Presentation Outline

2. Maintenance for the TE-CRG cryogenic installations or Managing several thousand interventions with maintenance plansNicolas Bonetti (CERN, Geneva)on behalf of the “Cryogenics Group” Technology Departement

3. PresentationOutline • INTRODUCTION: Cryogenic Installations of LHC • HIGHLY COMPLEX Installations • FOCUS on Maintenance Plans Organisation • SUMMARY • PROSPECTS

4. The LHC Accelerator Technology • 1800 SupraconductingMagnets • 24 km @ 1.8 K • 8 x 18kW @4.5 K • 36 000 t @ 1.9K • 150 t He Inventory (LHC + strategy)=7,5 MCHF

5. Magnets Distribution LHC Cryogenics global cooling scheme 5+2 sites equipped with large Helium refrigerators Large variety of sub-systems installed in caverns and tunnels

6. The refrigerators helium storage compressor stations liquid helium storage cold boxes helium transfer line liquid nitrogen storage

7. SomeDetails of LHC cryogenic hardware Diam: 250mm 33 kW @ 50 K to 75 K - 23 kW @ 4.6 K to 20 K - 41 g/s liquefaction 4.2 MW 48 boxes

8. PresentationOutline • INTRODUCTION: Cryogenic Installations of LHC • HIGHLY COMPLEX Installations • FOCUS on Maintenance Plans Organisation • CONCLUSIONS • PROSPECTS

9. Some global comparisons Nb of WO KW @ 4.5K We are not startingfrom scratch! DATA Base Evolution:

10. Global Reliability Challenges There is a vast number of components

11. 1/8e of LHC: production-distribution-magnets Total 8 sectors: Compressors: 64 Turbines: 74 Cold Comp.: 28 Leads: 1’200 I/O signals: 60’000 PID loops: 4’000 • • Tools to support Teams • E-logboog DB • CMMS DB for Sceduling and Tracability • Asset Management (MTF) • Reporting DB (BO & APEX) • Documents DB (EDMS) x 13.5 From LHC Magnet String test

12. LHC Cryo global availability 2012 Effective treatment of beam induced issues, A global success ! 2013 2010 Nice learning curve! mostly Cryo issues treated “on the fly” 2011 Good start before beam induced issues (energetic neutrons), 1st corrections Availability [%] 830 cumulated days with an average availability of 91.9% Operation for beams [cumulated days]

13. Performance and origin of downtine Global availabilityas seen by LHC during beam operation periods Others according to relative ratio of their average for the 8 sectors Percent [%] Evolution: - 2010: Correcting early Cryo bugs - 2011: Adapting to SEU (corrected @Xmas) - 2012: Outstanding performance ! • Examples of corrective actions: • - Screw compressor (internal “machining”due to damaged balancing piston) • Specific electronic controler failure: Mecos … • Instrumentation: valve actuator, sensor, … (260 days) (271 days) (290 days) (Full days, Mondays & Fridays of Technical Stops not counted here)

14. From the books: Immediate effect of (good!) practice Annoying if frequent, to be kept low with moderate efforts Serious cases requiring specific monitoring and significant efforts Origin of downtime, systematic analysis

15. Management Methods - Logistics Electricity-Controls Operation Accel. Operation Detect. Mechanics Instrum-Cryolab A structure adapted to the complexity • Management: 2 pers. • Electrical support: 11 pers. • Mechanical support 12 pers. • Instrumentation support +Cryolab: 10 pers. • Methods & logistics: 7 pers. • Operation LHC: 20 pers. • Operation Detectors: 12 pers. Maintenance level 1 &diagnostics process Other maintenance levels & methods 15

16. PresentationOutline • INTRODUCTION: Cryogenic Installations of LHC • HIGHLY COMPLEX Installations • FOCUS on Maintenance Plans Organisation • CONCLUSIONS • PROSPECTS

17. How itworkswithcompressors • Class • Categories • Association Position /Asset • Association Asset/Part • Models

18. How itworkswithcompressors • The next step is to associate the documentation in order to extract the critical spare parts, plans and manufacturer’s recommendations

19. How itworkswithcompressors Documentation Manufacturer’srecommendations Bill of Materials Layout MaterialsLists Procedures Plans, Sketches... Preventive Maintenance Task MCPS

20. How itworks: MaintenanceTask List • The contractorworks on the basis of fixedprice per task • The MTL contains 362 codes for standard maintenance tasks • The maintenance plans are based on definedcounterdependent or absolute time dependent

21. How itworkswithcompressors • The meterisreadregularly by techniciansduring the monthly inspections • It triggers the maintenance plans in fonction of the MeterInterval • Wecanalsoread the Meter Due

22. How itworkswithcompressors • WO are generatedin Work Packages • WO are treatedand closed

23. How itworkswithcompressors • Finally a complete report isdone by the technician for eachtask • We have formsthatwecurrentlyfill out manually • We are working on an online solution

24. How itworks: Structure to summarize Classes MonthlyStatement Meters Bill of Materials 810 29 Conditional Maintenance Absolute time value dependent Documentation Categories MTL 162 Positions Assets Parts 362 36240 1361 8858 Maintenance Plans - Inspections - Maintenance Tasks Approx.: 3500 WO for the LS1 11410 Impovements Procedure Layout Material List Complete Report

25. PresentationOutline • INTRODUCTION: Cryogenic Installations of LHC • HIGHLY COMPLEX Installations • FOCUS on Maintenance Plans Organisation • SUMMARY • PROSPECTS

26. SUMMARY • Maintain CERN cryogenics installations is a challenge!! • We have a lot of experience but a lot of work has to be done as well • The long shut down 1 is the great opportunity to verify the efficiency of our methods • The optimization is on the way…….

27. PresentationOutline • INTRODUCTION: Cryogenic Installations of LHC • HIGHLY COMPLEX Installations • FOCUS on Maintenance Plans Organisation • SUMMARY • PROSPECTS

28. Rotary machines

29. Vibration measurements as part of condition based maintenance Measuring points Tri-Axe Sensor Machinery Health Analyser Bearing data stored in analyses settings Measured frequency range as a function of machine conditions

30. Manythanks for your attention