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

1
Maintenance and Engineering Procedures and Tools
at Soreq Applied Research Accelerator Facility
I. Gertz, Y. Buzaglo, A. Grin, R. Michael, R.
Raizman, L. Weissman, A. Nagler Soreq NRC, Yavne,
Israel WAO 2007 September 26th, 2007
2
SARAF
3
SARAF Building and Infrastructure
4
Senior Engineering Team (SET)

• SET Members
• Electrical Engineer (Control Systems,
  Infrastructure, RF)
• Mechanical Engineer (Cryogenics, Vacuum)
• Physicist (Accelerator, Diagnostics, Beam lines)
• Industrial Engineer (Maintenance Management,
  Documentation)
• Safety Specialist (online safety, procedures
  for present and future)
• Two accompanying part time technicians
• Responsibilities
• Operation
• Systems Commissioning and Acceptance
• Maintenance
• Engineering and Technical Office
• Training

5
Operation

• 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

6
Accelerator Systems Commissioning 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

7
Accelerator Systems Commissioning 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

8
Engineering and Technical Office

• Engineering tasks and Technical Office
  responsibilities are entwined
• Engineering
• RD 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

9
Maintenance

• 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)

10
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
• BM is requested in the commissioning logbook (if
  encountered during shifts) or in a PM form (if
  encountered during PM)
• The BM Request is accepted and checked by the
  relevant SET member
• A BM form is issued
• BM is performed according to the procedures
• A BM technical report is prepared
• The BM technical report is checked and approved
  by the SET head
• The data base of the Computerized Maintenance
  Management System (CMMS) is updated
• The approved report is logged and stored in the
  BM archive

11
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
• A PM procedure form is issued by the technical
  office
• PM is performed and reported on the form
• The PM report is checked and approved by the SET
  head
• The data base of the CMMS is updated
• The approved report is logged and stored in the
  PM archive

12
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

13
Computerized Maintenance 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
• Assets Management
• Preventive Maintenance Scheduling and Management
• Report Generation

14
CMMS Asset Management
Component Data Screen
15
CMMS Asset Management
Service Providers Screen
16
CMMS - PM Scheduling and Management
Weekly Monthly Quarterly Semi-annual
17
CMMS Reports Generation
The 2007 Annual BM report
18
Workload during commissioning
19
Conclusions

• 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

20
Thank You
21
Breakdown Maintenance Report
22
Printed request for PM procedure