1. Operator Training Requirements
Chris Scanlon and Ritendra Bhattacharya
LCLS-II Software Review
November 14, 2018

2. Charge
1. GENERAL b. Is the schedule compatible with the overall plan including installation and commissioning? c. Is the control team organized and staffed to successfully complete the project? 3. DEFINITION AND DOCUMENTATION a. Are all automated functions (alarms, trips, interlocks / permissive, cause and effects, control loops, and automated sequences) sufficiently documented for coding, testing, commissioning, operation and troubleshooting? 5. BENCH TESTING a. Has JLab developed an appropriate plan for testing the cryoplant control systems? b. Is the EPICS HMI testing integrated with the PLC tests? 6. COMMISSIONING a. Has JLab developed a plan to perform commissioning? b. Have the required resources been identified? c. Does Jlab’s plan for commissioning and testing of the coldboxes appropriately address commissioning and checkout of the PLC controls prior to testing the coldboxes?
LCLS-II Software Review, November 14, 2018

3. Outline Semi-Automated Cryoplant Operator Intervention SLAC Support
Operator Requirements
Precommissioning
Commissioning Activities
Commissioning Schedule
LCLS-II Software Review, November 14, 2018

4. Semi-Automated Cryoplant
The LCLS-II cryoplants are not commercial air separation plants where you can push the start button and walk away. Operating a small cryogenic plant requires a deep knowledge of how the system works. This becomes more complicated when operating a 4kW 2K plant.
Steady state running is automated, thanks to many PID loops.
But even automated processes require operator supervision.
Due to many manual valves throughout the cryogenics plant, many transition operations are manual.
The manual operation philosophy provides flexibility during initial operation to cater the plant to actual conditions.
LCLS-II Software Review, November 14, 2018

5. Operator Intervention
Alarms and trips will require operator intervention, either remotely or on site. Whether they can be dealt with remotely or on site depends on many factors, including SLAC operational guidelines such as starting rotating equipment remotely.
water pump
warm compressor
recovery compressor
LCLS-II Software Review, November 14, 2018

6. SLAC Support
JLab has 1.5 FTEs to support SLAC through the 2 years of commissioning. This means that most operations will be performed by SLAC operators. JLab operators can teach SLAC operators to run a cryogenics plant, but this must be translated through SLAC site policies. In JLab’s experience, it takes a full time engineer 18 months to be competent in operating a cryoplant. SLAC operators will need to have a significant amount of time operating and maintaining a cryoplant before commissioning starts. There are 4 months before commissioning is scheduled to start.
LCLS-II Software Review, November 14, 2018

7. Operator Requirements
Operators must be able to
Read a P&ID and understand how that system works
Identify a need to troubleshoot mechanical and electrical systems
Troubleshoot process issues such as:
Excessive load on the plant
Poor insulating vacuum
Linac heat management
Technicians must know how to troubleshoot electrical and mechanical systems
Troubleshoot instrumentation
Calibrate PTs
Calibrate valves
LCLS-II Software Review, November 14, 2018

8. Every subsystem will need
Precommissioning
The PLC software and EPICS will be thoroughly tested prior to arrival at SLAC.
Precommissioning activities will need to start in February in order to start commissioning the recovery compressors in April 2019.
Every subsystem will need
To be vacuum pumped and backfilled multiple times to remove all of the moisture and gas that’s not Helium
Electrical power checkout
PLC running
Controls wiring and instrument checkout, calibration
LCLS-II Software Review, November 14, 2018

9. Commissioning activities
Before commissioning
Pump and back fill warm Helium tanks, Helium gas distribution system piping, recovery system piping.
Fill liquid nitrogen dewars
Fill warm Helium tanks
If SLAC employees can perform the precommissioning activities, JLab will have more resources available for commissioning.
LCLS-II Software Review, November 14, 2018

10. Commissioning Activities
Recovery compressors
Helium purifier
Warm Helium compressors
Secondary cooling water system
4K cold box
2K cold box
Oil processor
Instrument air system
Guard vacuum
LCLS-II Software Review, November 14, 2018

11. Commissioning Schedule
The P6 commissioning schedule was developed assuming that each subsystem and its supporting subsystems were installed prior to their commissioning. JLab received the installation schedule last week and has not had time to coordinate it with commissioning activities. JLab cryogenics staff will be on site during commissioning in addition to the possibility of remote support from other JLab cryogenics staff.
LCLS-II Software Review, November 14, 2018

12. Charge
1. GENERAL b. Is the schedule compatible with the overall plan including installation and commissioning? Maybe. c. Is the control team organized and staffed to successfully complete the project? Yes, but will need SLAC support. 3. DEFINITION AND DOCUMENTATION a. Are all automated functions (alarms, trips, interlocks / permissive, cause and effects, control loops, and automated sequences) sufficiently documented for coding, testing, commissioning, operation and troubleshooting? Yes. 5. BENCH TESTING a. Has JLab developed an appropriate plan for testing the cryoplant control systems? Yes. b. Is the EPICS HMI testing integrated with the PLC tests? Yes. 6. COMMISSIONING a. Has JLab developed a plan to perform commissioning? Yes. b. Have the required resources been identified? Yes, but will need SLAC support. c. Does Jlab’s plan for commissioning and testing of the coldboxes appropriately address commissioning and checkout of the PLC controls prior to testing the coldboxes? Yes, the cold box software will be thoroughly tested.
LCLS-II Software Review, November 14, 2018

13. THANK YOU FOR KIND ATTENTION
LCLS-II Software Review, November 14, 2018