Review of the operation scenarios and required manning of the activities P. Schnizer and L. Serio

Outline Introduction Scope Schedule and test plan Staffing – Operation team – Technical support team – Expert support team Corrective maintenance Preventive maintenance and consolidations Preliminary estimates Conclusions B180 Project – L. Serio3

Introduction Testing Super-FRS magnets requires: operating the infrastructure of the test facility, handling the magnets, performing the tests and analyse the data Other non-continuous activities include the troubleshooting, maintenance and consolidation of the test infrastructure The magnets are pressure vessels operated at cryogenic temperature and include high voltage equipment. Appropriate procedures and qualified personnel are required such that the facility can be operated in accordance with CERN regulations L. Serio4B180 Project –

Scope Identify the activities, resources (number and skills) and cost to perform the tests of the Super-FRS magnets in building 180 at CERN guarantee the safe operability, reliability and availability of the test facility and required infrastructure Identify key competencies from the Organizations (CERN, GSI) to staff the activities according to the requirements, expertise and type of activities If no particular expertise is required the staffing could be from either Organization or subcontracted to industry (other). L. Serio5B180 Project –

Requirements Operation of the test facility requires an operation team executing the day-by-day work a support team on call for specific non-continuous tasks regular but non-continuous activities such as survey specific corrective maintenance not handled by the operation team troubleshooting a support team to perform preventive maintenance and consolidations to guarantee availability & reliability experts available on best-effort basis to diagnose and resolve blocking issues L. Serio6B180 Project –

Assumptions Operation and maintenance during normal working hours Continuous processes (cryogenic and cooling water) require on-call intervention during non-working hours Safe shutdown and, if possible, re-start (safety, cost and schedule) The test facility will be commissioned in summer Prototype and pre-series magnets testing at the beginning of 2017 Series magnets testing from the end of 2017 until 2021 L. Serio7B180 Project –

Schedule L. Serio8B180 Project –

Test program L. Serio9B180 Project –

Staffing: Operation team The regular operation shall be executed during normal working hours by a trained operation team (CERN, GSI, other) It consists at least of: Team leader: with the obligation of overseeing all operation and ensuring that all foreseen work packages can be executed Craftsmen, mechanics, electromechanical, welders Electrician / instrumentation specialist Process operators Cryogenic operators Electrical tests and sensor test: executing all high voltage tests, continuity tests, sensors and cabling Magnetic measurement operator and data analysis engineer Survey technicians L. Serio10B180 Project –

Staffing: Technical support team Not continuous activities assigned according to expertise/responsibility efficiency / cost CERN Transportation and crane operation Safety checks (documents check) and validation Data acquisition and controls specialist technical support Power converter, energy extraction and quench protection technical support Magnetic measurements technical support GSI Magnets follow-up and analysis validation Magnets (test) acceptance L. Serio11B180 Project –

Staffing: Technical support on-call On-call personnel is required to provide prompt support to guarantee the safe and reliable operation or re-start to avoid long recovery times and potential financial losses: Cryogenics operator and maintenance technicians Cooling water system maintenance technicians Electrical power distribution The above could be provided by CERN maintenance and operation on-call services (staff and contractors) Nota: CERN is launching a call for tender for the operation and maintenance of its cryogenic installations by an industrial partner. Operation (cryogenics operation team) and maintenance of the cryogenic system could also be performed by the same contractor. L. Serio12B180 Project –

Staffing: Expert support team Expert support familiar with all design and construction details to analyse and propose consolidation to re-establish performances Expert support on best-effort basis from CERN can be provided for all systems (based on the WP responsibilities) Expert support on best-effort basis from GSI competence domain shall be located on site at CERN: Measurement system support Magnet analysis Magnet supervision and responsibility L. Serio13B180 Project –

Corrective maintenance If a measurement system or infrastructure component flags an error which the operation team does not know how to handle, it will call one of the persons of the corrective maintenance team The on-call services are required for cryogenics, cooling water and the electrical system which require immediate intervention to avoid long delays and potential financial losses For other systems the personnel working on normal working hours from the operation and technical support teams shall provide corrective maintenance L. Serio14B180 Project –

Preventive maintenance CERN will guarantee the reliability and availability of the infrastructure and test facility performing regular preventive maintenance or consolidations (if required) during shutdown periods. The following systems will be serviced during the annual shutdown: Cryogenic system Instrumentation, controls and DAQ Electrical distribution and cooling and ventilation Power converters Energy extraction The following systems require a more frequent recalibration. This will be triggered or performed by the operation team: Power converters direct current transformers (DCCT) Magnetic measurement equipment L. Serio15B180 Project –

Required resources and budget L. Serio16B180 Project –

Conclusions In summary and covering a period of 4 years of operation the required financial and human resources are: – 3.5 MCHF operation costs – 38.2 m-y (not counting the expert support on best-effort basis) A possible scenario for staffing sharing, based on available (existing) and required (future) competencies as well as the most efficient, reliable and safe operation set-up, is: – CERN: 7.4 m-y – GSI: 12 m-y – Other support (best from GSI): 18.8 m-y – Other industrial contract: 3.5 MCHF equivalent These doesn’t include consumables, fluids and electricity (all proposed to be charged at consumption costs) as well as expert support (CERN and GSI) It is recommended that the future operation crew participates to this phase in order to receive adequate training while supporting the commissioning activity L. Serio17B180 Project –