Computer Testing Commissioning Template Report by ygb19984

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									The Path to Accelerator Commissioning

                    F. Willeke
           Accelerator Systems Director
              NSLS-II PAC Meeting
              December 10-11, 2009
                        1                 BROOKHAVEN SCIENCE ASSOCIATES
                    Start-Up and Test Plan
framework of documents: clearly identifies requirements for
• documentation readiness,
• technical readiness,
• personnel Training and Qualification,
• hardware and software testing

 defines the acceptance criteria for CD-4 at the end of commissioning.

hardware and software testing:
•sub-system testing and qualification,
•integrated system tests 
•commissioning with beam
this document is necessary at this stage to start preparing for start-up

                                     2                        BROOKHAVEN SCIENCE ASSOCIATES
                                 Integrated Testing
Integrated Testing Technical test of Accelerator Subsystems
- Check out Safety Systems (this is not the “official” safety test)
-Prepare systems for operations
-Test automatic and semi-automatic turn-o procedures
- Verify Assignment, Polarization, Correct Magnitude
Systematic check of the components of the safety systems (door locks, shutter positions,
including correct wiring, interfaces to RF, main dipole Power Supply, injection/extraction
pulsed magnets
• Check Assignment, polarity and magnitude of the magnet current s in the accelerator
tunnel as directed by setting using the application
• Check assignments of thermal protection switches on magnets to PS via application
• Test of the vacuum system, fine-leak checking and fixing, in-situ bake-out
• Turn on/off all power supplies by automatic procedures
                                                  3                               BROOKHAVEN SCIENCE ASSOCIATES
                      Safety System Verification
• Formal technical check, Well documented process
•Performed by an independent group (Laboratory QA and Light Source ES&H personal
• Governed by Laboratory Standards and by DOE requirements
• Technical checks out include (but are not limited to)
   functioning of components
          - door contacts, door-warning lights
           - emergency buttons,
          - mechanical systems: fences,
          - warning signs, signs indicating emergency buttons
          - warning systems: acoustical warning, blink-lights, tunnel lightening, warning-tableaus
          - Interfaces to accelerator hardware: RF, main dipole, shutters, triggers for septa, gun,
  Interlock logics: check whether any kind of anomalous status will lead to desired effect (turn-off
           the beam, RF )
  training of operators and key personal

                                                  4                                 BROOKHAVEN SCIENCE ASSOCIATES
Requirements Radiation Safety Systems Testing

 • accelerator readiness review that must be conducted prior to a
 “Template for the Accelerator Readiness Review (ARR) Plan of Action”

 • BNL interlock requirements that apply:
 “Physical Access Controls for High and Very High Radiation Areas”
 Effective Date: Jan 8, 2004 (Reviewed: Jan 8, 2004) | Periodic Review Due: Dec 31, 2009
 • the interlock test program at the NSLS

                                          5                            BROOKHAVEN SCIENCE ASSOCIATES
                   Start-Up and Test Plan
framework of documents: clearly identifies requirements for
•documentation readiness,
• technical readiness,
• personnel training and qualification,
• hardware and software testing

 defines the acceptance criteria for CD-4 at the end of commissioning.

hardware and software testing:
•sub-system testing and qualification,
•integrated system tests,
•commissioning with beam 

                                     6                        BROOKHAVEN SCIENCE ASSOCIATES
particular mode of accelerator operation with beam aiming:

• test the function of accelerator hardware and software with beam,
• verify in particular the proper functioning of the equipment protection system,
• verify the adequacy of radiation safety shielding, area radiation monitoring,
ALARA system to minimize radiation
• check the integrity and the consistency of the subsystems as built
• develop refined settings of the hardware components to allow efficient
injection, and storage of accelerator beams with good stability, beam intensity,
the advertised beam parameters, and good beam lifetime.
• condition accelerator hardware for optimum performance (vacuum, RF)
• develop and document the procedures which are necessary to operate the
accelerator routinely and to perform continuous improvement and development.

                                        7                        BROOKHAVEN SCIENCE ASSOCIATES
         Commissioning Authorization

Commissioning needs BHSO approval
authorization process, addressing all relevant issues

• completeness of documentation,
•   technical readiness,
•    training of the staff,
•   existence of detailed commission procedures,
•   assessment of hazards,
•   safety and emergency procedures.

                             8                     BROOKHAVEN SCIENCE ASSOCIATES
               Guiding Documents

The NSLS-II Authorization Base is defined by the requirements and the
guidance in:

• DOE Order 420.2B “Safety of Accelerator Facilities”
• DOE Guide 420.2-1 “Accelerator Facility Safety Implementation
• DOE Order 413.3B “Program and Project Management for the
Acquisition of Capital Assets”
• BNL SBMS Subject Area “Accelerator Safety”

                                  9                        BROOKHAVEN SCIENCE ASSOCIATES
   Elements of the Authorization Base
Commissioning Modules
   • LINAC (including LINAC to Booster Transfer Line)
   • Booster (including Booster to Storage Ring Transfer Line)
   • Storage Ring
   • Full Operations (roll-up of first three modules)

Module Components (concluded by authorizations and reviews)
   • SAD (Safety Assessment Document)
   • ASE (Accelerator Safety Envelope)
   • Authorization Plan (commissioning plan)
   • ORE (Occupational Readiness Evaluation)
   • ARR (Accelerator Readiness Review)

                                10                      BROOKHAVEN SCIENCE ASSOCIATES
Coupling of Schedule Elements

           Includes staff training

                   11                BROOKHAVEN SCIENCE ASSOCIATES
                         Commissioning Stages
LINAC Frontend (gun pre-buncher) early delivery, commissioning and early tests by NSLS-II staff in
RF Lab, Special bunch-modes

LINAC commissioning by the vendor (responsible)
LtBTL (LINAC building part ) commissioned by NSLS-II-Staff , primary + secondary beam dump
LBTL commissioning by NSLS-II staff in parallel to booster integrated testing
Booster commissioning by vendor (vendor’s responsibility), participation of NSLS-II staff
BSTL (part in booster tunnel) performed by NSLS-II staff with project responsibility
Storage Ring Commissioning Phase 1 (without ID)
BSTL commissioning and injection set up ; the storage ring beam optics; adequacy of correction
systems; adequacy of safety and ALARA systems; efficient injection; adequacy of beam
instrumentation; orbital stability; RF set up and stability; RF conditioning; cryogenic stability; beam
stability; vacuum integrity and conditioning; high intensity operations
Storage Ring Commissioning Phase 2
Integrate Insertion devices

                                                     12                                 BROOKHAVEN SCIENCE ASSOCIATES
               Assumptions on Conditions

• accelerator tunnel air conditioned; tunnel temperature, humidity within specified range.

• final survey and alignment shortly before start commissioning (ground settling)

• heavy duty construction activities completed

• global utilities available: electrical, de-ionized water, chilled water, and liquid N2

CF deliverables

installation of girders and magnets completed ~1/2 year start of commissioning.
cable conduits and openings in the tunnel walls will be properly closed and shielded

                                             13                               BROOKHAVEN SCIENCE ASSOCIATES
    SR Subsystem Status at Commissioning
•   integrated testing complete
•   Injectors and transfer lines commissioned
•   personal safety system and interfaces thoroughly tested
•   equipment protection system is fully implemented and tested via the control system.
•   magnets systems installed well before commissioning,
•   precision alignment shortly before commissioning
•   insertion devices will not be installed
•   power supply systems are complete, technical interlocks have been properly tested
•   vacuum system has a vacuum of at least 10-7 mbar
•   two sc RF cavities installed driven by a single 310kW transmitter station.
•   full suite of beam diagnostics is installed and tested
•   water cooling systems have been installed tested
•   timing system implemented
•   control system is fully implemented
•   relational database is fully functional
•   all application programs deemed necessary for commissioning available
•   injection systems have been installed and tested
•   fast orbit feedback has been implemented
•   transverse feedback damper system installed and tested

                                              14                               BROOKHAVEN SCIENCE ASSOCIATES
Radiation Safety during Commissioning
• radiation protection systems installed and fully tested, no provisory solutions allowed, no
exception possible.
• initial beam intensity very small compared to nominal (0.1%).
• area monitors readings low intensity will be extrapolated to the next step in beam intensity.
• extrapolation is reviewed and analyzed at each level of intensity before the next step in intensity is
• initial high intensity studies: assume losses e much larger than under optimized normal
conditions may need special (temporary controlled radiation areas)
• beam containment system needs to be tested with beam, location of beam losses identified, beam
is lost dominantly in the extra shielded confirmed
• clear and unambiguous procedures operating staff needs to be trained to follow these procedures
before operations with continuous injection of high charge (top-off, high intensity operation) can

                                               15                                 BROOKHAVEN SCIENCE ASSOCIATES
  Storage Ring Commissioning Modules
Establish Initial Beam Operation, 5 moduls    70 commissioning modules
Check out Beam Instrumentation 4 moduls
Check out Safety Functions 3modules           Each needs ~4 shifts on
Fine tuning of Beam Optics 7modules           average
Functionality Tests 1moduls                   ~300 shifts
Fine Tuning of Orbit and Emittance 3modules
Synchrotron Radiation Measurements 4mod.      100 days
High Intensity Studies 10 modules
                                              Operational efficiency is
COMMSIONING PART II                           assumed 50%
Safety Related Measurements 2 modules
ID Integration 8 x 7 modules
Preparation of User Operation 3 modules       Need 200 days of

                                      16                      BROOKHAVEN SCIENCE ASSOCIATES
               Storage Ring Commissioning Part I
Establish Initial Beam Operation                                Functionality Tests
Obtain stored beam                                              Fast orbit feed-back test
Adjust and verify RF parameters                                 Fine Tuning of Orbit and Emittance
first Orbit Correction                                          Orbit correction to micron level
first iteration of correcting chromaticity and coupling         dispersion free steering and orbit correction
first iteration of obtaining acceptable injection efficiency    vertical emittance tuning
Check out Beam Instrumentation                                  Synchrotron Radiation Measurements
establish beam monitor calibration with local bumps              Measurement of power deposition s and power load
checking intensity monitors                                     check of temperature monitor system
checking out loss monitors                                      check of vacuum interlock
checking out emittance monitors                                 check of assumptions on absorber and mask temperatures,
Check out Safety Functions                                      monitoring and cooling
Checkout top-off safety functions                               High Intensity Studies
Check-out machine protection system                             Set up of high efficient injection
Check out BCS and ALARA functionality                           Set-up of RF feedback and fine tuning of feedback
Fine tuning of Beam Optics                                      parameters and LLRF
Beam Optics Checks and correction (Response matrix,             Single Bunch Intensity Limit measurements
phase advance,                                                  bunch lengthening by 3rd harmonic cavity
coupling measurements)                                          beam lifetime vs bunch length and bunch intensity study
Beam based alignment                                            BCS and ALARA studies with high intensity
measurement of chromatic distortions and correction             Vacuum conditioning beam
nonlinear dynamics related measurements and corrections         RF conditioning with beam
(D.A., amplitude dependent tune shift, width of resonances,     transverse damper test
higher order chromaticity)                                      Study of high multi-bunch intensity limitations
measure 1st and 2nd order momentum compaction factor
measure damping distribution
                                                               17                                    BROOKHAVEN SCIENCE ASSOCIATES
                  Commissioning Staffing
• commissioning will be organized in 3 8hr shifts per day and seven days per week.
• commissioning labor budgeted within the project
• commissioning requires operation of already commissioned subsystem
(injectors, cryogenics, utilities)
• commissioning requires the involvement of all accelerator physicists (budgeted) ,
subsystem experts (budgeted) and operators
• workload of off-hour shifts will be shared between all high level staff
• engineers and technicians on call during commissioning
• control room manned with 1 accelerator physicist ~33 weeks. @ 16000 hr (budgeted)
• involvement of engineers less regular, will depend on the commissioning program
• initially, one machine operator present every shift
 will gradually develop into a mode with 2 operators and no accelerator physicists.

                                            18                              BROOKHAVEN SCIENCE ASSOCIATES
Commissioning Information and Documentation

 • semi-formal meetings of 15 min at shift change ( coming and going shift crews)
 seamless transition from one shift to the next, communicate and discuss fine-tuning of program.
 3 shifts per day and thus there will be three such meetings.
 weekly commissioning meeting will summarize the commissioning results.
 opportunity to optimize the commissioning program and direction.
 • weekly commissioning meetings will be documented including all material presented.
 • commissioning carried out in modules (ca 200) each requires written plan:
        the purpose,
        the goal,
        supporting documents,
        results of calculations necessary to carry out the module
        estimate on the needed machine time
        labor resources required.
 • results of each module will be documented
 • raw data will be stored in an organized and accessible way
 • evaluation, resulting set-points, procedures, parameters will be documented
 • commissioning report will be published at the end of commissioning

                                               19                              BROOKHAVEN SCIENCE ASSOCIATES
     Applications needed for Commissioning
                                      Major Subsystem Control                    Utility Control
Operation Software
                                      Power supply page                          tunnel temperature and humidity monitor
overall status page
                                      RF monitor and control                     mechanical utilities status and control
status, alarm and warning monitor
                                      Vacuum display and control                 electrical utilities status and controls
permit system monitor and control
                                      Cryogenics system display and control      equipment enclosure monitor
data logger and data display
                                      pulsed magnet monitor and control          water cooling system display
electronic logbook
                                      injection element display and control      controls network monitor
Operations Software
                                      Insertion device control                   Accelerator physics applications
accelerator store/restore
                                      Front-end control and status               •static orbit corrections, first turn steering,
Injection Control
                                      Beam Diagnostics                           •chromatic correction,
power supply control
                                      Beam Orbit page with                       •response matrix measurements,
RF control
                                      Beam current history and lifetime          •phase advance measurements,
fast orbit feedback control
                                      bunch intensity display and history        •beam base alignment measurement,
fast transverse damper control
                                      beam emittance display                     •bpm test programs,
front-end monitoring and control
                                      Timing system display and control          •beam optics measurement,
machine protection displ &contr
                                      Synchronization system displ & contr       •beam based alignment of sextupoles,
magnet temp. interlock dspl & contr
                                      Tune display and control                   •analysis on nonlinearities
scraper and collimators
                                      Temperature monitoring display             •dispersion measurement and correction,
system turn-on, system shutdown
                                      Safety Systems                             •closed Orbit bump page
                                      personal protection system status
                                      equipment protection display and control
                                      beam containment display and control
                                      top-off status monitor
                                                           20                                       BROOKHAVEN SCIENCE ASSOCIATES
Accelerator Control Room during Commissioning
 accelerator control room is the location where:
 • operators operate the accelerator
 • operators coordinate with technical staff about technical difficulties and interventions
 • accelerator experiment are carried out
 • a logbook on accelerator operations is kept and maintained,
 • information in case of an emergency is to be obtained and such information will be delivered to
 • an access point is established which manned 24hr a day 7 days a week
 • day-to-day coordination between accelerator and experimental floor are exchanged,
 • shift-change briefing meetings are held,
 • first hand information on the status of the accelerator is available
 • the responsibility for operating the accelerator safely within the safety regulations resides
 • routine safety measures are coordinated (LOTO)
 • preparation of the accelerator for operations is coordinated after an interruption
 • computer provide an optimized selection of delays for quick overview of accelerator status
 • an emergency stop button and other special installation (LAN, site-wide audio) are installed
 functionality very different between commissioning and operation
 at commissioning assumed that the control room is close to the accelerator hardware
 control room LAN is accessible from the accelerator tunnel and from the mezzanine.

                                                21                                BROOKHAVEN SCIENCE ASSOCIATES
Commissioning Schedule

          22             BROOKHAVEN SCIENCE ASSOCIATES
Commissioning Budget


• We have defined a clear path to commissioning
• The associated formal procedures and the regulatory has been
taken into account in the planning
• There is good understanding of the circumstances under which
commissioning will take place
• There is a good understanding what needs to be done which is
base of the preliminary plan
• Commissioning budget and schedule are in place (need to revisit
once the plan has matured
• Next goal is to present a “Start up and Commissioning Plan” to be
presented at the Lehman review in February

                                 24                       BROOKHAVEN SCIENCE ASSOCIATES
Accelerator Commissioning and Operation Authorization

                         25                 BROOKHAVEN SCIENCE ASSOCIATES

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