately the chief LHC coordinator on that day
SPS MKE4 heater problem: after analysis of a thyratron related problem a decision was taken to replace the suspected damaged heater module This required locating a spare module, and the removal of the faulty module for future repairs
SPS MKD thyratron switch replacement: heavy maneuvering, specialists (not an evident one man job). This operation is a complex one, requiring transport, crane maneuvering, specialists, potentially dangerous and costly, re-conditioning of system (procedure) and follow up of faulty thyratron switch
‘The technical diversity of the systems under EC responsibility presents a challenge and requires high levels of expertise from individuals. All members of the team cannot always intervene on equal competence levels’
TE-ABT-EC Maintenance methods and policy
21
Written follow up of intervention Usually carried out in the logbook system, operation and EC
logbook Discussed at weekly ‘Piquet’ meetings Actions follow-up are required
TE-ABT-EC Maintenance methods and policy
22
Storage of spare equipment PLC spare parts critical stock (en-ice-plc, b.864) Electronic modules/cards (b.865) Power supplies (b.865) + building HV elements spares (b.865, b.867, in-situ) Power distribution components (b.865) Spares in-situ for surface controls (BA’s) (Electronic
modules, power electronics, thyratron switches) Spare part lists (Excel file) with components and
spare location for each installation
TE-ABT-EC Maintenance methods and policy
23TE-ABT-EC Maintenance methods and policy
24
Storage of spares at 865
TE-ABT-EC Maintenance methods and policy
865 2-A50
25
Documentation types Electronic designs schematics, layouts, PCB
masks, drilling drawings, mechanical features Functional specifications and Engineering
specifications, internal notes, papers Minutes of meetings, summaries Mechanical designs System layouts, timing schemes, cabling
schemes, procedures, stock lists Many more .... !
TE-ABT-EC Maintenance methods and policy
26
Documentation Storage
TE-ABT-EC Maintenance methods and policy
Much of previous list still stored on DFS volume (should be avoided), some in file holders/no electronic versions.
Ongoing guidelines still to be finalised for the EDMS framework.
27
Pre-installation quality control Electronic diagrams reviewed by third party Surface and visual checks for H/W Weekly rounds on surface points of
equipment controls Visual inspection of produced PCB’s Electronic hardware test procedures
TE-ABT-EC Maintenance methods and policy
28
Recapitulative summaryHardware Software
Maintenance OK OK
Procedures OK OK
Storage OK GOOD
Documentation GOOD GOOD
Quality check OK OK
Module tracking POOR n.a
Returned hardware for repairs
OK n.a
TE-ABT-EC Maintenance methods and policy
POOR, OK, GOOD, EXCELLENT
29
To take away today Maintenance and methods is a vast complex
subject ! There are no all ‘encompassing’ solution This leaves room for bigger ideas and
concepts What is OK today will not suffice in the future There are maintenance methods systems,
they are long and tedious (massive legacy of data entry) to put in place and require resources
TE-ABT-EC Maintenance methods and policy