Maintenance and Engineering Procedures and Tools at Soreq Applied Research Accelerator Facility

Maintenance and Maintenance and Engineering Procedures Engineering Procedures

and Tools at Soreq and Tools at Soreq Applied Research Applied Research

Accelerator FacilityAccelerator Facility

I. Gertz, Y. Buzaglo, A. Grin, R. Michael, R. Raizman, L. Weissman, A. Nagler

Soreq NRC, Yavne, Israel

WAO 2007September 26th, 2007

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SARAFSARAF

Accelerator Building and Infrastructure Cryogenics RF

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SARAF Building and SARAF Building and InfrastructureInfrastructure

Building CHW HVAC

Comp. Air Communication Safety

Electrical Supply and Distribution Control Systems

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Senior Engineering Team (SET)Senior Engineering Team (SET)SET Members: o Electrical Engineer (Control Systems, Infrastructure, RF)o Mechanical Engineer (Cryogenics, Vacuum)

o Physicist (Accelerator, Diagnostics, Beam lines)

o Industrial Engineer (Maintenance Management, Documentation)

o Safety Specialist (“online” safety, procedures for present and future)

o Two accompanying part time technicians

Responsibilities:o Operation

o Systems Commissioning and Acceptance

o Maintenance

o Engineering and Technical Office

o Training

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OperationOperation

Most infrastructure systems were accepted and serve accelerator installation and commissioning purposes

SET members ware trained up to supervisor level to operate the infrastructure systems

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Accelerator Systems Commissioning Accelerator Systems Commissioning and Acceptance (1)and Acceptance (1) SET members are participating and assisting in

accelerator installation, commissioning and acceptance tests

Effort is lead by the accelerator contractor personnel and is under their responsibility

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Accelerator Systems Commissioning Accelerator Systems Commissioning and Acceptance (2)and Acceptance (2)

Emphasis is on thorough learning and understanding of all systems and components

SET members spend about 40% of their time on these tasks

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Engineering and Technical OfficeEngineering and Technical Office

Engineering tasks and Technical Office responsibilities are entwined

Engineering R&D of accelerator supplementary systems (Control, Diagnostics,

infrastructure) Writing maintenance and operating procedures

Technical Office Documentation of engineering tasks Updating of documentation and drawings Archiving of engineering data Maintenance schedule Coordination among SARAF and external contractors and suppliers Purchasing of spare parts and stock management

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MaintenanceMaintenance

Maintenance procedures concern operational and mechanical systems conditions

Currently, maintenance is mainly performed on The building Infrastructure systems Cryogenics Part of the accelerator vacuum and RF

The maintenance works are divided into: Breakdown Maintenance (BM) Preventive Maintenance (PM) Predictive Maintenance (PdM)

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Breakdown Maintenance (BM)Breakdown Maintenance (BM) Most of the systems are still in their warranty periods, so

they are usually repaired by the system contractor In urgent cases, breakdown maintenance is performed by

SET members The procedure for BM is

1. BM is requested in the commissioning logbook (if encountered during shifts) or in a PM form (if encountered during PM)

2. The BM Request is accepted and checked by the relevant SET member

3. A BM form is issued

4. BM is performed according to the procedures

3. A BM technical report is prepared

4. The BM technical report is checked and approved by the SET head

5. The data base of the Computerized Maintenance Management System (CMMS) is updated

6. The approved report is logged and stored in the BM archive

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Preventive Maintenance (PM)Preventive Maintenance (PM)

For accepted systems PM procedures have been written and scheduled by the technical office

The procedures are based on the system contractor requests and maintenance timetables (with small deviations)

PM is performed either by SET members, the system contractor or other external contractors

The procedure for PM is 1. A PM procedure form is issued by the technical office

2. PM is performed and reported on the form

3. The PM report is checked and approved by the SET head

4. The data base of the CMMS is updated

5. The approved report is logged and stored in the PM archive

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Predictive Maintenance (PdM)Predictive Maintenance (PdM) Predictive Maintenance (PdM) is an integral part of preventive maintenance Measurements of systems parameters are performed routinely to observe

patterns and predict equipment breakdowns or malfunctions Typical measurements and operations include

Thermal imaging of electrical cabinets Electric current measurements of motors and other equipment Pressure and flow measurements of process cooling water systems Gas and water analysis in relevant systems

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Computerized Maintenance Computerized Maintenance Management System (CMMS)Management System (CMMS)

For the abovementioned tasks we developed a Computerized Maintenance Management System (CMMS), which enables SET members to schedule and structure maintenance tasks

The SARAF CMMS is a Microsoft Access based maintenance database management system which includes

1. Assets Management

2. Preventive Maintenance Scheduling and Management

3. Report Generation

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CMMS – Asset ManagementCMMS – Asset ManagementComponent Data ScreenComponent Data Screen

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CMMS – Asset ManagementCMMS – Asset ManagementService Providers ScreenService Providers Screen

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CMMS - PM Scheduling and ManagementCMMS - PM Scheduling and Management

Weekly

Monthly

Quarterly

Semi-annual

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CMMS – Reports GenerationCMMS – Reports GenerationThe 2007 Annual BM reportThe 2007 Annual BM report

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Workload during commissioningWorkload during commissioning

20%

40%

20%

20%Operating

Systems Commissioning andAcceptance

Maintenance

Engineering

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ConclusionsConclusions Development and assimilation of maintenance and

engineering systems during accelerator installation and commissioning presents a big challenge for SARAF Senior Engineering Team.

Currently, the biggest effort is the accelerator installation and commissioning, so maintenance and engineering receive a smaller share of the workload

It is unequivocal that after the accelerator systems will be accepted, the maintenance load will grow accordingly. Therefore major SET tasks are: Verified written procedures

A CMMS including all of the accepted systems Appropriate training of SET members Development of a maintenance culture

Thank YouThank You

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Breakdown Maintenance ReportBreakdown Maintenance Report

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Printed request for PM procedurePrinted request for PM procedure