LCLS Maintenance Personnel and Procedures Paul Bellomo
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Transcript of LCLS Maintenance Personnel and Procedures Paul Bellomo
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Topics
Scope and Perspective
Why we know we are ready
Department descriptions
ARTEMIS
The maintenance process
Examples
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Scope and Perspective
Accelerator equipment
New electrical, mechanical, electro-mechanical and electronic equipment from the injector gun through the end of the tune-up dump TD-11.
New control room in Building 5
New substations K10B, S520, MCC S20, panel-boards
Operations Directorate
12 Departments, only 5 directly involved
Controls, CEF, Klystron/Microwave, Mechanical Fabrication, Power Conversion
Perspective
Maintenance departments
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Why We Know We Are ReadyAll departments
LCLS equipment possesses some new features, but is not totally unlike the equipment that SLAC currently services and maintains
Designers are the persons/groups that will maintain the equipment
Maintenance personnel are qualified and have been involved in the LCLS design from the start. Training requirements are modest and provided by LCLS, Department, or outside agency
Staff quantity is adequate to handle increased LCLS workload. The documentation (detailed later) needed to support the systems exist
Procedures (detailed later) needed to maintain the systems exist
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Department Descriptions
Department Head – Hamid Shoaee, staff of 75
Software and hardware sections
Software Section
Write low-level applications, EPICS drivers, displays
Maintain MATLAB infrastructure (licenses), ensure compatibility with all control room platforms
Provide network hardware and software
Provide control room infrastructure (alarms, displays, servers and workstations)
Development and maintenance are the same people
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Department Description - Controls (Continued)
Hardware SectionBeam Containment System (BCS)
Prevents radiation from 'escaping' the shielding enclosure
BSOICs, BTMs, LIONS, toroids and current monitors
Machine Protection System (MPS)Protect equipment from beam damage
VME processor-based protection ion chambers (PICs), RTDs, digital monitors
Personnel Protection System (PPS)Protect personnel from radiation exposure, laser and electrical hazards
PLC driven systems
Vacuum - PLC based gages, valves, pumps and interlocks
Movers - Tables, mirrors, cameras, wire scanners
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Department Head – John Weisend, staff > 150
CEF Operations - Bernie Romero, staff of 28
Electrical maintenance of substations and electrical distribution equipment
Beam-line manifolds and plumbing
Documentation
One-line diagrams
Panel-board schedules
Manufacturer drawings and instruction manuals
Beam line assembly and layout drawings
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Klystron/Microwave DepartmentDepartment Head - Chris Pearson, staff of 80
Microwave Engineering and Maintenance/AMRF, staff of 15
Positron Source, Damping Rings, LINAC, LCLS LINAC and SLC RF systems and 2856MHz pulsed klystrons
PEP (HER and LER) and SPEAR 3 RF systems and 1.2 MW, 476MHz CW klystrons
Documentation
Rack front views and Captar rack profile drawings
Electrical interconnect diagrams, cable database
Electronic chassis diagrams
Manufacturer drawings and instruction manuals
ELPs, EWPs, bench test, hi-pot procedures
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Mechanical Fabrication Department (MFD)
Department Head – Karen Fant, staff of 80
Mechanical fabrication/maintenance – no design
Vacuum gages and pumps on the vacuum side, pneumatic valves, beam pipe and other components designed by others (LCLS staff)
Magnet cooling water hoses, disassemble magnets to find magnet problems and ground faults
On-call support of Operations
Documentation
Beam line assembly and layout drawings
Vacuum pump-down procedures
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Department Head – Paul Bellomo, staff of 75
DC magnet power systems and RF modulators
Cables, cable tray and raceways
Dedicated maintenance staff of 31 people, 24/7, 3-shift operation
Participate in power system commissioning
Documentation
Rack front views and Captar rack profile drawings
Electrical interconnect diagrams, cable database
Electronic chassis diagrams
Manufacturer drawings and instruction manuals
ELPs, EWPs, bench test, hi-pot procedures
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ARTEMIS
Accelerator REMEDY Trouble Entry & Maintenance Information System
Web-based problem reporting, work scheduling and work status program
Report and track both hardware and software problems
Incorporates ISMS core functions
Five statesNew Entry – report problems or schedule maintenance
In Progress – Jobs in progress or have more work to do
Scheduled Jobs – Input from the New Entry state
Review To Close – All known work completed, ready for management review
Closed – trouble report entered into archive
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ARTEMIS
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The Process
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Example S20 Power Distribution Layout
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Example One-Line Diagram
Excerpt from ID-950-075-03
Substation K10B 13.8kV:480V to S20 MCC to 6 Power Supply Racks
Portion of S20 MCC shown
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Example Rack/Equipment Profile
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Example Electrical Interconnect (EI/ELP) Diagram
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The PCD Process – Example 1
LCLS bend magnet system fails unexpectedly at 3AM. The indications are that a power supply has failed.
LCLS Operations files an ARTEMIS and also notifies the PCD owl shift supervisor/maintenance manager (MM). Ops classifies the problem as critical, because the machine is down without this particular magnet.
MM evaluates the system, reviews past ARTEMIS reports and chooses appropriate technicians to troubleshoot the problem.
The MM, the technicians then assess the situation, from the technical, logistics and safety standpoints. The system is 480VAC input, 40VDC output.
Appropriate test equipment and PPE (Category 0 with Class 0 gloves)
The group notifies Ops that it is responding to the call. Ops turns the system over to PCD. PCD applies LOTO. ARTEMIS upgraded to “in process”
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The PCD Process – Example 1 Continued
Work progresses power system will not turn on. After several hours, the solution is not readily apparent.
Ops escalates the problem to the designated system expert or Department Head. After 3 hours without resolution the Department Head and LCLS manager are notified. Work continues
The technical expert finds and solves a short in the power supply rectifier. Parts are field-replaced.
Ops is notified that the system is running. The system is returned to Ops.
Technicians file “review to close” ARTEMIS report, file e-log detailing the problem, the solution and parts used.
The PCD MM checks the parts inventory and if below a pre-determined critical level, orders replacement parts.
PCD closes the job internally
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The PCD/MFD Process – Example 2
A ground fault is discovered in a magnet system. Ops files ARTEMIS and notifies PCD.
The fault keeps the system off. It must be repaired immediately
PCD locks out the system. They troubleshoot the system and determine that the ground fault is in the magnet. PCD asks Ops to notify MFD. The ARTEMIS is annotated and responsibility re-assigned.
PCD replaces personal LOTO with group LOTO. The PCD MM is now responsible for the system.
MFD is called. MFD responds and confers with PCD. PCD demonstrates that the power supply cannot be turned on.
MFD apply personal locks over the PCD group locks. MFD apply other LOTO, verify magnet ground fault existence and perform work necessary
to remove the ground fault.
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The PCD/MFD Process - Example 2 Continued
The ground fault is found and repaired. The magnet is re-assembled and hi- potted.
MFD personnel remove their locks. PCD is re-called.
PCD replaces Group with personal locks. PCD hi-pots the system, remove their locks, turn the system on and release it to Ops.
PCD technicians file a “review to close” the ARTEMIS and file e-log entries
PCD MM conducts safety de-briefing and closes the job
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Last Slide
The SLAC maintenance groups are ready and eager to safely and professionally support the LCLS project