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NEH Safety Systems

NEH Safety Systems. Enzo Carrone June 30 th , 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.

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NEH Safety Systems

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

  2. 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. 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 9001-2000.

  4. Safety Systems Section Documentation Structure

  5. 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

  6. 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.

  7. 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

  8. 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

  9. 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.

  10. 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.

  11. 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.

  12. 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

  13. Implementation, Operations, and Maintenance

  14. Proposed PLC PPS ‘Dev and Rev’

  15. Established SSS ECO • Emphasis on review and development documentation; • Enables a project management approach; • Collects development and review docs for auditability.

  16. 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

  17. Review Status • Final Design Review #2 (April 22, 2009) • Initial Acceptance Test Review (internal and external) • Starting this week.

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

  19. PPS FEE Schedule

  20. FEE/NEH Schedule

  21. 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).

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