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. Accelerator Building and Infrastructure Cryogenics RF SARAF

3. Communication Control Systems Building CHW HVAC Comp. Air Safety Electrical Supply and Distribution 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 • 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. 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