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 26 th, 2007

2 26/9/2007 SARAF Accelerator Building and InfrastructureCryogenicsRF

3 26/9/2007 SARAF Building and Infrastructure BuildingCHWHVACComp. AirCommunicationSafetyElectrical Supply and DistributionControl Systems

4 26/9/2007 Senior Engineering Team (SET) SET Members: oElectrical Engineer (Control Systems, Infrastructure, RF) oMechanical Engineer (Cryogenics, Vacuum) oPhysicist (Accelerator, Diagnostics, Beam lines) oIndustrial Engineer (Maintenance Management, Documentation) oSafety Specialist (“online” safety, procedures for present and future) oTwo accompanying part time technicians Responsibilities: oOperation oSystems Commissioning and Acceptance oMaintenance oEngineering and Technical Office oTraining

5 26/9/2007 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 26/9/2007 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 26/9/2007 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 26/9/2007 Engineering 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

9 26/9/2007 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 26/9/2007 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

11 26/9/2007 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

12 26/9/2007 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 26/9/2007 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 1. Assets Management 2. Preventive Maintenance Scheduling and Management 3. Report Generation

14 26/9/2007 CMMS – Asset Management Component Data Screen

15 26/9/2007 CMMS – Asset Management Service Providers Screen

16 26/9/2007 CMMS - PM Scheduling and Management Weekly Monthly Quarterly Semi-annual

17 26/9/2007 CMMS – Reports Generation The 2007 Annual BM report

18 26/9/2007 Workload during commissioning

19 26/9/2007 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

Thank You

21 26/9/2007 Breakdown Maintenance Report

22 26/9/2007 Printed request for PM procedure