LHC MAINTENANCE POLICY AND REQUIREMENTS

1. LHC MAINTENANCE POLICY AND REQUIREMENTS T.Pettersson - EDMS:536848

2. Contents • Introduction – LHC & TQM • Cost of down-time • Availability indicators • Designed for availability – the Power Converter approach • Cryogenics – maintenance management now! • Quench protection – Energy Extraction • RF • Technical infrastructure maintenance • Common LHC Maintenance policy? • Tools available to help you… • Conclusion T.Pettersson - EDMS:536848

3. LHC and TQM • The reliability and availability of the LHC will depend not only on the quality of its components but also on the quality of the maintenance of these components… • This maintenance quality involves everyone and all the activities related to LHC. • Quality also means conformance to requirements (you should get what you ask for…). • Quality can and must be managed. • This is known in industry as Total Quality Management (TQM) and it implies: • A process for managing quality is defined; a philosophy of perpetual improvement of how we execute our activities. T.Pettersson - EDMS:536848

4. The Principles of TQM • Quality can and must be managed. • Everyone in the LHC has a customer and is a supplier of something. • Processes, not people constitute the problems to solve. • Everybody is responsible for the quality achieved – not only the QAWG! • Problems must ideally be prevented, not just fixed after they have happened. • Quality can and must be measured. • Quality improvements may be small but must be continuous. • The quality standard is defect free. • Goals are based on requirements, not negotiated. • Life cycle costs should be taken into account, not only the initial costs… • Management must be involved and lead the process. • Plan and organize for a permanent quality improvement. T.Pettersson - EDMS:536848

5. Cost of down-time • LHC CtC is ~ 3.5 BCHF • LHC experiments ~ 1.5 BCHF • Expected yearly operation duration ~ 160-180 days • Expected life-time ~ 20 years • Average yearly maintenance cost of a technical installation is ~ 2% of capital cost (industry). • Physicists of course, worry much more about integrated luminosity… T.Pettersson - EDMS:536848

6. Global availability indicator - MTTR The MTTR indicator can be split into nine parts: 1 – Production reactivity 2 – Maintenance reactivity 3 – Availability of man power 4 – Diagnostic Delay 5 – Preparation Delay 6 – Stock Logistics Delay 7 – Purchase Logistics Delay 8 – Work duration 9 – Administrative Delay T.Pettersson - EDMS:536848

7. Some examples of approaches taken • Orbit corrector power converters (AB/PO) • Cryogenics (AT/ACR) • Quench protection and Energy extraction system (AT/MEL) • Radiofrequency (AB/RF) • Technical infrastructure (TS dept). T.Pettersson - EDMS:536848

8. Designed for availability • 752 Power Converter units for orbit correction. Expected MTBF ~ 80.000 hours • AB /PO expects to lose on average 1 orbit corrector power converter unit every 4:th day (100+ hours)! • Sufficient power in the remaining corrector power supplies to permit operation for 60-90 days without stoppage. • Implies that when the machine stops – everything has to be ready for rapid intervention including logistics in the tunnel to permit rapid exchange of any failing supply (25-65 kg). (MTTR factors) • Faulty equipment is repaired on the surface (“off-line”). T.Pettersson - EDMS:536848

9. Cryogenics – Maintenance Management Now! • Maintenance plans, tasks and spare parts policy are being defined taking into account manufacturers information, operational experience and detailed process knowledge. • Plans and spares lists are based on industrial state-of-the-art approach and methodology are prepared using the CERN asset tracking and maintenance management system (CAMMS) • Maintenance plan will be validated on the initial cryogenic installations going into operation for subsystem commissioning. • Experience will be gathered, stock levels of spares adjusted, maintenance routines (preventive and corrective) optimised. • Outsourcing of maintenance requires extensive preparations of contracts to provide clear objectives and to get reasonable performance from the contractor. T.Pettersson - EDMS:536848

10. Cryogenics – general approach 1. Corrective maintenance as needed during the operational periods 2. Preventive maintenance: - every winter shutdown on rotating machines, oil levels, filters, inspections, etc. - instrumentation and actuators calibration every two years - safety devices verification and validation every two years – tbc • Major overhaul of pumps (every 20'000 hours) and compressors (every 40'000 hours). Issues: • How to deal with maintenance of equipments still under warranty and/or in commissioning but already critical for subsystem commissioning? • Definition of component criticality with no operational experience and lack of support from manufacturers? • Missing resources to establish a complete maintenance plan, spare parts lists, component criticality, maintenance indicator to improve and optimize spare, preventive and corrective maintenance… MTTR3! T.Pettersson - EDMS:536848

11. Maintenance of the Quench Protection System • The Quench Protection and Energy Extraction systemsmust be both reliable and available! This is reached by: • Systematic repair of faults • Analysis of data, acquired during quenches, and action • Diode voltages • Heater voltage recharging etc. • Beam Loss Pattern • Other information in Post Mortem • Analysis of data, taken during test periods, and action • Monthly ≥1 day maintenance with access • No LHC run may start without a check of the QP and EE Systems T.Pettersson - EDMS:536848

12. Requirements for the repair/maintenance • Material • Spares are available and can be repaired/ replaced • Manpower issue (MTTR3) • At HERA there are 12 persons with experience available when the need arises (24h/24h, 7d/7d) • In AT/ MEL 4 persons are available today (expecting 2 more later…) • No detailed plans have been made today, MEL is waiting for experience from the HW commissioning before commitments are made. T.Pettersson - EDMS:536848

13. Radio Frequency System • Detailed work on maintenance management issues by the time the RF hardware is being commissioned, i.e. towards end 2006. • The RF group has a vast experience from running RF systems in other accelerators for guidance. • Spares for critical equipment are acquired as required already now. T.Pettersson - EDMS:536848

14. Technical Infrastructure Maintenance • The old ST division was an early adapter of CAMMS and much work has been done on: • Standardised terminology! • Naming conventions…. • The Top Ten of non-disposable equipment • Maintenance cost par equipment or family • Number of on-failure (corrective) maintenance per month • Costs of Spare Parts per month • Mean Time Between Failure (MTBF) • Mean Time To Repair per equipment (MTTR) • Yearly maintenance cost ~ 1.9% of installed value for technical equipment. T.Pettersson - EDMS:536848

15. Outsourced maintenance • Major issues seen: • Contract specifications – needs have to be defined very carefully. • Performance – you get (sometimes) what you pay for… • Planning of activities – has to concur with the accelerator schedule. • Tracking of interventions – work orders traced in CAMMS • Inventory management. T.Pettersson - EDMS:536848

16. Maintenance policy? • Objective is clear – no LHC downtime except scheduled! • Present status, location, stocks, maintenance procedures and interventions on all equipment installed must be managed - Create dashboards for all equipment families that clearly show both costs incurred and services effectively supplied. • Identify the real processes along with potential bottlenecks, split them into sub-processes. Document the procedures and alleviate the bottlenecks where possible. • Time measurement of the sub-processes must be done automatically using a computer application – an asset tracking and maintenance management system. • Each intervention must originate an Work Order – no action without a trace! • Analyse, evaluate and compare the performance indicators (MTTRj) – otherwise they are of no use. T.Pettersson - EDMS:536848

17. Tools available to help you… • A computerized asset tracking and maintenance management system is used to do this – we have MP5 ( new release is called D7i). • LHC equipment tracked by the MTF application will automatically be accessible from MP5/D7i. But maintenance procedures must still be created for each family of equipment. • The technical infrastructure is already mostly managed with MP5/D7i as is parts of the cryogenics installations. Much experience exists and is available for you to profit from! T.Pettersson - EDMS:536848

18. Tools available to help you…dashboardwith maintenance performance indicators…. T.Pettersson - EDMS:536848

19. Conclusion • Maintenance management of LHC equipment has already started! • Keeping LHC available will be taxing resources in the various accelerator and technical departments. This has been expressed by ALL groups that have contributed! • A strict policy of keeping track of all equipment in the complex, their maintenance procedures and the interventions on any equipment related to the availability of LHC is required. • Use of a tool is mandatory but manpower resources must also be made available. • Key indicators can be created to measure how well the quality aspects of the maintenance activities are managed, i.e. they will indicated how the LHC availability is being managed. • LHC QAWG will be asked to prepare general rules and advise on implementation issues for each equipment group. T.Pettersson - EDMS:536848

20. Acknowledgements Thanks to F. Bordry, L. Serio, K-H Mess, T. Linnecar and I.Ruehl who shared their information about their aproaches to this subject. T.Pettersson - EDMS:536848