accelerator directorate, spear3 program division ...€¦ · october 15, 2009 accelerator procedure...

SLAC National Accelerator Laboratory Accelerator Directorate, SPEAR3 Program Division

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Document Expiration Date: “02/24/2011” (One year from last review date)

October 15, 2009 Accelerator Procedure PROC-SLAC-AD-SPEAR3-MSG-SAPE-082-R5 of 15

Work Authorization and Approvals

Approvals/Review Name Signature Date

Author: David A. Ernst

Technical Supervisor Approved by: Robert DiMattia

BLDG/Area Manager Approved by: Ed Guerra

MS Group Leader Approved by:

Benjamin Scot

System Manager Approved by:

David A. Ernst

Reviewed by: Add reviewer name



Document Revision Draft 5.0 Date of Issue: March 25, 1993

Process/Procedure Owner: David A. Ernst

PROC-SLAC-AD-SPEAR3-MSG-SAPE 082

October 15, 2009 Accelerator Procedure PROC-SLAC-AD-SPEAR3-MSG-SAPE-082-R5 Page 1 of 15

Table of Contents

Work Authorization and Approvals ................................................................. i

1. Introduction ................................................................................................ 2

1.1 Purpose ............................................................................................................................ 2

1.2 Scope ................................................................................................................................ 2

1.3 Roles ................................................................................................................................. 2

1.4 Definitions and Acronyms ................................................................................................. 2

1.4.1 . Precautions and Limitations ................................................................................................. 2

1.4.2 . Policies ................................................................................................................................. 3

1.4.3 . Equipment Description ......................................................................................................... 3

1.4.4 . Related Procedures .............................................................................................................. 3

1.4.5 . Guidelines ............................................................................................................................ 4

1.4.6 . Drawings/Documentation .................................................................................................... 4

1.4.7 . Pre-work Evaluation ............................................................................................................. 4

1.4.8 . Training ............................................................................................................................... 4

1.4.9 . Tools .................................................................................................................................... 5

1.4.10 Post Work Requirements ..................................................................................................... 5

1.5 Authorizations/Work Release ........................................................................................... 5

1.6 Potential Hazards and Mitigations .................................................................................... 5

2. Procedure (Step By Step) ......................................................................... 7

2.1 Pre-Shutdown Evaluation ................................................................................................. 7

2.2 SLAC Site Requirements ................................................................................................... 7

2.3 SPEAR3 LCW System Shutdown Step by Step Procedure ................................................ 7

2.4 Relieving Stored LCW Hydraulic Energy ........................................................................... 8

2.5 Verify System Pressures After the System Shutdown ...................................................... 8

2.6 Cleanup ............................................................................................................................ 9

2.7 Figures/pictures .............................................................................................................. 10

Appendix A – Dictionary of Terms ................................................................ 13

Appendix B – Acronyms ................................................................................. 13

Appendix C – Document Change Control .................................................... 14


1. Introduction

1.1 Purpose

This document is a step by step procedure to safely shutdown the SPEAR3 accelerator Low Conductive Water (LCW) system.

1.2 Scope

This procedure only applies to the shutdown of the SPEAR LCW system of the ring, buildings 100, 101, 118,122.

When performing the SPEAR LCW System shutdown procedure, strict work controls shall be followed to ensure the safety of the personnel performing this procedure.

1.3 Roles

The SPEAR3 core support team Mechanical Services personnel shall use this procedure to pressurize the SPEAR 3 accelerator Low Conductivity Water (LCW) system.

System Support

During the day shift this procedure is performed primarily by SPEAR3 core MSG personnel with the support from SLAC FAC Operations Maintenance Mechanic on duty. The FAC Maintenance Mechanic will monitor and adjust 1801 pump loads to maintain overall site system pressures to compensate for the SPEAR LCW system. During swing and graveyard shifts, SPEAR Operations will contact FAC Operations Maintenance Mechanic on duty and communicate the desire to shutdown the SPEAR LCW system during emergency situations. The on-call SSRL/MSG systems manager will be notified of the reasons for the unscheduled start-up.

1.4 Definitions and Acronyms

The definitions and acronyms used in this document that need to be defined in order to ensure proper interpretation of the procedure are listed in Appendix B. The SLAC Archives & History Office has a list that can be found at URL listed below:

http://www.slac.stanford.edu/history/slacspeak/slacspeak.A.shtml

1.4.1 Precautions and Limitations SLAC Site System Requirements

Contact the SLAC Facilities Operations Maintenance Mechanic on duty to monitor the 1801 pump pressures during the shutdown of the SPEAR3 LCW system. Radio communications on the SLAC


operations channel must be maintained with the Maintenance Mechanic during the entire LCW startup or shutdown procedure. CAUTION! Do Not Attempt To Open or Close the SPEAR3 LCW System without SLAC Facilities Operations Support. Site System Damage May Occur. The SLAC Facilities maintenance mechanic is required to make adjustments to the 1801 LCW system to balance the site systems due to the addition of the SPEAR LCW system load. The Maintenance mechanic must make adjustments in order to maintain proper site system pressures. Note: Radio communication must be maintained with SPEAR3 core inspection team during the entire LCW shutdown.

1.4.2 Policies 1. SLAC-I-720-0A29Z-001-R023.0 ES&H Manual, Chapter 14,

“Pressure, Vacuum, and Cryogenic Systems”. 2. SLAC-I-720-0A29Z-001-R023 ES&H Manual, Chapter 16, "Spills". 3. SLAC-I-720-0A29Z-001-R023 ES&H Manual Chapter 43,

“Industrial Wastewater”. 4. SLAC-I-720-0A29Z-001-R023 ES&H Manual, Chapter 22, "Waste

Minimization and Pollution Prevention". 5. SLAC-I-720-0A29Z-001-R000 ES&H Manual, Chapter 51,

“Control of Hazardous Energy” 6. SLAC-I-720-0A29Z-001-R023.5 ES&H Manual, Chapter 19,

“Personal Protective Equipment”

1.4.3 Equipment Description The SPEAR 3 LCW piping supplies Low Conductivity Water (LCW) to many systems of the SPEAR accelerator system. The LCW system cools the electron beam components such as Vacuum chambers, Beam mask, Beam stoppers RF, Electro magnets, and power supply systems and other SPEAR accelerator components not mentioned requiring water cooling for operation. The entire system uses approximately 1,815 gallons per minute (GPM) during normal operation.

The SPEAR LCW cooling system is supplied its LCW from the 1801 pump pad via a 10” feeder line which enters SPEAR piping from under End Station "A" (ESA). The Main supply pressure is nominally 255-256 psi. The supply valve is located at the southwest end of Building 118. The return valve is located in the southwest outside corner of building 131. The main return pressure is nominally 25-35 psi.

1.4.4 Related Procedures List the procedures referenced in the process/procedure.


ELP-SLAC-AD-SPEAR3-MSG-SAPE-220 SPEAR 3 LCW Equipment Lockout Procedure

PROC-SLAC-AD-SPEAR3-MSG-005 Water Holding Tank and Pumping System Procedure.

PROC-SLAC-AD-SPEAR3-MSG-SAPE-071 SPEAR3 LCW Startup Procedure

1.4.5 Guidelines List the guidelines referenced in the process/procedure.

If at any time during this procedure a situation occurs that you are unfamiliar with or that would cause deviation from the procedure, stop and re-evaluate the work plan with your supervisor.

Before performing this procedure, do a walk-through of the procedure where the work is to be performed. If the area or equipment has changed and differs from the procedure, do not proceed. Bring the procedure back to supervision for a review or inspection of the procedure.

Upon completion of this procedure, the technician and supervisor will meet and discuss the job with the intention of improving the work process planning and the procedure as appropriate. Suggestions for potential improvement to the mechanical system will be included in this discussion.

1.4.6 Drawings/Documentation GP 581-656-07-C2

1.4.7 Pre-work Evaluation Depending on which system is being worked on, every situation will be different as far as who to contact to receive authorization to perform the task. The things that will always remain the same are following proper LOTO protocol along with proper de-energization of the hazardous energy.

This procedure will commonly be performed during accelerator breakdowns and repairs and systems need to be shutdown.

Perform a Pre-work tailgate meeting with supervisor and workers prior to stating this procedure.

1.4.8 Training Before performing this procedure, the individual(s) must possess the special skills, knowledge, and training to complete this task safely. All


ES&H training must be current as required by the SLAC Training Assessment (STA) tool.

1.4.9 Tools List tools used to implement this process/procedure, if applicable.

Two way radios

Flashlights

1.4.10 Post Work Requirements Clean up job site waste

Remove all tools and extra LOTO devices

Remove signs, barricades and boundary tape

Notify SPEAR operations work is complete

Close out MSG SharePoint WPC Form

1.5 Authorizations/Work Release

This job requires multiple site communications and authorizations and a release to start this work safely and to control the hazardous energies related to this procedure. One must be authorized by their supervisor and trained according to the workers Activity & Training Authorization (ATA) to perform this procedure. In addition a work release must be obtained by the building manager and or area manager before work is to be started. Persons performing this work must review the Area Hazard Analysis (AHA) for SPEAR tunnel and special SPEAR tunnel training is required to proceed.

Before making any changes in the status of any SPEAR3 accelerator system, notify the following faculty and personnel for authorization and work release:

SSRL System Manager “David A. Ernst” (Ext. 3846) Authorization

Supervisor “Robert DiMattia” (Ext. 5457) Authorization

Area Manager “Ed Guerra” (Ext. 3909) Work Release

SPEAR Control, SPEAR Operator (Ext. 2751) Work Release

1.6 Potential Hazards and Mitigations

The potential hazards and mitigation methods that exist for this job include:


Control of Hazardous Energy

The energy hazards associated with the SPEAR3 LCW system shutdown includes:

Pressure (hydraulic) 0-400 psi

To prevent injury from the listed hazards, when starting this system all system and sub-system piping must be connected in the proper manner. Any open system must be secured with LOTO before proceeding. Since the system is considered in the off status, perform the following tasks:

Potential Hazard Mitigation

Discharge of Low conductive water (LCW) spray or stream of 1-300 psi pressure at personnel causing injury

Ensure all headers and subsystem piping is properly connected or isolated with LOTO prior to opening the system to pressure.

Not Authorized to perform this work

Persons using this procedure must be authorized by their supervisor to perform this work. Work must be detailed in workers ATA.

Deviation of this work procedure

Persons shall completely understand this work process before proceeding. This procedure Must be followed in order to eliminate any possible injury to personnel or possible damage to SPEAR and

site LCW system components from over pressurization.

Discharge accelerator Low conductive water with possible tritium into local Environment

through the site storm drain system.

Ensure system is ready to be pressurized. Discharge system pressure Only into provide sanitary sewer recovery systems.

Head lacerations when accessing accelerator housings

PPE: Wear (ANSI Z89.1-1997, type I, class E) Hard Hat when accessing accelerator housings

Water spray PPE: Wear (ANSI Z87.1-2003) or better Safety Glasses

Cuts and scrapes to hands PPE: Wear supervisor approved leather or mechanic style gloves.

Dropping heavy tools and equipment on feet

PPE: Wear Safety-Toe Footwear (ANSI Z41.1- 1967) or better.

Loud water noise PPE: Wear (ANSI S3.19-1974) or better hearing protection when opening supply line.


2. Procedure (Step By Step)

The following set of procedures must be followed to accomplish a given task.

2.1 Pre-Shutdown Evaluation

Step 1 When applicable contact FAC Operations Maintenance Mechanic supervision well in advance to schedule shutdown activities.

Step 2 Stage LOTO devices in isolation valve locations.

2.2 SLAC Site Requirements

Step 1 Contact the FAC Operations Maintenance Mechanic on duty to monitor the 1801 pump pressures during the shutdown of the SPEAR LCW system. Radio communications on the SLAC operations channel must be maintained with the Maintenance Mechanic during the entire LCW shutdown procedure.

CAUTION!

Do Not Attempt to Open or Close the SPEAR or Beam line LCW System without SLAC FAC Operations Support. Site System Damage May Occur.

Note: The FAC Operations maintenance mechanic will be making adjustments to the 1801 LCW system (See figure 2.7.1) to balance the site systems due to the SPEAR LCW load being removed. The CEF must make adjustments in order to maintain proper site system pressures. Closing the LCW supply slowly gives the FAC Operations maintenance mechanic time to make adjustments. During radio communications the FAC Operations maintenance mechanic may request you to stop periodically in order to stabilize his system.

Radio communication must be maintained with the FAC maintenance mechanic during the entire LCW shutdown.

Confirm with the SSRL MSG System Manager that all accelerator systems requiring LCW are off and that the LCW system is ready to be taken off-line.

2.3 SPEAR3 LCW System Shutdown Step by Step Procedure

Step 1 Communicate to the SPEAR Operator and MCC that you are shutting down the SPEAR and Beam line LCW system.

Note: Always close the main supply valve prior to closing the return valve. This will eliminate the chances of deadheading and over-pressurization of the system causing possible damage to components and hoses.

Step 2 Communicate to the FAC Maintenance Mechanic that you are ready to close the supply valve to the SPEAR LCW system.


Note: The main LCW supply valve is located in the southwest corner in front building 118.

Step 3 The FAC Maintenance Mechanic will be required to adjust the flow and pressure at the 1801 pad.

Note: Pumps at the 1801 pad will need to be taken off line to shutdown the SPEAR and Beam line LCW systems.

Step 4 With 2-way radio communication between FAC Maintenance Mechanic and SSRL shutdown team, close the SPEAR main (BLACK) supply valve (See figure 2.7.3) slowly by reducing system pressure in 50 psi increments as instructed by the FAC Maintenance Mechanic at the 1801 pump station. When completely closed Apply the required LOTO.

Step 5 With 2-way radio communication between FAC Maintenance Mechanic and SPEAR3 core support shutdown team, close the SPEAR main (BLACK) return valve (See figure 2.7.2)

Step 6 Communicate to the FAC Maintenance Mechanic on duty that you are ready to shutdown the Beam line LCW system.

Step 7 Slowly close the (BLUE) building 120/130/131 LCW valves. Close building main supply valve (See figure 2.7.5). Apply the required LOTO.

Step 8 Slowly close the (BLUE) building main return (See figure 2.7.6). Apply the required LOTO.

Note: The 120/130/131 LCW supply & return valves are located near the End Station “A” LCW feeders going to building 140.

Step 9 Communicate to the FAC Maintenance Mechanic on duty that the SPEAR and Beam line LCW shutdown is complete.

2.4 Relieving Stored LCW Hydraulic Energy

Step 1 Verify all LOTO is applied on all main supply and return valves.

Step 2 If correctly isolated the system pressure should be approximately 50.0 psi.

Step 3 Open the SPEAR LCW drain valves in East & West straights to bleed stored energy to designated sumps. The return pressure should drop to 0 psi.

Step 4 Open building 120/130/131 drain valve located at main strainer to bleed stored energy into designated manhole sump. The return pressure should drop to 0 psi.

Note: All LCW drained and disposed of will be handled as to SLAC site ES&H policies). (Verify at main tree gauges as well as the electronic gauge display in SPEAR control room.

2.5 Verify System Pressures After the System Shutdown

SPEAR LCW System

Step 5 Verify pressure gauges on SPEAR3 piping tree (See Figure 2.7.4).


Step 6 Verify electronic pressure gauges on SPEAR3 EDM panel (See Figure 2.7.4).

Supply LCW main pressure = 0 psi. Return LCW main pressure = 0 psi. Klystron LCW building 101 regulated pressure = 0 psi RF cavity SPEAR housing regulated pressure = 0 psi RF HVPS building 514 regulated system pressure = 0 psi Power supply building 118 regulated system pressure = 0 psi Booster klystron test station building 122 regulated system pressure = 0 psi Beam line LCW system Supply LCW main pressure = 0 psi. Return LCW main pressure = 0 psi. Note: (See figure 2.7.4) System is now verified when analog and digital pressure gauges all read 0 psi.

Step 1 The SPEAR3 core team leader or system manager will notify SPEAR Operations, MCC, and the SSRL Beam Line Operator that the SPEAR LCW system is now at normal operation.

Step 2 The MSG team leader will make appropriate log entries in the SharePoint LCW E-log.

2.6 Cleanup

Step 1 Remove all tools and extra LOTO devices.

Step 2 Remove any temporary signs, barricades and boundary tape.


2.7 Figures/pictures

Figure 2.7.1: 1801 Pumping Station

Figure 2.7.2: SPEAR Main Return Valve


Figure 2.7.3: SPEAR Main Supply Valve

Figure 2.7.4: SPEAR EDM electronic Panel and analog gauge panel at piping tree


Figure 2.7.5: Building 120, 130, 131 Main Supply Valve.

Figure 2.7.6: Building 120, 130, 131 Main Return Valve.

Supply

Return


Appendix A – Dictionary of Terms

Apply LOTO – A Lock out tag out device installed to prevent work exposure to a hazardous energy.

Appendix B – Acronyms AHA – Area Hazards Analysis

ANSI – American National Standards Institute

ASME – American Society of Mechanical Engineers

ATA – Activity & Training Authorization

BIO - Building Inspection Office

BTS – Beam to SPEAR

ELP – Equipment Lock out Procedure

ES&H – Environment Safety & Health

HCW – High Conductivity Water

HVPS - High Voltage Power Supply

IV – Isolation Valve

JSA – Job Safety Analysis

LCW – Low Conductivity Water

LION – Long Ionization Chamber

LTB – Linac to Booster

LTD – Linac to Diagnostics

MPS – Machine Protection System

MSDS – Material Safety Data Sheet

Neslab ™ - Recirculation Chillier Manufacture

PPE - Personal Protection Equipment

PPS – Personal Protection System

PSI – Pressure Per Square Inch

RSWCF – Radiation Safety Work Control Form


RF- Radio Frequency

RP – Radiation Physics

RPFO – Radiation Physics Field Operations

SAPE – SSRL Accelerator Procedure Engineering

SME – Subject Matter Expert

SOC - Safety Overview Committee

ST – Stopper

SPEAR - Stanford Positron Electron Accelerating Ring

TCW – Temperature Controlled Water

Appendix C – Document Change Control

This chart contains a history of the revisions made to this document. Typically the document itself should be stored in revision control, and a brief description of each version should be entered in the revision control system. This may be unnecessary given SharePoint’s functionality.

Revision Number

Date of Issue Author(s) Brief Description of Change

0.0 1993-Mar-25 Ernst, David A. Initial Draft

1.0 2004-Oct-22 Ernst, David A. Stand-Down Review, added 120/131 changes

2.0 2005-Aug-19 Ernst, David A. System Manager Changes

3.0 2006-Nov-09 Ernst, David A. Scheduled review change PEO to CEF

4.0 2007-Oct-19 Ernst, David A. Remove return boost pump detail, updated index and approval sheet

5.0 2010-Feb-24 Ernst, David A. New SLAC format, review

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