1 Enzo Carrone 1 NEH Safety Systems NEH ARR 2009 NEH Safety Systems Enzo Carrone June 30 th, 2009

2 Enzo Carrone 2 NEH Safety Systems NEH ARR 2009 PPS and BCS Status Both systems are currently ready for safe operation to the FEE PPS successfully certified (IAT) on June 24-26; BCS components certified on June 26. Hutch systems HPS will be ready by the end of July.

3 Enzo Carrone 3 NEH Safety Systems NEH ARR 2009 Safety Systems Section PPS and BCS Systems combined into a single Section. Full-time QC Group Leader (M. Saleski). Manages Review Process. Oversees Engineering Change Order Process. Full-time Documentation Manager (S. Starner). Documentation system compliant to DOE Order 414.1C and ISO

4 Enzo Carrone 4 NEH Safety Systems NEH ARR 2009

5 Enzo Carrone 5 NEH Safety Systems NEH ARR 2009 Safety Systems Section Documentation Structure

6 Enzo Carrone 6 NEH Safety Systems NEH ARR 2009

7 Enzo Carrone 7 NEH Safety Systems NEH ARR 2009

8 Enzo Carrone 8 NEH Safety Systems NEH ARR 2009 Safety Systems QA Subject to a new Engineering Change Order (ECO) process Better tracking of requirements, specifications, reviews (peer and formal), and system documentation. New project QA approach Bench and pre-IAT field test of system software Acceptance tests performed for complex SLAC-built assemblies (such at stoppers) Cold and energized checkout of installed hardware Und Complex lessons learned with subcontractors Formal IAT reviews with stakeholders Overall, better management of schedule Indirectly affects quality

9 Enzo Carrone 9 NEH Safety Systems NEH ARR 2009 Documentation Control A single on line repository is available for all released documents. Formal Documentation Control is in place. Measures taken to regulate the Preparation, Change, Withdrawal, Review, Approval, Release, Distribution, Access, Availability, Storage, Disposal of documents. Document management Plan, Document Change Control Procedure, design Review Plan, Drawing Management Procedure, Engineering Change Order Procedure.

10 Enzo Carrone 10 NEH Safety Systems NEH ARR 2009 Configuration Control Elements Prevention of Unintended Change Physical Security of System Labeling Training Control of Intended Change Work Planning (adequate review of design) Work Authorization (RSWCF) Verification of Work (RSWCF) Periodic Confirmation of System Integrity Routine testing and inspections

11 Enzo Carrone 11 NEH Safety Systems NEH ARR 2009 Configuration Management Documentation Document Management Plan Document Change Control Procedure Document Change Order Design Review Plan Software Configuration Management Engineering Change Order Procedure Engineering Change Order Drawing Management Procedure

12 Enzo Carrone 12 NEH Safety Systems NEH ARR 2009 Software Configuration Management Support Software versions are checked during annual certification. Written procedures exist for extracting PPS code from CVS and for uploading it to PLCs. A documented training program tracks personnel PLC qualifications in the Section.

13 Enzo Carrone 13 NEH Safety Systems NEH ARR 2009 Software Configuration Management Procedure PPS Software is stored in a dedicated PPS repository. Released software always has “N.0.0” version tag. Documented software bench testing is performed prior to deployment.

14 Enzo Carrone 14 NEH Safety Systems NEH ARR 2009 Software Configuration Control Issues Program Security: All communication to the safety-critical PLCs is through TCP/IP to ‘buffer’ Allen-Bradley PLC, then via DeviceNet (serial data communication). Safety-critical program ‘smart card’ cannot be written to while in the PLC Communication from the safety-critical PLCs is through DeviceNet to ‘buffer’ Allen-Bradley PLC and output to control system via TCP/IP Network Access Security: Hardwire Enable from MCC required Only specific IP addresses are allowed to issue PPS commands Physical Access Security: PLCs and DeviceNet are inside locked racks.

15 Enzo Carrone 15 NEH Safety Systems NEH ARR 2009 Software Version Management Version Management: Software versions are checked during annual certification Written procedures Exist for extracting PPS code from CVS and uploading it to PLCs A documented training program tracks personnel PLC qualifications in the Section

16 Enzo Carrone 16 NEH Safety Systems NEH ARR 2009 Implementation, Operations, and Maintenance

17 Enzo Carrone 17 NEH Safety Systems NEH ARR 2009 Proposed PLC PPS ‘Dev and Rev’

18 Enzo Carrone 18 NEH Safety Systems NEH ARR 2009 Established SSS ECO Emphasis on review and development documentation; Enables a project management approach; Collects development and review docs for auditability.

19 Enzo Carrone 19 NEH Safety Systems NEH ARR FEE/NEH PPS Checkouts Cold Checkout Verifies Hardware and Cable Plant is installed and wired correctly Verifies No Ground Shorts in the Cable Plant EEIP Hardware and Racks Hot Checkout Verifies Functionality of Hardware, Devices, and PLCs Hi-Pot Cable Plant

20 Enzo Carrone 20 NEH Safety Systems NEH ARR Review Status Final Design Review #2 (April 22, 2009) Initial Acceptance Test Review (internal and external) Starting this week.

21 Enzo Carrone 21 NEH Safety Systems NEH ARR 2009 PPS Review Status for FEE & NEH Major Review to Date LCLS SCR: May 31 st 2007 [Bong, Stefan, Horton, Hastings] LCLS PDR: Feb 29 th 2008 [Lessard, Tompkins, Schmerge, Anthony] LCLS FDR: Oct 22 nd 2008 [Anthony, Mueller(LBNL), Lessard] RSC: Oct 31 st 2008 LCLS FDR2: Apr 22 nd 2009 [ Perry Anthony, Zoe Van Hoover, Luc Lessard, Paul Miller, Robert Mueller, Mike Woods]

22 Enzo Carrone 22 NEH Safety Systems NEH ARR PPS FEE Schedule

23 Enzo Carrone 23 NEH Safety Systems NEH ARR 2009 FEE/NEH Schedule

24 Enzo Carrone 24 NEH Safety Systems NEH ARR 2009 Conclusions PPS/BCS has a Quality Assurance model in place; LCLS management is aware of the Safety Systems process and supports it throughout the project lifecycle (from conception to certification); LCLS, Operations, Radiation Physics are heavily involved in all review phases from early on (from requirements/specifications to user manual).