Resources and cost for the operation of
the test facility
P. Schnizer on behalf of FAIR project team members
L. Serio on behalf of bldg. 180 test facility project team members (TE
and EN departments)
Outline
•
•
•
•
Introduction
Requirements and schedule
Resources
Conclusions
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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
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Outline
•
•
•
•
Introduction
Requirements and schedule
Resources
Conclusions
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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
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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 2018/2019
• Series magnets testing from 2019 to 2022
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Schedule
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Outline
•
•
•
•
Introduction
Requirements and schedule
Resources
Conclusions
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Required minimum resources and budget
operation engineer in charge
availability
cryogenics
working hours and on-call 0.5 eng
operation team
operation support team
magnetic measurements team
normal working hours
on-call 24/365
normal working hours
maintenance team
on call 24/365 and SDs
1 op
4 op
WP
power c. quench pr energy extrsurvey
test facility MM
1 eng
1 eng
1 op, 1
elecmec, 2
mec
2 op
0.25
0.5
cooling
0.2
1 elec, 1
contr, 1 mec
0.25 op
contract
Total
electrical cont & DAQ handling
0.1
Total for 5 years
FTEy
FTEy CERN
1.35
6.75
FTEy GSI
3.7
18.5
cost of FTEy industry [kCHF]
1158
5790
Not inclusive of electricity costs
GSI personnel to review, analyze and accept data to be added
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Outline
•
•
•
•
Introduction
Scope, schedule and test plan
Resources
Conclusions
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Conclusions
• In summary and covering a period of 5 years of operation
the estimated financial and human resources are:
– 5.8 MCHF operation costs (excluding electricity)
– 25 m-y (not counting the expert support on best-effort basis and
GSI analysis personnel)
• 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: 6.75 m-y
– GSI: 18.5 m-y
– Industrial support contract: 5.8 MCHF equivalent
• The team shall be established well ahead of the start of
operation to ensure appropriate training
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recepti
on
area
occupation of the test benches
reception
area
Test program
Reception at CERN
Unloading
Reception test
Installation from temporary storage to Test Bench
Connection to the test bench
Test at Room Temperature
DAQ system preparation
Leak test
Purging
Cooling 300 - 80 K
Cooling 80 - 4 K
Filling Lhe
Preparation Work at 4 K
DAQ system at 4 K
Protection system set up
Powering the magnet at 4 K
Magnetic measurements at 4 K
Stationary loss measurements
Warm up
Test at Room Temperature
Disconnection from test bench
0.75 days
1 day
1.25 days
1.5 days
2.5 days
2 days in //
2 days in //
1.5 days in //
2 days in //
8 days
1 days
1 days
2 days in
2 days in //
1 day in
3 days
10 days
3 days overnight for
static losses and no AC
losses
10 days
1.88 days
2 days
Electrical disconnection
1 day
Hydraulic disconnection
1 day
Installation from test bench to temporary storage
1.25 days
Loading
4 hrs
3
4
8
1
1
1.5
1.5
10
0
10
2
2
1.5
41
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Staffing: Operation team
• The regular operation shall be executed during normal working
hours by a trained operation team (GSI)
• 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 (Contractors @ CERN)
• Electrician / instrumentation specialist (Contractors @ CERN)
• Process operators
• Cryogenic operators (Contractors @ CERN)
• Electrical tests and sensor test: executing all high voltage tests, continuity
tests, sensors and cabling
• Magnetic measurement operator and data analysis engineer
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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
Survey team
• GSI
• Magnets follow-up and analysis validation
• Magnets (test) acceptance
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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 entrust the operation and maintenance of its cryogenic
installations to an industrial partner. Operation (cryogenics
operation team) and maintenance of the cryogenic system could
also be performed by the same contractor and invoiced to GSI
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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
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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
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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
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