ls1 – en-he transport and handling related issues 12 th june 2012

LS1 – EN-HETransport and Handling related

issues12th June 2012

I. Rühl / EN-HE

Agenda EN-HE objectives for LS1 Transport and handling activities Assistance works EN-HE equipment readiness

Cryo-Magnet replacement infrastructure Lifts Cranes Remote handling equipment

Divers ConclusionLS1 day- 12/06/2012 I. Rühl / EN-HE 2

EN-HE objectives for LS1 Provide all requested transport and

handling activities Provide assistance work Get all the necessary transport and

handling equipment ready for reliable operation Maintenance and consolidation projects

LS1 day- 12/06/2012 3I. Rühl / EN-HE

EN-HE-Heavy Handling• Prepares, organizes and executes all transport and handling operations

for accelerators and experiments and CERN users in general• Section of 10 staff and a base contract of 50FTEs that will increase to

about 90 to 100 FTEs during LS1 (~1100 man-months in 2013) • Actual budget is approved only for standard operations, on-going

projects and experiences– During normal LHC run: central budget for standard operations (install a

transformer or transport a cable drum every now and then) + project budget for experiments and approved projects requesting fix teams.

– LS1 increase of base activities (60 transformers, 800 cable drums), the financing is not clear.

• Provide large flexibility but request to perform almost all operations overnight is unrealistic and unfair

LS1 day- 12/06/2012 I. Rühl / EN-HE 5

Transport + Handling activitiesZone Work Time Date Manpower Remarks Planβ n°ATLAS Detector maint. / upgrade 16 m 11/2012 to

04/201464 man monthsBudget approuved

PL M. Nessi

ALICE Detector maint. / upgrade 16 m 11/2012 to 04/2014

64 man monthsBudget approuved

PL W. Riegler

CMS Detector maint. / upgrade 16 m 11/2012 to 04/2014


PL A. Ball

LHCb Detector maint. 16 m 11/2012 to 04/2014


PL R. Lindner

LINAC4 Installation of accelerator 12 m 2013/2014 12 man monthsBudget approuved

PL M. Vretenar

HIE ISOLDE Installation of beam line 4m 2013/2014 12 man monthsBudget approuved

PL D Parchet

SPS Exchange (~30)aimants MB/MQ

2 m 01/2013 to 04/2013

8 man monthsBudget requested

PL J. Bauche SPS

Upgrade jacks de 52910 a 63510

2 m 11/2012 to 04/2014


PL P. Bestmanm

11311

Irradiated cables removal (lss1,ba5,tcc2)

6 m 05/2013 to 11/2013


PL G. Gros

Temporary removal of lss1 magnet line

2 m 05/2013 8 man-monthsBudget requested

PL G. Gros

LS1 day- 12/06/2012 I. Rühl / EN-HE6

Transport + Handling activitiesZone

Work Time Date Manpower Remarks Planβ n°

LHC

Replacement of 19 cryo-magnets

2 m 01-05/2013 10 man-monthsBudget requested

PL JP Tock 1460

R2E blindages RR13/17, RR53/57…

14 m 12-2012 to01/2014

112 man-monthsBudget approuved

PL AL. Perrot 10959…etc,

Replacement of 1232 racks DYPB

8 m 01-08/2013 32 man-monthsBudget requested

PL K. Dalherup 1486

Collimateurs/TDI 0.5 m 11/2013 2 man-monthsBudget requested

PL R. Bebb/ F. Loprete

1149-1461-1495..etc

MKB/MKI/MKD installation

1 m 11/2012 3 man monthsBudget requested

PL L. Ducimetiere

11024-11034-11036…etc,

Installation of 60 new transformers

6 m 01/2013 to 06/2013


PL G. Le Godec 1514

Shielding removal and installation pmi2-rb24-rux45, rux65,…

1 m 12/2012 20 man monthsBudget requested

PL C. Bertone 11180-11182-11187

R2E relocation 2 m 01.2013 to 03.2014


PL A-L. Perrot 1084-1085-1086

General services, cable drums (800!), UPS

8 m 05/2013 to 11/2013


PL JC. Guillaume

LS1 day- 12/06/2012 I. Rühl / EN-HE 7

Comment - T+H activities

• Unlikely that every transport / handling maneuver can be attributed to ‘one’ client.

• During the LHC installation, a central budget was put in place for the ‘transport and handling’ activities required for the machine installation.

• Proposal – central budget for these kind of activities also for LS1 – envelope to be discussed once all work packaged are confirmed!

LS1 day- 12/06/2012 I. Rühl / EN-HE 8

EN-HE-HH contact persons Transport + Handling activities

1st contact person

2nd contact person

3rd contact person

On call service via 72201

T+H activitiesMeyrin, PS, PSB, etc

Y. Bernard164043

S. Fumey163041

S. Pelletier163380

Contractor S130 working in shifts

No on call service via contractS130 foreseen

1 staff (alternating) CERN

T+H activitiesPrevessin,SPS, etc

P. Vallet163868

P. Brunero163011

Y. Bernard164043

T+H activitiesLHC

S. Fumey163041

S. Pelletier163380

P. Brunero163011

T+H activitiesATLAS

S. Pelletier163380

S. Fumey163041

Y. Seraphin160119

T+H activitiesALICE

Y. Seraphin160119

S. Fumey163041

S. Pelletier163380

T+H activitiesCMS

E. Dugue164686

S. Fumey163041

P. Brunero163011

T+H activitiesLHCb

Y. Seraphin160119

P. Vallet163868

S. Fumey163041

T+H activitiesDivers

P. Brunero163011

S. Pelletier163380

C. Bertone164356

LS1 day- 12/06/2012 I. Rühl / EN-HE 9

EN-HE-Assistance Work

• Organizes, plans and carries out infrastructure works for CERNs accelerators + experiments

• Installation and maintenance of manual and motorized industrial doors incl. shielded doors

• 3 CERN staff; up to 30 FTEs via FSU contract(s)

LS1 day- 12/06/2012 I. Rühl / EN-HE 11

Assistance work - ProjectsZone Location Work Time Date Remarks Planβ n°

PS PS complex + CTF3

Infrastructure work for new PS access system

19 m 06/2012 to 12/2013

PL P. Ninin 1515 ?

LINAC4 Meyrin Infrastructure works + inst. Of jacks

12 m 2013 PL M. Vretenar

LHC PA5 Relocation works – R2E 16 m 01/2013 to 04/2014

PL Anne-Laure Perrot

LHC PA7 (left + right of TZ76)

Sealing of collimator regions + ventilation by-pass (EN-CV)

2 m 03-o4/2014 PL S. Redaelli ?Parameters – input HSE ?ECR 557796 (P. Collier)

11306

LHC PA 2,4,6+8 Installation of 16 fire resisting doors between UJs+Uas and sealing off UAs / RAs

2 w / PA

06-12/2012 PL S. Weisz 11296

LHC all Manufact. + inst. of >300 QRL access platforms

12 m 06/2012 to 06/2013

PL O. PirotteECR in preparation

All all Miscellaneous work requested by clients

16 m 01/2013 to 04/2014

Requested and paid by clients

LHC all Orphan works 16 m 01/2013 to 06/2014

PL F. BordryBudget to be foreseen

LS1 day- 12/06/2012 I. Rühl / EN-HE 12

EN-HE-AW contact persons Assistance work

1st contact person

2nd contact person

3rd contact person

On call servicevia 72201

Assistance works + doors maintenance

A. Foreste160468

J. Sakkinen163816

P. Vincent160386

Staff - on best effort basis

LS1 day- 12/06/2012 I. Rühl / EN-HE 13

EN-HE-Handling MaintenanceEN-HE-Lift Maintenance

• Covers all necessary technical, administrative and managerial actions during the life cycle of the industrial transport, handling and lifting equipment

• For maintenance purposes approximately 20 FTEs provided by four service contracts are permanently on site. An additional 20 FTEs intervene according to a fixed intervention schedule, for breakdown interventions or upon request.

• Network of local and international equipment specialists/experts.

LS1 day- 12/06/2012 I. Rühl / EN-HE 15

Preparations for LHC cryo-magnet replacements

Zone

Location Work Time Date Remarks Planβ n°

LHC all sectors incl. TI2

Cleaning and repair of optical guidance line

8 w Accord. to operation needs

Permanent task during replacement period

11312

LHC all sectors incl. TI2

Cleaning and repair of power feed rail

4 w 12/2012 Permanent task during replacement period

11303

LHC S 3-4 Replacement of power feed rail and inst. of protection

2 w 01/2013 Due to water infiltration 11299

LHC UJ22 Maintenance of 6 MAFI convoys

5 m 01/2013 to 05/2013

Permanent task during replacement period

11141

LHC all sectors Clearing up of transport zone

4 w 12/2012 Equipment groups ?

LHC all sectors Removal of shielding walls from transport zones

8 w 12/2012 to 01/2013

EN-HE-HH on behalf of ? UJ13 : 10965 ->11093UJ17 : 11094 -> 11134RR13 : 10964, …

LS1 day- 12/06/2012 I. Rühl / EN-HE 16

LIFT - MaintenanceLift Bldg Zone Work Time Date Remarks Planβ n°

AS 7xx PM, PX

LHC Compulsory lift maintenance

2h/lift monthly Add. costs if outside normal working hours6am to 8pm; 5/7d

11232

AS 7xx PM, PX

LHC Periodic safety Inspections

3h/lift annually Done in parallel with maintenance (2h+1h)

HSE ?

AS 7xx PM, PX

LHC Overhaul of generator units

4d/lift during LHC run

Program scheduled to be finished before LS1

Current Work

AS 7xx PM, PX

LHC Overhaul of lift door mechanisms

2d/lift tbc Preferably done before LS1 (during TS)

11230

AS 7xx PM, PX

LHC Conformity works according to new regulations

3d/lift tbc Preferably done before LS 1 (during TS)

11223

AS 7xx PM, PX

LHC Increased maint. freq. due to increased runs

2h/lift Every two weeks

Add. Budget requested 11232

AS xxx PS, SPS, etc

Compulsory lift maintenance

2 h monthly Add. costs if outside normal working hours

PS : 11958SPS : 11960

AS xxx PS, SPS, etc

Periodic safety Inspection

3 h annually Done in parallel with maintenance (2h+1h)

HSE ?

LS1 day- 12/06/2012 I. Rühl / EN-HE 17

LIFT - ProjectsLift Bldg Zone Work Time Date Remarks Planβ n°

AS45 361 Booster Lift replacement 8 w 07-08/2013 DO-27516/EN released 11070

AS35 269 Booster Lift replacement 8 w 03-04/2013 DO-27582/EN in prep. 11075

AS504 BA2 SPS Lift doors replacement

2w 12/2012 New doors at CERN 11078


2w 01/2013 New doors at CERN 11079


1w 12/2012 New doors already installed; finishing works

11082

AS513 BA7 SPS Repair of hydraulic jack

3w 01/2013 Via maintenance contract E111

11081

AS717 PM54 CMS Lift machine replacement

4w+ 12/2012 Project under study

New 107 Meyrin New lift(s) 8 w tbc

New 192 Meyrin New lift 8 w tbc

New 774 Prevessin New lift(s) 8 w tbc

AS96 193 AD Meyrin

Lift replacement 8 w 2013, tbc

LS1 day- 12/06/2012 I. Rühl / EN-HE 18

CRANE - MaintenanceCrane Zone Work Time Date Remarks Planβ n°

9 PR Brunnhuber3 PR TAIM

LHC, ATLAS, ALICE, CMS

10 years intensive maint. program on 12 cranes by manufacturers

2 d / PR3 weeks

12/2012 to 01/2013

In view of reliability and availability during LS1Budget requested

5 PR SD (LEP time)3 PR SX5 PRUX

LHC, LHCb

Intensive maint. + PSI on all critical cranes

4 w 12/2012 to 01/2013

In view of reliability and availability during LS1

11374

4PR (360-surface)1PR (361-cavern)

Booster Intensive maintenance and repair on all cranes

4 to 6 w 02-03/2013

In view of reliability and availability during LS2

PR 565 BB5 (75t)PR567 ECA5 (40t) PR570 ECA4 (40t) PR572 BA4 (40t)

SPS Assessment of consolidation needs for LS2

2 w 04/2013 To define major revamping/replacement works at the beginning of LS2 or in between LS1 and LS2

PR40 (sector 65)other PR

PS Assessment of consolidation needs for LS2

1 w 04/2012 As above

LS1 day- 12/06/2012 I. Rühl / EN-HE 19

CRANE - ProjectsCrane Bldg Zone Work Time Date Remarks Planβ n°

PR709 SX2 LHC-ALICE Revamping – new hoist 2 w1 w

06-07/201211/2012

Final modificationsCavern mode

PR706 + PR702

SXL2 (ext.)

LHC-ALICE Repl. 2 cranes (63t gantry + 2t)

2 - 3 weeks 07–08/2012 Contr. B1330/EN

New 170 new ISOLDE (Meyrin) new 5t crane (PR251) 2 w 08/2012 Contr. B1304/EN 11547

PR142 183 ATLAS (Meyrin) Repl. 30t crane 2 w 09/2012 Contr. B1330/EN 11274

PR39 157 East area (Meyrin) Revamping 40t (45t) crane 2 m 09-10/2012 Contr. B1331/EN 11280

PR67 157 East area(Meyrin)

Revamping 20t (25t) crane 2m 10-11/2012 Under study! 11283

PR131 191 ATLAS (Meyrin) Renovation 170t crane 2 m 11-12/2012 Contr. B1331/EN 11285

PR561 ECN3 North area (Prevessin) Revamping 40t crane 2 m 11-12/2012 IT-3886 released on

04.06.201211287

PR84 180 ATLAS (Meyrin) Revamping 60t crane 1 month 04/2013 Contr. B1331/EN 11292

PR6, 7, 8,PR 20, 21 PS PS tunnel Repl. 5 cranes (2t -

7.5t) 3 w 05/2013 Contr. B1304/EN11058, 11068, 11072,11074, 11076

PR91 180 ATLAS (Meyrin) Revamp. 40t crane 1 m 11/2013 Contr. B1331/EN 11293

New new N-TOF; AD ext.;

BA3bis

New 7.5t, 10t, 10t cranes

1 w / crane

2014 Contr. B1304/EN

LS1 day- 12/06/2012 I. Rühl / EN-HE 20

EN-HE-Handling TechnologiesREMOTE HANDLING - Projects

Eq. Bldg Zone Work Time Date Remarks Planβ n°

Robot 170 ISOLDE Replacement of 2 robots

6 m 07-12 /2013

Tests in bldg. 927 under way

11829

TIM PA1 + PA5

LHC TIM RP monitoring 4 m 01-04 /2014

Project under study 11839

Remote controlled crane

LHC Collimator exchange 2 w 01-04/2014

Trials in the tunnel 11840

Collimator separation

LHC Collimator vacuum disconnection

4 w 01-04/2014

Trials in the tunnel 11841

LS1 day- 12/06/2012 I. Rühl / EN-HE 21

EN-HE-LM(HM/HT) contact personsTransport + Handling equipment

1st contact person

2nd contact person

3rd contact person

On call service via 72201

Lifts projects + maintenance

A. Calderone160249

JP. Lappe160012

N. Perez169285

Contracts E080 + E111 24/24h; 365/365d

Crane consolidation

O. Boettcher160011

R. Rinaldesi01.09.2012

G. Roche164084

-

Crane maintenance

D. Lafarge168786

G. Roche164084

JP. Granchelli160251

Contract E09716/24h; 5/7d

Industrial truck maintenance

JM. Chevalley162980

H. Lourenco166012

Contract E09816/24h; 5/7d

Remote handling

B. Feral164704

JL. Grenard160946

C. Bal164622

Staff - on best effort basis

LS1 day- 12/06/2012 I. Rühl / EN-HE 22

DIVERS 1/2Lift operators

Lift availability most critical during LS1 due to the enormous number of people that have to get in and out of the tunnel

Main failure cause during LHC installation – damaged doors

>25’000 people (approx. 200 runs*20 people/lift) entered the LHC tunnel during the last ‘open days’ at CERN – without a single breakdown – lift operators were in place

Proposal to put lift operators (via GS-IS) in place that follow the major work sites (i.e. splice consolidation) 2(4) operators / 1(2) shift / 17 months 155,-

(310,-)kCHF

LS1 day- 12/06/2012 24I. Rühl / EN-HE

DIVERS 2/2Standard mobile equipment

RTL tractors RTL PEFRA for LHC

55 tractors (+ 12 Fire brigade) RTL Keys managed by EN/MEF

RTL for SPS 42 tractors (including 12 new) Standard keys on the tractor

‘Engagement de conduite’ put in place by HSE/EN-HE for the use of the tractors in the tunnels LHC and SPS

LS1 day- 12/06/2012 25I. Rühl / EN-HE

Draft

Conclusion 1/2 Transport and handling activities

Main projects identified but only few financed (client budget or central budget?)

Cryo-magnet replacement and R2E works during night shifts but no more …

Considerable increase (factor 2) of contractors manpower; at limit of supervision capacity per CERN staff

Need LS1 planning team to evenly distribute workload in order to avoid peak workloads; stable workforce between 90 and 100 FTEs

No transport and handling on call service via contract S130 – to be confirmed by LS1 PL

LS1 day- 12/06/2012 27I. Rühl / EN-HE

Conclusion 2/2 Equipment readiness and assistance work

Preparation (maintenance, consolidation) of ‘critical’ equipment well under way

Lifts remain critical for all tunnel access and exit operations

Proposed increased maintenance frequency Proposed lift operators for intensively used lifts Need of one week stop for each LHC lift for repair and

consolidation works Additional budget for increased maintenance

activities and on call services requested Assistance works already now heavily requested;

budget for orphan works to be foreseen by LS1 PLLS1 day- 12/06/2012 28I. Rühl / EN-HE

ls1 – en-he transport and handling related issues 12 th june 2012

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