Operational Experience and Consolidations for the Current Lead Control Valves of the Large Hadron Collider

The Large Hadron Collider superconducting magnets are powered by more than 1400 gas cooled current leads ranging from 120 A to 13000 A. The gas flow required by the leads is controlled by solenoid proportional valves with dimensions from DN 1.8 mm to DN 10 mm. During the first months of operation, signs of premature wear were found in the active parts of the valves. This created major problems for the functioning of the current leads threatening the availability of the LHC. Following the detection of the problems, a series of measures were implemented to keep the LHC running, to launch a development program to solve the premature wear problem and to prepare for a global consolidation of the gas flow control system. This article describes first the difficulties encountered and the measures taken to ensure a continuous operation of the LHC during the first year of operation. The development of new friction free valves is then presented along with the consolidation program and the test equipment developed to validate the upgraded valves prior to their installation into the LHC.