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Maintenance and Efficiency

Maintenance and Efficiency. Paul W. Sampson Maintenance and Accelerator Support Group Leader: CAD/RHIC Brookhaven National Laboratory. Short Background. CAD at BNL in Upton New York, USA RHIC Large superconducting collider 500GeV cm for polarized proton running

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Maintenance and Efficiency

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  1. Maintenance and Efficiency Paul W. Sampson Maintenance and Accelerator Support Group Leader: CAD/RHIC Brookhaven National Laboratory

  2. Short Background • CAD at BNL in Upton New York, USA • RHIC Large superconducting collider • 500GeV cm for polarized proton running • Species to Au (U this year?) • Dissimilar species • Many “parasitic” users on injectors: • LINAC • Tandem Van de Graff • EBIS • Booster • AGS Paul W. Sampson

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  5. Maintenance Support Group Role • Plan and coordinate work throughout the accelerator complex. • Emphasis on operations and uptime. • Integrate Professional Trades, Technical, Engineering and Physics staff activities during shutdown, failure (unscheduled maintenance) and scheduled maintenance periods. Paul W. Sampson

  6. Goals: Maximize uptime and optimize accelerator output • Integrated Luminosity is king? • STAR, PHENIX, Overall integrated luminosity. • What cost for improvement? • Parameters vary for varying species in RHIC • Use and maintenance of different systems. • Differing beam parameters. • Safety/Radiation issues- affects on access and equipment availability. • New systems commissioning. • Internal goals: • Beam parameters. • Available time at store, setup minimization • Calendar time at store. Paul W. Sampson

  7. Reliability formula complicated • End of life. • Installation and commissioning. • Infant mortality • “Roll up period” • Legacy systems. Paul W. Sampson

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  9. Shutdown • Annual occurrence. • Duration factors: • Budget. • Major work schedule. • Experiment upgrades/readiness. • Climate. • Documented utilizing data base tool. • Progress tracked and Project published. • Goals • Complete shutdown work. • Prepare for structured pre-startup checkout. • Minimize start up (time to Physics). Paul W. Sampson

  10. Unscheduled Maintenance • Major failure or other prolonged downtime. • Goal of maximizing use of time and access while minimizing the recovery. • Coordinated by Maintenance Support Group. • Schedule are created as necessary, depending on length of downtime. • Each day run similar to a scheduled maintenance day. Paul W. Sampson

  11. During the run: “Minor” Failure (>4hours) • Small low impact jobs to be performed. • “Fast” experimenter access • Coordinated by on duty Operations Coordinator, with assistance and advice from Maintenance Support Group as needed. • Documented by standard methods. Paul W. Sampson

  12. During the run:Scheduled maintenance days. • Usually 8-12 hours, biweekly. • Driven by experimental access. • Accelerator access for: • Preventative Maintenance. • Repair • Modification • Installation • Commissioning. • Shutdown planning • Inspection/work observation • Continuation of shutdown/installation work. Paul W. Sampson

  13. How maintenance days directly impact availability… • Scheduled maintenance days demand that the program is off. • Many required tasks require prolonged access. • Some systems have long lead time before work can be performed. • Source cool down. • Cryogenic warm up. • Radiation cool down periods. • Setup and recovery after maintenance period. • Human error: • Systems left in inoperable state following maintenance period. • Failure of improperly maintained equipment or systems. Paul W. Sampson

  14. Reliability and Maintenance days: • Preventative maintenance periods should be focused on reducing failures. • Repairs to systems and infrastructure. • Accelerator tunnel/Radiation area access: • PM and repair • Installation, testing and commissioning of new and modified systems. • Low intensity test cycles following maintenance period: • Used for machine development. • Tests and implementation modified and modes before they are adapted as operational. • Scheduled as part of the maintenance period. Paul W. Sampson

  15. Reliability and maintenance days • Maintenance day goals: • Complete tasks necessary to maintain current mode of running at the accelerator complex. • Prepare for any new running conditions expected. • Minimize the total duration and the time from end of maintenance to a return to smooth running. • Some tasks performed can cause unstable running and increased failure in the days that follow maintenance periods. • Vacuum bleed-up. • Ion source maintenance. • Cryogenic. • RF systems. • Super Conducting power supply systems. Paul W. Sampson

  16. Reliability after maintenance: • New running modes can cause increased failure for various reasons: • More aggressive magnetic cycles. • Increased high voltage. • Additional interlocks. • Re-integration of repaired systems: • Feedback elements. • Interlocking devices- loss monitors, chipmunks/radiation monitors, beam permit or inhibit systems. • Failure of new or un-commissioned systems: • Apertures in the beam pipe. • Improperly grounded devices. • Miss-configured interlocks or inhibits • Miss-configured devices (current loops). Paul W. Sampson

  17. Maintenance methods for increased reliability • Scheduled Maintenance Days • Job Requests • Benefit and impact analysis • Prioritization • Individual work planning • Overall work planning and scheduling • System recovery • Accelerator recovery • Return to physics Paul W. Sampson

  18. Before maintenance days • Determine which tasks are actually necessary. • Avoid low return, high risk jobs. • Carefully document accelerator status before turn off. • Define parameters for recovery. • Schedule accesses for efficiency- 4 hours to secure accelerators. • Communicate with all groups • Scheduling meeting, web, CCTV, face to face … Paul W. Sampson

  19. Job Request: Create Paul W. Sampson

  20. Pic of list Paul W. Sampson

  21. Work planning: • Individual jobs are planned by cognizant techs or engineers. • Job request is submitted to the MSG for review. • Primary approval given and schedule created. • Final review with upper management, experimenters and run coordinators. • Staff briefing. • Schedule posts. Paul W. Sampson

  22. Schedule: Paul W. Sampson

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  24. Execution • Complex formally handed over to Maintenance Support Group • MCR staffing: • Maintenance Coordinator (MC) to run activities, normally from MCR. • Utilize Operations Coordinator, Operators and support staff. • Leads keep MC informed of progress, emergent issues and job completion. • MSG leader appraised of major change, facilitates review, approval and schedules changes as necessary. • Maintenance coordinator executes changes. Paul W. Sampson

  25. Communication: • During the maintenance, it is communication is essential. • CCTV • Web, elogs, Job request system. • Radio, pagers and telephone… Paul W. Sampson

  26. End of maintenance: • Job closeout statements reviewed by MC before final closure. • Tiered access allows for recovery of systems to begin as soon as they are ready. • Injectors • RF • Power supply • Vacuum • Instrumentation • Specialist confirms with MSG that systems have been returned to operational condition. • Specialist remains on alert until program is recovered Paul W. Sampson

  27. Return to Physics • Accelerators are returned to operating condition as available. • Schedule work accordingly. • After injectors have recovered, RHIC test ramp performed. • Structured hand off to MCR for routine operation. • Maintenance Coordinator’s Journal closeout. • Operations Coordinator’s journal entry. • Maintenance day summary/closeout. Paul W. Sampson

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  31. Results • Since structured systems introduction in 2005: • The methods described have produced a marked improvement in performance on and after maintenance periods. • Return to productive running has steadily improved. • In many instances, machine performance is actually better immediately following maintenance periods. • Could maintenance have actually helped??!! Paul W. Sampson

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  33. Maintenance Effectiveness Trend Paul W. Sampson

  34. Other comments: • Maintenance and repairs done behind physics stores. • Software releases. • Systems maintenance: BPMs. • Systems commissioning, improvement. • Studies following Maintenance days. • Dual mode days- Maintenance on one machine and science on another. Paul W. Sampson

  35. Acknowledgements: • Availability, “Top Ten” and integrated luminosity plots adapted from presentation “Operating Statistics” by P. F. Ingrassia, Brookhaven National Laboratory. • “RHIC from space” courtesy of BNL Photo archives. Paul W. Sampson

  36. Thank you Paul W. Sampson

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