LSST Workshop • Bremerton, WA • August, 2015 1LSST Workshop • Bremerton, WA • August, 2015

I&T and Operating and Support Hazards

Martin NordbyChief Mechanical Engineer

LSST Camera Safety ReviewAugust 18, 2015

R1

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Topics

• Plans for capturing I&T and operating and support hazards– LCA-15 Hazard List O&SHA List– I&T process flow development– Operations Concept Document– Maintenance planning

• Plans for addressing I&T and O&SH hazards through management processes– Work planning– Work control– SLAC ES&H

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LCA-15 Hazard List O&SHA List

• As we have discussed, LCA-15 includes operating and support hazards• Ultimately, these hazards will end up in a new Operating and Support Hazard Analysis

List• Our current Hazard List will be replaced by implemented designs and verification test

results, demonstrating that hazards have been addressed• The O&SHA will form the basis for capturing hazards involving personnel:

– Hazards associated with “generic” work associated with camera I&T: handling, hoisting and rigging, ESD and contamination control, … (this is what we currently have captured in the O&SHA hazards)

– Hazards associated with integration and test of partial assemblies or those in an incomplete state

– Hazards associated with troubleshooting and partial disassembly during maintenance and re-work

• These hazards are then addressed in the appropriate work planning and control (WP&C) documents

• We’ll walk through the process we are involved in now to identify these O&SHA hazards and then developing the necessary process controls

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I&T process flow development

• I&T work processes are being developed using a detailed flow chart– Basic work sequencing to integrate and test the camera (completed for CD-1 Review)– Fixtures and test equipment needed for each step (completed for CD-2 Review)– Detailed activity steps capture all aspects of the final design and define

requirements for fixtures and test equipment (completed for CD-3 Review; in work)– Work process steps

and hazards associated with each activity

– Final traveler for each work process step, including hazards associated with the step and mitigations and controls to address the hazard

Detail of I&T flow, showing verification tests in red

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Operations Concept Document

• LCA-282, “Camera Operations Concept Document” captures plans for camera operations and maintenance

• We are using this to motivate decisions on operations plans for the camera, including:– Operational break-down of camera components– Camera internal state models– Camera modes and transitions between modes– Use cases for the camera in each mode

• For use cases with the camera in Maintenance Mode, one aspect of the use case and activity definition is an understanding of the hazards associated with carrying it out

• As the activities are further defined, we will develop procedures to implement them

Camera Maintenance Mode Use CasesAccess/Secure Camera Body Access Back FlangeMaintain Mechanisms Access/Secure Utility TrunkRemove/Replace Mechanisms Leak Check CryostatInspect Components in Camera Body Service, Leak Check Vacuum SystemsAccess Front of Camera Replace System Electronics Swap Out Filter Component in Utility Trunk

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Maintenance planning has been baked into the design

• Modularity allows for:– Straightforward removal/replacement of components and assemblies– Bench-top re-verification of assemblies prior to re-integration– Minimizing impact on neighboring components and collateral damage

• Provisions for maintenance in the design– Back flange bays: removable covers allow access for servicing and removing carousel

components– Housing portholes: provides access for replacement of carousel filter clamps– Front flange notch: allows for quick removal of

auto changer– Shroud: removable panels provide access to

L1-L2 strut feet, shutter, auto changer, and L3• Spare units

– Assemblies: Auto Changer, Shutter, RTMs– Components: power supply boards, vacuum

components, cabling

Modular ComponentsL1-L2 Assembly and L1 and L2 lensAuto ChangerCarousel clamps and actuatorsShutterFiltersRaft Tower ModulesPower Supply BoardsRefrigeration system heat exchangers

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Provisions for camera maintenance

Shroud panels detach

Portholes provide access to carousel clamps

Back flange bay covers removed

All back flange mounting bolts are accessible for torque checking

Camera access points for maintenance

SMRs are accessible for ground- or telescope-based survey and alignment, as needed

Removable panels in Utility Trunk provide access to power supply crates and vacuum components

Notch in camera body allows for Auto Changer removal in situ

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Management processes for handling personnel and system hazards during I&T and maintenance• Plans for addressing hazards through management processes

– The previous charts show how we have been/are/will be identifying O&SHA hazards– Once identified, we have 3 broad sets of management processes to address

mitigations and ensure that they are implemented

• Work planning

• Work control

• SLAC ES&H procedures

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Work planning

• LCA-138 outlines our WP&C process; this boils down to two areas:

• Use of travelers– Work activities are written down ahead of time, then reviewed and approved– eTraveler system has been implemented to capture this entire process, including

revision control on travelers– Part of this process involves identifying O&S hazards, as well as risks to the

hardware, environment, and health (industrial hygiene)

• MRRs and TRRs– Manufacturing Readiness Reviews for subsystems and Test Readiness Reviews for

the I&T effort will be used to provide a formal means to assess the totality of procedures, drawings, and other documentation that is in place

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Work control

• During the I&T effort, work is controlled through a standard process implemented by the SLAC ES&H division and called out in LCA-138, PSAP

• This breaks down as follows:

• Training– All personnel involved in camera I&T work will be registered users at SLAC– Work scope and associated personnel hazards will be addressed, and the need for

ES&H training assessed—training logs are managed by our ES&H Division– Camera-specific training will address hazards related to equipment safety

• Authorization– Work is authorized to be accomplished when approved travelers and trained

personnel are identified to accomplish the work– This recognizes the we are ready and capable to do the work

• Release of work– Work is released to be done on a daily basis by the camera I&T floor manager– Per SLAC ES&H processes, this is the only mechanism to start work– This allows the work to be done

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SLAC ES&H procedures

• Beyond the authorization and release process described, SLAC has pre-defined processes and requirements in place to authorize a number of other classes of work

• Examples:– Work on high voltage (>50 V) electrical systems– Hoisting and rigging– Pressurized systems– Work in elevated or confined space– Seismic safety standards for equipment– Oxygen deficiency– …