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

Review of the operation scenarios and required manning of the activities

P. Schnizer and L. Serio

L. Serio 3

Outline

• Introduction• Scope, schedule and test plan• Staffing– Operation team– Technical support team– Expert support team

• Maintenance and consolidations• Preliminary estimates• ConclusionsCERN – GSI c.tte meeting 20150623

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. Serio 4CERN – GSI c.tte meeting 20150623

L. Serio 5

Outline



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).


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

• a pool of experts available on best-effort basis• to diagnose and resolve blocking issues


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 Q4 2016.

• Prototype and pre-series magnets testing in Q2 – Q4 2017

• Series magnets testing from 2018 to 2021


Schedule


3 test benches, 2 CWUs13 days cold testing J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N DCommissioningSeries Magnets TestingShort Multiplets Proto . . .Long Multiplet Proto . . .Dipole Proto . . .First Series Short MultipletFirst Series Long MultipletFirst Series DipoleFirst Energy Buncher ?Last Energy Buncher ?PANDA testing ?

3 tb, 2 cwu, 13 days cold test Accruals of activitiesmagnet testing rate Forecasted planning wrt current delay1.5 magnets modules/month Forecasted planning according to delayed activities

Baseline0.9 multiplets/months0.6 dipoles/month Main critical milestones

2016 2017 2018 2019 2020 2021

Test program

L. Serio 10

Reception at CERN 0.75 daysUnloading 1 dayReception test 1.25 daysInstallation from temporary storage to Test Bench 1.5 daysConnection to the test bench 2.5 daysTest at Room Temperature 2 days in //DAQ system preparation 2 days in //Leak test 1.5 days in //Purging 2 days in //Cooling 300 - 80 K 8 days 8Cooling 80 - 4 K 1 days 1Filling Lhe 1 days 1Preparation Work at 4 K 2 days inDAQ system at 4 K 2 days in //Protection system set up 1 day inPowering the magnet at 4 K 3 days 1.5Magnetic measurements at 4 K 10 days 10

Stationary loss measurements3 days overnight for static losses and no AC losses

0

Warm up 10 days 10Test at Room Temperature 1.88 days 2Disconnection from test bench 2 days

Electrical disconnection 1 day

Hydraulic disconnection 1 day

Installation from test bench to temporary storage 1.25 days

Loading 4 hrs

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CERN – GSI c.tte meeting 20150623

L. Serio 11

Outline



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


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


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.


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. Serio 16

Outline



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


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. Serio 19

Outline



Required resources and budget

L. Serio 20

availability cryogenics test facility MM power c. quench pr energy extrsurvey cooling electrical cont & DAQ handlingoperation engineer in charge working hours and on-call 0.5 eng 1 eng 1 eng

operation team normal working hours 1 op

1 op, 1 elecmec, 2 mec 2 op 0.25 0.5 0.2 1 op

support team on-call 24/365 4 opmagnetic measurements team normal working hours

maintenance team on call 24/365 and SDs1 elec, 1 contr, 1 mec contract

expert support team best effort TE/CRG TE/MSC TE/MSC TE/EPC TE/MPE TE/MPE EN/MEF EN/CV EN/EL EN/ICE EN/HE

WP

CERN – GSI c.tte meeting 20150623

Totaltotal yearly resourcesCERN staff/fellows/PJAS 1.85 m-y CERNGSI staff 3 m-y GSIother support best from GSI staff/fellows/PJAS 4.7 m-y other GSIother industrial support contract kCHF 870 kCHF otherdoesn't include consumables and electricity

7.412

3480

Total for 4 years

18.8

L. Serio 21

Outline



Conclusions• In summary and covering a period of 4 years of operation the

estimated financial and human resources are:– 3.5 MCHF operation costs (excluding electricity)– 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

• It is recommended that the future operation crew participates to the commissioning phase for support and in order to receive adequate training L. Serio 22CERN – GSI c.tte meeting 20150623

L. Serio 24TE TM – B180 Project – 20150106

availability cryogenics test facility MM power c. quench pr energy extrsurvey cooling electrical cont & DAQ handlingoperation engineer in charge working hours and on-call 0.5 eng 1 eng 1 eng

operation team normal working hours 1 op

1 op, 1 elecmec, 2 mec 2 op 0.25 0.5 0.2 1 op

support team on-call 24/365 4 opmagnetic measurements team normal working hours

maintenance team on call 24/365 and SDs1 elec, 1 contr, 1 mec contract

expert support team best effort TE/CRG TE/MSC TE/MSC TE/EPC TE/MPE TE/MPE EN/MEF EN/CV EN/EL EN/ICE EN/HE

Totaltotal yearly resources 5.5 5 3 0.25 0.5 0.2 0.1CERN staff/fellows/PJAS 1 0.25 0.5 0.1 1.85 m-y CERNGSI staff 1 2 3 m-y GSIother support best from GSI staff/fellows/PJAS 0.5 4 0.2 4.7 m-y other GSIother industrial support contract kCHF 800 25 15 10 20 870 kCHF otherdoesn't include consumables and electricity

WP

availability cryogenics MM power c. quench pr survey cooling electrical handlingoperation engineer in charge working hours and on-call 0.5 eng 1 eng 1 eng

operation team normal working hours 1 op 2 op 0.25 0.5 0.2 1 opsupport team on-call 24/365 4 opmagnetic measurements team normal working hours

contractexpert support team best effort TE/CRG TE/MSC TE/MSC TE/EPC TE/MPE TE/MPE EN/MEF EN/CV EN/EL EN/ICE EN/HE

Totaltotal yearly resources 5.5 5 3 0.25 0.5 0.2 0.1CERN staff/fellows/PJAS 1 0.25 0.5 0.1 1.85 m-y CERNGSI staff 1 2 3 m-y GSIother support best from GSI staff/fellows/PJAS 0.5 4 0.2 4.7 m-y other GSIother industrial support contract kCHF 800 25 15 10 20 870 kCHF otherdoesn't include consumables and electricity

7.412

3480

Total for 4 years

18.8

Documents

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