mttr, spare parts and stand- by policy for atb equipments r. losito ab/atb 23th jan. 2008 atc/aboc...

MTTR, spare parts and stand-by policy for ATB equipments

R. LositoAB/ATB

23th Jan. 2008 ATC/ABOC Days 1

Acknowledgement

• Information (and several slides) came from I. Efthymiopoulos, L. Gatignon, O. Aberle, Y. Kadi, A. Masi, F. Loprete, J. Spangaard


Outline

• Status of mechanics and spares• Status of controls and spares• Stand-by policy• Conclusions


Outline




Spares for the

LHC injector chain

Acronym short description Installed Spares Risk

Linacs

LTB.SLx Collimators 4 1? 12Itx.SHx Slits 12 1? 3,6Stripping foil Stripper 1 - 3,6

Booster

PPM Sieve 1 - 3,6

PS

Int. Dump 47 + 48 Internal Beam dumps 2 1?* 2,7Ralentisseur Beam dump 1 - 5,4

PS complex

xSTPx Stoppers 20 1 per type 1,8 - 6

TT2

Stripping foil Stripper 1 1 3,6

AD

DR.SHV1305 Scraper 1 ? 0,6

LEIR

Absorber Pb absorber/stopper 1 - 1,8EI?.SLH01? Slits 2 - 3,6

SPS

BRCx Collimators 3 - 8,4TBSE Transfer line stopper 3 1 8,4TBSJ Injection beam dump 1 - 8,4TBSM First turn stopper 1 - 8,4TCE North extraction collimator 1 1 (old) 8,4TCSC Collimator 2 1 8,4TED Transfer line dump 5 1 8,4TIDH Low energy beam dump 1 1 8,4TIDP Momentum scraper 1 - 8,4TIDVG High energy beam dump 1 1 (old, Ti foil) 8,4

(objects without

drawings / documentati

on or inventory to

be done)

*Vacuum leak on Dump 48, under

investigation


Dump familySPS Inj. Stopper

(TBSJ)

SPS Collimator(TCE)

SPS Internal Dump(TIDVG)

Core Assembly

PS Internal dump (48)


“Dumps”Similarities: Very robust, designed for dumping (LEP times or before), heavyRisk of failure: mediumFailure: PS dumps: Vacuum or water leak, motorisation (recently)

TED: Water leak, switchesOther dumps: Water or vacuum leak

Strategy: Replace object, no intervention for repair (radiation level)MTTR(replace): 2 days

Spare TIDVG to be upgraded (consolidation), no final design spare, PS dump to be analyzedAcronym short description Installed Spares

Dump family

Int. Dump 47 + 48 Full beam dump transfer lines 2 X

TBSJ Injection beam dump 3 1

TED Transfer line dump 5 1

TIDH Low energy beam dump 1 -

TIDV High energy beam dump 1 -

TIDP Momentum scraper 1 1 core

TCE Extraction collimator 1

TCSC Extraction collimator 2 1

Ralentisseur Beam dump 1 -

PS Dump 48



“Stoppers”Similarities: Movable devices, robust design, interlock chain for accessRisk of failure: mediumFailure: Pneumatic jacks, Read-out (switches), vacuum leaks.Strategy: Replace object, limited intervention on pressurized air and

switches, preventive maintenance and monitoringMTTR: 1.5 days

Switch plate prepared for quick exchange (has to be upgraded for 60% of old stoppers)

Acronym short description Installed Spares

Stoppers

xSTPxSafety stoppers (slow, fast, single, double, small)

301 per type

TBSE Transfer line stopper 3 1

TBSM First turn stopper 1 -


Stopper family

SPS 1st Turn Stopper(TBSM)

SPS Transfer line Stopper (TBSE)

PS slow Stoppers

xSTPx


“Collimators and slits, others”Similarities: Movable devices, robust design, smallRisk of failure: mediumFailure: Pneumatic jacks or Read-out (switches), vacuum leak, mechanicsStrategy: Replace object, limited intervention on pressurized air or

motorisation and switches, preventive maintenance and monitoringMTTR: 1 dayAcronym short description Installed Spares

Collimators and slits

BRCx and LTB.SLx Collimators 7 1

EIx.SLH01x and Itx.SHx Slits 14 1

Absorber Pb absorber/stopper 1 -

Acronym short description Installed Spares

Sieve, scrapers, stripper

PPM Sieve 1- (recommended

by APC)

DR.SHV1305 Scraper 1 1

Stripping foil Stripper (TT2/Linac3) 2 1/-


Special

Sieve and fast stopper

Pb absorber/stopper

Description Types # Installed Repair time Impact in case of failure

TCC2 Others Total

Absorbers XABSXCIOXCONXTGU

9791

98111

~ 1 day

Beam line stopped or reduced beam performance

Collimators XCHVXCSV/HXCLD

27

7173

9243

~ 1 dayCorresponding beam stopped or limited functionality

Dumps XTDXXTDV

25

25

~ 1 day,~1 week

Can be compensated by reconfiguration of the access system

Tilter XTIO 1 1 Presently not in use

MicroColls XCRT 2 2 ~ 1 week Primary beam in H8 excluded

Splitter XSPL 1 1 1 year No spare available!No ions possible in H2 (NA61)

Beam Acceptance -Colls

XTAX 12 5 17 1 year No spares, renovated 2001-2003Block beam line

With the exception of XTAX, Microcollimators and XTDV’s, spares are availableand can be installed in 1 day. Extra time for cool-down required if in TCC2,

affecting the whole North Area.

North Area Beam Obstacles – AB/ATB

North Area Beam Obstacles – AB/ATB

• Mechanics of beam obstacles not in bad shape– The most critical items, XTAXs recently renovated

• Spare elements exist or can be made in reasonable delays

• Failures and interventions typically stop the corresponding beam line. – Can be absorbed with re-scheduling and good will from the

experiments• Failures in elements located in the upstream part of the

beam lines or in TCC2 imply switching off the whole North Area for the time of the intervention– Plus the cool-down time if in TCC2

East Area

Description Types Installed Repair time Impact

Stoppers STP 10 ~2 weeks East hall beams stopped *)

Collimators MCH, V 9 ~ 2 weeks East hall beams stopped *)

Marguerites 3 ~ 1 day 1 beam stopped (3 for North target)

Both the T7 and North branch marguérites are broken and must be repairedduring the shutdown (BI + ATB)

DIRAC has asked for a spare T8 marguérite to be prepared (BTV → AB/BI)

*) Intervention requires opening of the roof and intervention by crane Stops all East Area beams

Outline



Status: controls

DC Motorization

• based on a DC motor with the positioning feedback ensured by a rotary or linear potentiometer.

• Used in CNGS target, T2, T4, T6, T10, TIDH, TIDV, TIDP, TBSJ


AC Motorization

• based on a AC motor generally with or without (In/Out) position feedback.

• Used for heavy loads (shieldings, dumps…)


Siemens Control Solution:

CONTROLE

OP ARRET

MODE

LOCAL REMOTE

R S T

380 v

INTERCOM

220v

24v

CPU

24v

AUX

RS1- x

I O

RS1- x

I O

MOTORSHIELD

MOTORSHUTTER

1 A

A03 - O

AB

O

ET 200-S

DC 24v

3 R

K 1

90

3 - O

BA

OO 3R

K130

1-O

GB

OO

-1A

A2

3R

K130

1-O

GB

OO

-1A

A2

SM321

DI16 24Vcc 0

21

345670

21

34567

1

32

456789

1312

14151617181920

L+

M

1 8

92

147

136

125

114

IM 153-1

ET 200- M

153

-1A

A03-0

XB

0

SM321

DI32 24Vcc 0

21

345670

21

34567

1

32

456789

1312

14151617181920

L+

M

22

2423

252627282932

3433

3536373839

1

40

321

-1B

L00-0

AA

0

SM331

AI8 12bits 0

1

2

3

4

5

6

7

1

32

456789

1312

14151617181920

L+

M

C 1011

SM331

AI8 12bits 0

1

2

3

4

5

6

7

1

32

456789

1312

14151617181920

L+

M

C 1011

SM331

AI8 12bits 0

1

2

3

4

5

6

7

1

32

456789

1312

14151617181920

L+

M

C 1011

331

-7K

F02-0

AB

O

331-7

KF

02

-0A

BO

331-7

KF

02

-0A

BO

321-1

BH

50-0

AA

0

SM331

AI8 12bits 0

1

2

3

4

5

6

7

1

32

456789

1312

14151617181920

L+

M

C 1011

331-7

KF

02

-0A

BO

SM331

AI8 12bits 0

1

2

3

4

5

6

7

1

32

456789

1312

14151617181920

L+

M

C 1011

331

-7K

F02-0

AB

O The AC motors are controlled with the Siemens AC starter

modules RS1-x

SM322

0

1

2

DO8RELAY

3

4

5

6

7

13

57

912

1416

1820

L+

M

4

8

13

17

SM331

0

1

2

AI8 12bits

3

4

5

6

7

1

32

456789

1312

14151617181920

L+

M

C 1011

SM3320

1

AO4 12bits

2

3

1

43

56789

10

1413

1516171820

L+

M

1112

SM321

0

21

34

DI32 24Vcc

Byte 0 & 1

567

1

32

456789

L+

0

21

34567M

1312

14151617181920

M-

M+

U

V

W

Earth

+15V

0V

-15V

Ready

Ready

Tach+

Tach-

Earth

Ref+

Ref-

Earth

Ired

Agnd

SpeedIout

Speed EnableTorque Enable

Reset

Dgnd

Earth14

13

12

11

10

9

8

7

6

5

4

3

2

2

3

4

5

6

2

3

4

5

X3

X2

X1

1

1

1

+24V

Ref+

Ref-DAC Test+

DAC Test-

+24V

+24V

+24V

Torque EnableReset

Speed Enable

0V

0V

0V

Ready

MOTOR 2

MOTOR 1

MOTOR 2

MOTOR 1

MOTOR 2

MOTOR 1

MOTOR 2

MOTOR 1

321- 1BL00-OAAO

322-1MF01-OAAO

331-7KF02-OABO

332-5HD01-DABO

Security OUT

+24V

Cable M1

Local/RemoteSecurity IN

Retracté

+24V +24V

R

L

R

*6 ASPA

R SNT

3 2567

ST

R 470

The DC motors are controlled with PI drivers

Parvex RTS The speed and/or

torque reference, the enabling signals and

the current speed and torque are exchanged with the PLC by means

of DO, AI and AO modules.

Parvex RTS

Spares

• For equipment in SPS, transfer lines and CNGS up to 30%

• Synergy with BT (same motors and controllers)

• Controls electronic recent, we can buy additional spares if needed.


Equipment in North and East experimental areas

Inventory: 76 AC Motors 213 DC motors

AC and DC MotorsThe motors are controlled by a CERN-made module called the

Position Controller on a CERN-made field bus called the Equipment Bus. For the AC motors there is an additional power chassis.

In the Equipment where objects move only in IN/OUT position the control of these motors is integrated in a system based on PLC. The PLC controls a module called the Motor Driver for the DC

motors and a power chassis for the AC motors.

Spare partsIn theory enough (all those dismounted in the West area by BI), but integration into CCC controls no more supported by AB/CO

(only Alistair knows how to do it!). Need to be renewed (Siemens solution), but no consolidation budget available (>1MCHF).

Equipment in SPS, Linac 2, Linac 3, LEIR

Inventory: 63 stepping motors

Control solution for Stepping Motors Scrapers and collimators in SPS LSS5

12 stepping motors and 10 position read-out resolvers in total, controlled with a MIDI electronics, from SPS building BA5

25 “Slits” in Linac, 24 in Linac 3 and 4 in CLIC and LEIR Old system G64

Spares MIDI (SPS and LEIR): shared with BI LINACS: no spares: to be consolidated during 2009, new solution (based

on “CO standard solution”) operational in 2010 (subject to availability of additional staff from consolidation budget).

Outline



Stand-By Policy

• ATB has no stand-by service• We do not foresee to have one: number of

calls/year 10÷20/year per team (mechanics/electronics). Mostly minor problems.

• Main reasons of calls:– Beam stoppers blocked (compressed air or

electrical)– Failing end-stroke Switches– Problems of connectivity to equipment or

alarms/interlocks. Often during start-up.• To be re-assessed after LHC start-up?


Status: controls

Conclusions (1/3)

• Situation under control in SPS & transfer lines but:– TIDVG to be modified or re-designed

• Situation not under control in PS complex:– Objects obsolete– Limited knowledge of their status and limits– Consolidation will improve most urgent problems. – On long term, better knowledge should be built

to ensure compatibility with circulating beam– Side effect of consolidation: people now use the

objects increasing the risk of failure!!!


Conclusions (2/3)

• Situation not under control in PS complex:– PS Dumps: no more spare?– Sieve: spare recommended by APC,

under discussion for consolidation program.

– Safety elements: consolidation budget will be made available in 2008.


Conclusions (3/3)

• Situation not under control in Experimental Areas:– Mechanics ok– Controls obsolete, only Alistair knows how

to keep them alive– Budget to renew hardware too high for

consolidation (>1.5 MCHF, <5kCHF/axis)– CO (Alistair) should continue to support

the SL-equip and Equipment bus till a solution ($) is found.


mttr, spare parts and stand- by policy for atb equipments r. losito ab/atb 23th jan. 2008 atc/aboc...

Documents

atcaboc days

stopper1 slide

dump family sps

days spare tidvg

investigation slide

tbsjinjection beam dump1

ps dumps

days switch plate