RHIC CRYOGENIC SYSTEMS MAINTENANCE PROGRAM
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1 RHIC CRYOGENIC SYSTEMS MAINTENANCE PROGRAM Brookhaven National Laboratory
2 Major Plant Equipment Categories / Locations Compressor Refrigerator Service Buildings
3 The Maintenance program is based on the following Preventive. Physical inspection and Measurements. Manufactures requirements. On demand maintenance (breakdowns)
4 Compressor Plant The Heart of the Cryo- system! 20 First Stage compressors arranged 2 units per skid. 4 Second Stage compressors arranged 1 unit per skid. A Redundant Compressor, this unit can be configured as a 1 st or 2 nd stage compressor. A Utility Compressor, this unit is used for gas clean-up and gas management operations. Other equipment in the compressor building : oil distribution system, filtering media, valves, instrumentation, a purifier station and vacuum station.
5 Maintenance Program for the compressors Bearing replacement on the main compressor motors (2250 and 600 hp). Compressor shaft seal replacement. Compressor to motor alignment check. Suction valve actuator replacement. Filter replacement (oil). Oil analysis and oil pump repair. Cleaning of motor vents. Major over-haul on the compressor and motors.
6 Howden Compressor Reliance Electric motor
7 Refrigerator and Cold Boxes Turbo-expanders and lube oil skids.ge Rotoflow type. Gas Recovery Compressors. Regeneration equipment. Vacuum stations. Valves and Instrumentation. Contamination removal equipment.
8 Maintenance Program for the Expanders and oil-lube skids Bearing replacement. Shaft and seal replacement. Heat barrier replacement. Rotor replacement. Guide vane replacement. Filter replacement Oil analysis. Pump maintenance Transducers and pneumatic controllers
9
10
11 Other Refrigerator equipment Gas Recovery Compressor: (Dunn&Bush)(Sullair) Filter replacement, oil analysis and shaft seal replacement. Regeneration Skid: Filter and Absorbent media, blower maintenance and valve seal replacement. Vacuum Skids: Oil replacement, pump and instrumentation repairs. Process valves and Instrumentation: Seal replacement, entire valve replacement, valve calibration, transducer calibration or replacement, power supply replacement. Contamination Monitors: Instruments to monitor undesirable elements such as moisture,oxygen and nitrogen. Cell calibrate or replacement.
12 Oxygen Monitor Hygrometer Nitrogen detector
13 Service Buildings and Tunnel Equipment Control and Process valves. Circulators (Barber-Nichols Co.). Vacuum Equipment. Relief valves. Instrumentation.
14
15 Maintenance performed Valve seal replacement. Vacuum pump refurbish or replacement. Valve calibrations. Instrumentation power supply repair or replacement. Relief Valve certification (ASME Code). Circulator maintenance. 1005E equipment (Two stage Sullair, model 1660 refrigerator)
16 Summary: Maintenance done in-house. (equipment repair and replacement, the calibration of instrumentation and electronic component repair) Contract Maintenance ( major over haul of compressors,instrument air compressors) The maintenance done to our equipment plays a vital role in providing the refrigeration that is required for the RHIC project.
17 Summary: continued Maintenance done in house is based on the following criteria. Daily physical inspection of equipment. Review of shift log data on equipment. Equipment status is monitor and controlled in the control room during the physics run.
18 RHIC CRYOGENIC SYSTEMS MAINTENANCE PROGRAM Brookhaven National Laboratory
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