NEH Safety Systems

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NEH Safety Systems

• Enzo Carrone
• June 30th , 2009

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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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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.

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Safety Systems Section Documentation Structure
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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

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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.

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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

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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

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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.

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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.

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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.

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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

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Implementation, Operations, and Maintenance
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Proposed PLC PPS Dev and Rev
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Established SSS ECO

• Emphasis on review and development documentation
• Enables a project management approach
• Collects development and review docs for
  auditability.

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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

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Review Status

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

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PPS Review Status for FEE NEH

• 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

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PPS FEE Schedule
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FEE/NEH Schedule
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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).