1. Cryogenics Operations 2008, CERN, Geneva, Switzerland 1 CRYOGENICS OPERATIONS 2008 Organized by CERN Industrial contributions to the maintenance of CERN helium cryoplants F. FERRAND & F. BARACCO On behalf of ALLS maintenance team 22th-26th September 2008

2. Cryogenics Operations 2008, CERN, Geneva, Switzerland 2 Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection 22th-26th September 2008

3. Cryogenics Operations 2008, CERN, Geneva, Switzerland 3 Cryogenic maintenance overview: Scope of work 5 Local Control rooms + 1 Central Control Centre 23 main cryogenic installations @4.5K 12 Magnet Test Bench 81 screw compressors and high voltage motors (160kW to 1,8MW) 22 medium and high pressure compressors (45 to 600kW) 300 vacuum pumps 100 gas turbines & cold compressors 1’000 cryogenic valves for refrigeration units 120 large GHe vessels 30 large LN2 vessels 65’000 I/O signals treated by industrial control 5’000 instrumentation materials 3’000 pressure safety valves 22th-26th September 2008

4. Cryogenic labs & none LHC Experiments LHC cryogenics Beam & Experiments Cryogenics Operations 2008, CERN, Geneva, Switzerland 4 Cryogenic maintenance overview : Yearly schedule Warm up Standard Operation -LHC Preventive plan Winter Maintenance Shut Down Cool down -Curative maintenance intervention: Work Orders -Store management -CMMS deployment -Preparation of LHC Shut Down -Preventive plan Warm up Operation Spring/Summer Maintenance Shut Down Cool down Operation Result Orientated O& M contract 22th-26th September 2008

5. External contractorCERN Departments Cryogenics Operations 2008, CERN, Geneva, Switzerland 5 Cryogenic maintenance overview : Internal Vs External - INSTRUMENTATION - Measurement calibration - Control valves calibration - Gas analysers calibration - Electrical maintenance - MECHANICAL - Preventive maintenance plan - Predictive vibration & oil analysis - Safety valves follow-up & repair - VACUUM - Preventive maintenance plan - Gauge calibration - Pumps maintenance - Leak detection - Vacuum pumping & conditioning - METHODOLOGY - CMMS deployment - Spare parts procurement - Store management - Continuous improvement Control - Supervision - Automation CERN safety - Pressurized vessels - Safety Valves control Instrumentation - Tunnel instrumentation Utilities - Water cooling - Power supply Mechanical Support - Re-engineering - Retrofit CERN TS - CMMS administration Maintenance interface & coordination 22th-26th September 2008

6. Cryogenics Operations 2008, CERN, Geneva, Switzerland 6 Cryogenic maintenance overview : Contractor team organization Mechanical Management Operation Team leader Maintenance Team leader Equipment 1 Vacuum Equipment 2 Instruments Equipment 3 Spare part Procurement & storage Helium cryogenics Technical specialists organised by field Process orientated staff organised by equipment or plant section Day + Standby duty Shift + Standby duty External contractors Corporate Technical Support 22th-26th September 2008

7. Cryogenics Operations 2008, CERN, Geneva, Switzerland 7 Cryogenic maintenance overview : Industrial contributions Erection & Commissioning Cryogenic test RUN Equipment list consolidation Criticity study CMMS Arborescence Support major Overhauling Deploy CMMS Spare parts selection Spare parts procurement Large scale cryogenic operation for LHC and Experiments Develop maintenance plan Curative maintenance Preventive maintenance Develop predictive methods Develop plant follow up Create maintenance DB Develop Reporting tools Improve practices Future…Present Store centralization project Not so far away Methods Spare parts Organization Field work Expertise Cost optimization 22th-26th September 2008 Work Orders system Implement KPI Increase reliability Increase availability Develop predictive methods Develop Reporting tools Spare parts selection

8. Cryogenics Operations 2008, CERN, Geneva, Switzerland 8 Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection 22th-26th September 2008

9. Cryogenics Operations 2008, CERN, Geneva, Switzerland 9 Focus 1: vibration analysis Scope of work »Screw compressors  Power above 250kW LHC accelerator: 63 compressors all considered as critical LHC Experiments: 10 compressors all considered as critical Labs & testing areas: 8 compressors »Proximity piping vibration level measurement Measurement methodology »Manual measurement with mobile spectrometer »Monthly measurement basis »Specific campaigns for oil pumps and large vacuum equipments 22th-26th September 2008

10. Cryogenics Operations 2008, CERN, Geneva, Switzerland 10 Focus 1: vibration analysis 2 3 4 1 V H A 12 physical points / 14 effective points (« multiplexing ») 22th-26th September 2008

11. Cryogenics Operations 2008, CERN, Geneva, Switzerland 11 Focus 1: vibration analysis Level measurement  Indicators according to ISO 10816-3  81 machines x 12 points = 972 indicators per month !!! 22th-26th September 2008

12. Cryogenics Operations 2008, CERN, Geneva, Switzerland 12 Focus 1: vibration analysis General Key Point indicators 22th-26th September 2008

13. Cryogenics Operations 2008, CERN, Geneva, Switzerland 13 Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection 22th-26th September 2008

14. Cryogenics Operations 2008, CERN, Geneva, Switzerland 14 Focus 2: mobile devices for instrumentation Field technician on siteOperators in control Rooms Relevé des données sur la supervision Liaison téléphonique avec le technicien de terrain Cell Phone to get information from supervision Température, pressure, 4-20mAmps signal… 22th-26th September 2008

15. Cryogenics Operations 2008, CERN, Geneva, Switzerland 15 Focus 2: mobile devices for instrumentation 22th-26th September 2008

16. Cryogenics Operations 2008, CERN, Geneva, Switzerland 16 Focus 2: mobile devices for instrumentation SCAN Memory Card 8Go Unicos Calibration history available in mobile device  Batch Real Time data available through supervision network  Online Automatic copy Maintenance DB Field technician Read only Read/write Read/write - Synchro Manual typing signal 4-20mA Simulated Pressure Signal 4-20mA F. FERRAND & F. BARACCO, 22th-26th September 2008

17. Cryogenics Operations 2008, CERN, Geneva, Switzerland 17 Focus 2: mobile devices for instrumentation 22th-26th September 2008

18. Cryogenics Operations 2008, CERN, Geneva, Switzerland 18 Focus 2: mobile devices for instrumentation Duration of shut down Data availability in maintenance DB, almost real time Processus Efficience Reliability of information, real time value checking by the data base Device adapted to field work Good feedback from field technicians and customer F. FERRAND & F. BARACCO, 22th-26th September 2008

19. Cryogenics Operations 2008, CERN, Geneva, Switzerland 19 Contents Cryogenic maintenance overview Focus 1: Develop predictive maintenance - Vibration analysis Focus 2: Develop reporting tools - Mobile devices for instrumentation Focus 3: Spare parts selection 22th-26th September 2008

20. Cryogenics Operations 2008, CERN, Geneva, Switzerland 20 Focus 3: Spare parts selection Create homogeneous equipment listings, built from various suppliers worldwide  CMMS template Criticity study  failure frequency, detection, impact 22th-26th September 2008

21. Cryogenics Operations 2008, CERN, Geneva, Switzerland 21 Focus 3: Spare parts selection Installations similarities, cross checking of 8000 references Budget sizing  Cost of spares Vs Cost of equipment 22th-26th September 2008 »Approach excludes capital spare parts: compressor and turbines »Ration in between 2 and 4% as a first basis

22. Cryogenics Operations 2008, CERN, Geneva, Switzerland 22 Focus 3: Spare parts selection Management of spare parts »Specification and procurement »Centralised warehouse project for cryogenics cryoplants spare parts  Ongoing project to be finalized end of 2008 22th-26th September 2008

23. Cryogenics Operations 2008, CERN, Geneva, Switzerland 23 Q&A Thank you for your attention 22th-26th September 2008 F. FERRAND & F. BARACCO