Injector, Sector 21, Bunch Compressor 1

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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 Ready

• All 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 Section
• Beam 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 gt 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 Department

• Department 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 states
• New 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
Substation K10B 13.8kV480V to S20 MCC to 6 Power
Supply Racks Portion of S20 MCC shown
Excerpt from ID-950-075-03
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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