Long Shutdown 1 The upgrade of 600 A ENERGY EXTRACTION SYSTEMS

1. Long Shutdown 1The upgrade of 600 AENERGY EXTRACTION SYSTEMS

2. Overview • 600 A Energy Extraction ; what, where, how ? • 600 A EE upgrade; what ? • Intervention statistics • LS1 actions and some details • Findings • Resources • To do • Planning

3. Energy Extraction 600 A circuit

4. 600A Energy Extraction Systems • 202 systems installed in the LHC tunnel in corrector circuits with stored energy between 2.2 and 150 kJ • In 15 different locations; • 8 x UA parallel service tunnel and 6 x RR and 1 x UJ tunnel caverns • Systems developed in close collaboration between CERN and the Budker Institute of Nuclear Physics (BINP), Novosibirsk, Russia.

5. 600A Energy Extraction Systems

7. Intervention Statistics • Between 2010 – 2013: 143 interventions • 113 Preventive Maintenance (Technical stops) • 30 Corrective Maintenance (Piquet Service) • 21 interventions stopped (or delayed startup of) LHC • Total intervention time approx. 775 hours - analysis, intervention and follow up - often more persons involved

8. Intervention Statistics ctnd. • 36 breakers were changed (plus ~25 in period before) • 90 %: holding-coil issues • 10 %: main axle, micro switch, thread, unknown • 40 interventions only for Preventive Breaker maintenance during TS • 10 interventions for Electronics • 19 interventions for Rest: Software, HWC steps, connections..

9. LS1 Actions • Breakers - Regular maintenance and Consolidation • Equalizing Resistors – Installation & wiring of Thermostats • Voltage measurement channel improvement • Visual inspection of main axles – Endoscope • Individual System Test (IST) • Hard-Ware Commissioning (HWC)

10. LS1 actions LIST 1 New Voltage divider board 2 New voltage measurement wires + Vtap 3 Thermostats on equalizing Resistors 4 New Thermostat connection PCB 5 Wiring Thermostat PCB to connector SK24 6 Replacement of A and Z imbus to hexag. Screws 7 Screwed connections "torque" check 8 Breaker maintenance general and Breaker plate gluing 9 Visual inspection main axle 10 Interlock PCB resistor change 11 Interface card firmware upgrade 12 Acquisition and Monitoring board (firmware) upgrade 13 New measurement PCB 14 Replacement of transformer (- overheated zener) 15 Dump Resistor modification RQTL9 Added activities - unscheduled at start of LS1

11. LS1 Flow Chart

12. LS1 Actions details CHASSIS: New Measurement card Interface Firmware Upgrade DQAMS (firmware) upgrade Voltage measurement Gain adjustment

13. LS1 actions LIST 1 New Voltage divider board 2 New voltage measurement wires + Vtap 3 Thermostats on equalizing Resistors 4 New Thermostat connection PCB 5 Wiring Thermostat PCB to SK24 6 Replacement of A and Z imbus to hexag. Screws 7 Screwed connections "torque" check 8 Breaker maintenance general and Breaker plate gluing 9 Visual inspection main axle 10 Interlock PCB resistor change 11 Interface card firmware upgrade 12 DQAMS (firmware) upgrade 13 New measurement PCB 14 Replace transformer (- overheated zener) 15 Dump Resistor modification RQTL9

14. LS1 Actions details Power Part: Replace orange wire by new V-tap Remove orange measurement wire Replace imbus screws by hexagonal

15. LS1 Actions details Power Part: Dismount Burndy 48 pin-and 28 pin-support And Insert 2 wires /pins in correct empty places Inside 60x90 cm rack without side space

16. LS1 actions LIST 1 New Voltage divider board 2 New voltage measurement wires + Vtap 3 Thermostats on equalizing Resistors 4 New Thermostat connection PCB 5 Wiring Thermostat PCB to SK24 6 Replacement of A and Z imbus to hexag. Screws 7 Screwed connections "torque" check 8 Breaker maintenance general and Breaker plate gluing 9 Visual inspection main axle 10 Interlock PCB resistor change 11 Interface card firmware upgrade 12 DQAMS (firmware) upgrade 13 New measurement PCB 14 Replace transformer (- overheated zener) 15 Dump Resistor modification RQTL9

17. LS1 Actions details Power Part: Thermostats on all 606 Req. Prepared at surface in 281 PCB for thermostat series connection

18. LS1 actions LIST 1 New Voltage divider board 2 New voltage measurement wires + Vtap 3 Thermostats on equalizing Resistors 4 New Thermostat connection PCB 5 Wiring Thermostat PCB to SK24 6 Replacement of A and Z imbus to hexag. Screws 7 Screwed connections "torque" check 8 Breaker maintenance - general and Breaker plate gluing 9 Visual inspection main axle 10 Interlock PCB resistor change 11 Interface card firmware upgrade 12 DQAMS (firmware) upgrade 13 New measurement PCB 14 Replace transformer (- overheated zener) 15 Dump Resistor modification RQTL9 > 27.000 screws checked

19. Breaker consolidation • Performed by Dr. Alexandre Erokhin (with support from MariuszBlaszczyk) • Budker Institute for Nuclear Physics • Project leader on Power Converters and Magnets Protection Design, • Now attached to Krakow University (AGH) • Collaborating with CERN since 1997 on Energy Extraction Systems – Modeling and Design

20. Breaker consolidation • Loosening of holding coil mechanism • Weak design of U-shape and dimensional tolerances • Needs to achieve • Plate Glue Action in all 606 breakers • Open all breakers (anyway foreseen for regular maintenance) • Plate gluing • Tuning gaps and forces • Cleaning main contacts

21. Solutions

22. Maintenance • Tuning gaps and forces => Decreasing number of switch closing failures

23. Main axe problem

24. Visual inspection - Visual inspection by endoscope - Several images per breaker - > 2700 pictures for 606 breakers

25. Visual inspection cntd. - Data base of the pictures for each breaker & system with the names of the circuit – Traceability for each breaker

26. Findings during maintenance • Zener diode overheated – patch from 2008 to lower DC voltage on holding coil • Decided to change transformer ; costs 8 kCHF • Several loosened screws were reported – randomly located • Visual inspection show one suspect breaker – with possible weak main axle fixation • RSF1.A23B1 B Breaker

27. Completed

28. Completed 600 A EE UPGRADE Hardware : 99.5% COMPLETED

29. Special thanks to: • Alexandre Erokhin (All subjects) • Mariusz Blaszczyk – assistance with breakers maintenance and part of Marek’s team • Bozhidar Panev – electronics upgrade voltage measurement, heat-run, preparation • Tatyana Erokhina – PCBs: replacing the components, endoscope database, transformer replacement • Polish team under Marek Ciechanowski’ssupervision – manufacturing of cables and mounting of thermostats, screws, transformers: • MariuszBlaszczyk, • PawelBaran, • Tadeusz Jeziorek, • MaciejKosik • PawelDubert – preparation and general help

30. TO DO B4&OLS1 • Interface board: Firmware upgrade • Measurement board: Replacement • UA67: replacement of 16 systems in 8 racks • Individual System Tests • HardWare Commissioning • Acquisition and monitoring card: Hardware and software upgrade to complete voltage measurement transfer with high resolution

31. Planning 2014 • Replacement of 8 racks (16 systems) in UA67 • Individual System Tests - IST • February – June 2014 • 1wk / sector for 2 teams of 2 test-engineers • HardWare Commissioning tests - HWC • June – December 2014 • 1wk / HWC step (PLI.b1?) & PNO.b1 for 2 teams of 2 test-engineers

32. Thank you for your attention!