Transcript Upgrade - Indico

Upgrade, IST and Powering tests of
the 13kA Energy Extraction system
LS1 Review
Bozhidar Panev – 02.06.2015
OUTLINE
1. What was accomplished on 13kA EE systems during LS1
• Upgrades
• Maintenance
• Measurements and IST
2.
3.
4.
5.
6.
7.
Preparation for LS1 activities
People and teams involved in work
What went well
Difficulties
Future optimization
Conclusions
2
Overview of the 13kA EE system
Interface
electronics
BCMs
DQRQ
R=7.7 or 6.63
mOhms
Upgrades
1. Installation of snubber capacitors and new arc chambers in RQD/RQF
systems  completed in 35 days instead of 25 foreseen.
2. RB dump resistor – mechanical modification  40 out of 48 resistors
were completed in 1 month. “Roman pots” and beam pipe supports
postponed the modification of 8 DQRBs.
3. BCM upgrade – powering and protection of the holding coil 
completed in 1 month it had been foreseen for 2 weeks
4. Replacement of the Curie-temperature based thermostat on the RB
dump resistors by bi-metal type
5. Reconfiguration of all extraction resistors back to the origin
(70mΩ for dipole and 6.6/7.7mΩ for quads systems)  performed
together with switch maintenance
6. Preventive maintenance – verification of all bolted contacts and multipin connectors  completed in 4 months.
7. Relocation of some EE components – both sides of LHC point 1 and 5
 completed on time. Well collaborated with CV and transport service
4
Switch maintenance – list of activities
1. Examination and inspection of all mechanical and electrical parts
2. Cleaning and alignment of the main and arcing contacts
3. Main contacts mechanical pressure verification
4. Measurement/adjustment of air gaps (∆1 and ∆2)
5. Check visually the main armature – clean and grease if necessary
6. Check status of micro-switches and their performance
7. Verification and re-tightening of flexible BB connections
8. Adding lubricant on the rotating axes if necessary
30 systems maintenance performed between (Jul – Sep) 2013
2 systems (P3) – at the end of 2013
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Measurements and IST (March-Aug) 2014
After a comprehensive upgrade and maintenance a series of tests were
required to qualify the systems functionalities prior to power the associated
main circuit.
Only a thermal performance of extraction resistors was evaluated during
HWC.
• HV qualification tests
RB systems: 2.5kV – 3min.
RQD/F systems: 1kV – 3min
• Functional tests (without current)
Scope: To verify the performance of the EE
systems comprising all operation aspects.
It includes:
 regular opening, internal fault, closing
failure, powering failure, spurious
opening, fan failure, water flow rate,
etc.
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Measurements and IST (March-Aug) 2014
• Tests with current using dummy loop between EE system and PC
Scope: To verify the proper system performance under current.
It includes:
• regular opening at 1kA, 5kA and 13kA, slow and fast opening at
13kA, spurious opening of one branch at 13kA, etc.
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Other measurements:
Holding coil polarity check
Opening delay measurement
“Busway” conical connection resistance measurement
Breakers contact resistance and current sharing measurement
• Check list: The very last check of all important parts and connections
before release the system for powering
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Conical joints validation – Heat Runs
• The measurement of the conical contact resistance was unplanned
activity. The EE section kindly agreed to perform it on behalf of EN-EL
• The initial idea was to carry out the measurements only at those places
where the water cooled cables were replaced UA(47,63,67,83,87)
• Later it was extended to all UA areas. It was worth  7 conical joints
having higher contact resistance (>0.6uΩ) were revealed. They had not
been subject of intervention during LS1
• 4 people from AGH and 2 CERN staff were assigned to
participate and carry out the measurement
• The preparation of the measurement setup took 1.5
months
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Preparation for LS1 activities
Planning and preparation for LS1 started well in advance. A large part of
the components and materials were available long before LS1.
• RQD/F systems: snubber capacitors and all their auxiliary parts were
prepared for transport and installation at the end of 2011
• RQD/F systems: new arc chambers production started in 2011. All
were delivered at CERN in the first half of 2012
• RB systems: New dump resistor thermostat  available for
installation since 2011
• BCM upgrade (circuit breakers and contactors)  delivered and
tested in Nov 2013. Installation completed at the end of Jan 2014
• Cooling station relocations in point 5  all mechanical parts were
produced in 2013. Relocation completed on time for the IST
• IST measurement setup  prepared and tested in Feb 2014
• Heat run measurement setup  built in July 2013
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People involved
IHEP Team:
1. Mikhail Ovsienko
2. Sergei Avramenko
3. Aleksander Pushkarev
4. Viktor Iaichkov
AGH-UST Team:
1. Marek Ciechanowski
2. Maciej Kosik
3. Tadeusz Jeziorek
4. Stanislav Cyganik
Supporting people: Mathieu, Sandor, Bozhidar
Planning and coordination: Knud, Felix
IHEP team (experts from Russia): They have previously participated in EE
system maintenance and upgrades.
Arrived in CERN June 2013  15 man-months in 2013 and in 2014
AGH team: High technically skilled, became quickly familiar with many
aspects of system design and operation. Contributed significantly during
upgrades and IST.
Arrived in CERN April 2013  15 man-months in 2013 and in 2014
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What went well
• All upgrades and maintenance program planned before and during
LS1 were successfully accomplished
• All main activities were established and presented in November
2012.
• Only few changes were made during LS1 related to preventive
maintenance
• The IST campaign completed on time – one week before the
beginning of the HWC, according to the last version of the general
planning
• During the training quench program all 32 systems performed very
well. Very few issues were registered and quickly fixed
• “Check list” after the IST did not find any mistakes
• 992 tests were performed in total for all 32 EE systems. ~5GB of
data were produced and analyzed. The results from each system
were published in the DFS. To be stored in EDMS
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Difficulties
• Unexpected issues:
– HV test on 3 RB systems (RR13,17,57) initially did not pass.
Reason: A layer of impurities deposited inside flexible hoses due to the
long period of no water flow.
– FPA board modification. The new feature in the DQLPU created a
leakage current (1mA) sufficient to blind the EE system
• Conical connection validation (heat runs)  unforeseen activity.
– Six people were involved in 4 months validation campaign
• The IST test procedure was not approved prior to the beginning of IST
campaign
• Automatic analysis software – not operational at beginning of HWC
• Signatures of the performed tests. Not enough experts around to sign all
tests on time for HWC to continue
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Future optimization
• Continuous conical joint monitoring system would be useful to evaluate
the status of connections after the “findings” during the heat run.
• Improvement of the IST measurement setup
• Automatic analysis tool to be fine-tuned for operation as well as for next
HWC. Differentiate between warnings (no immediate action needed but
experts must be informed) and faults.
• Optimize temperature measurements of the dump resistor
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Conclusions
1. Having experienced and motivated teams, familiar with EE facilities
was very important for successful completion of upgrades and
maintenance
• The AGH team was well trained and can be used in future
2. Starting the preparation and planning of upgrades well in advance
was another essential point – most of the parts and materials were
ready for installation before the beginning of LS1
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Thank you
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Additional slide
Activity
Snubber installation
DQRB modification
BCM Upgrade
Switch maintenance
Connectors check
IST
IST preparation
DQSCR relocation
Thermostat replacement
Check list
Started
July 2013
April 2013
Dec 2013
July 2013
April 2013
March 2014
Jan 2014
Sept 2013
July 2013
March 2014
Ended
Sept 2013
Sept 2013
Jan 2014
Sept 2013
Aug 2013
Aug 2014
Feb 2014
Nov 2013
Aug 2013
Aug 2014
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