CURRENT STATUS OF CV INSTALLATIONS, WORKS DURING LS1 AND PROBLEMS ENCOUNTERED DURING START-UP NORTH AREA Bill Bannister / Jani Lehtinen EATM – 7 th October 2014

INDEX Primary & Raw water Demineralised water Chilled water Ventilation Conclusion

PRIMARY & RAW WATER 1/2

PRIMARY & RAW WATER 2/2 Status – CT2 (Primary water) : Running Cold water pumps : OK Hot water pumps : 4 pumps running out of 5, actually 1 pump redundancy. Coupling to be replaced – BA81 (Raw water) : Running – BA82 (Raw water) : Running Problems at the users side, running on potable water back up system actually Works done during LS1 – General maintenance – Maintenance of cooling tower fan motors – Replacement of the main electric switch-board breaker – Installation of a reject water isolation valve – Reparation of a pipe leak under road Gentner – Installation of manual insulation valve in to the BA82 Problems encountered : – One motor failure on a hot water pump (Primary water) – One coupling failure on a hot water pump (Primary water)

DEMINERALISED WATER 1/3

DEMINERALISED WATER 2/3 Status – BA80 & TDC2/TCC2 : Running 1 Pump out of service (Mechanical seal failure, to be repaired this week) – BA81 & EHN1 & TT’s : Running Power supply cables for 3 motors are to be replaced (not planned yet, quotes to be received) 1 pump mechanical seal to be replaced (not planned yet) – BA82 & EHN2 & ECN3 : Running 1 Pump out of service (Problem of a electric drawer). Repair today. Works done during LS1 General maintenance of the cooling stations Revision of ½ of the demineralised water pumps and motors (changing mechanical seals and bearings) Removing of redundant equipment Changing of piping in BA81 cooling circuit Changing of 18 leaking manual isolation valves in TDC2/TCC2 Changing of valves and actuators of the demineralised water circuit “security valves” in BA80 Changing of flow meters for EN/STI group in BA80 and TCC8 Installation of a safety valve and piping modifications in BA81 Cleaning of the tubular heat exchanger for the redresser circuit in BA82 Vacuum pump connections in ECN3 (NA62) T10 cooling system in ECN3 Modification of old ED control valves in BA80, BA81 and BA82 to a manual valves

DEMINERALISED WATER 3/3 Problems encountered : – Several motor break-downs delaying the EPC & MNP22 magnet tests Two motors found out of service during the yearly maintenance in BA81 Leaking weld repair in BA81 Motor failures during the start-up phase in BA81. The main problems have now been understood and the start-up procedure will be modified. Electric motor protections have been modified slightly from 110% to 100% nominal current (BA80 and BA82 to do during technical stop end October) – 1 Mechanical seal failure in BA80 and 1 in BA81 – 1 coupling failure in BA82 – Asbestos removal of joints in TDC2/TCC2 – Problems with automats – Large number of small leaks

CHILLED WATER 1/2

CHILLED WATER 2/2 Status – BA81 Production and distribution : Running 1 Pump out of service (TT83 – TT85, Leak due to the shaft sleeve failure. Spares due this week. Works done during LS1 – General maintenance – Changing of chilled water piping in TCC2 and TCC8 (including asbestos removal in a radioactive area) – Changing of chilled water coils in TCC2 and surface BA80 (4 units in total) – Changing of circulators on three ventilation units in the transfer tunnels – Maintenance of the electrical supply drawers (ABB) of the chilled water production and distribution in BA81 – Installation of flow switches for the distribution pumps in BA81 – Installation of a sand filter in BA81 Problems encountered : – Experiment NA61 at the end of the line in EHN1, there is just enough pressure to work the regulation valves of DC cooling systems.

VENTILATION 1/2

VENTILATION 2/2 Status – Experiments : Running NA61 : There is no humidity control, weather dependent may cause a problem for the user ECN3/TCC8 : Fan for the ventilation unit for the gallery GHN300 is out of service – Transfer Tunnels : Running – Buildings (BA80, BA81, BA82, EHN1, EHN2) : Running – Barracks EHN1 & EHN2 : Running Works done during LS1 – General maintenance – Changing of the regulation of the ventilation units (temporary solution) in TCC2 & TCC8 (2016 permanent solution) – Changing of the supply/control cupboard of one of the surface ventilation units (BA80) – Changing of condensation pipes of the ventilation units in TCC2 and TCC8 – ECN3/TCC8 ventilation modifications (G. Peon) – Dismounting of the supply/control cupboard of the hydrogen extractors (EHN2) Problems encountered : – Regulation and alarm transmission problems

MISCELLANEOUS 1/2 Other works done during LS1 – Cartography of the asbestos on the chilled water pipes and lagging – Cartography of the compressed air network – Sumps : General audit of the sumps during the maintenance (fiche de puisard) FTDP – replacing the discharge pipes, modification of the cabling FTDP Modification of the cabling through BA2 FTDP – Modification of the level switches – Dismounting of old compressed air dryers

MISCELLANEOUS 2/2 Future projects – General : EHN1 extension (M. Obrecht) – Ventilation : TDC2/TCC2 ventilation control upgrade (R. Barrière) ECN3 ventilation (G. Peon) Remplacement ventilation units computer room BA81 Installation of an aérotherme (hot air curtain) main door EHN1 côté Salève – Cooling: Soft start / frequency drives for demineralised water distribution pumps (open) Modification of the supervision of the chilled water production and distribution BA81 Improvement of the NA61 cooling EHN1 (open) – Compressed air : Installation of 3 new compressed air dryers in the b. 860 Installation of flow meters and security valves for the compressed air network (open) – Other : Modification of drainage trays for hot water circulating pumps EHN1 Installation of a sump pump outside TCC2 structure Installation of a piping for a possible evaporator in TCC2 (open) – Security : Installation of handrails at reject water and neutralising water tank access – CT2

CONCLUSIONS The north area was build at 1970’s which makes the installations age at 40 years, well in excess of general life expectancy for CV installations. There are known problems, especially with controls systems and pipework integrity, however, today all systems are running with redundancy. Quite a few problems at the restart of the demineralised cooling systems. Similar problems in the past that were not documented. Lessons have been learned, new start-up procedures will be created. Consolidation of the demineralised water distribution should be reviewed. Request that shutdown planning to be managed as per the SPS (regular progress meetings, key dates/times identified as early as possible). For example, what is the availability of ZN installations during this months Technical Stop?

Extra Slides

COMPRESSED AIR

SUMP PUMPS

POTABLE WATER

FIRE HYDRANTS