Risk Assessment and Personnel Review at Brookhaven National Laboratory
This document discusses risk assessment and personnel review conducted at Brookhaven National Laboratory for the HL-LHC AUP Vertical Magnet Test Stand. It covers post-mitigation risks, threat identification, risk ranking, and detailed assessment of facility breakdown risks related to critical equipment. The assessment includes impact probabilities, downtime, repair costs, and schedule impacts.
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RISK ASSESSMENT AND PERSONNEL Joseph F Muratore Superconducting Magnet Division Brookhaven National Laboratory Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1-2, 2018
Charge 4b Charge 2a Outline Charge 4c Charge 2b Charge 5c AUP Risk Registry Risk Assessment Magnet Vertical Test Risks Risk Management Summary 2 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
AUP Risk Management Plan US-HiLumi-doc-339 3 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
AUP Risk Management Plan US-HiLumi-doc-89 4 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
Risk Registry Post-mitigation risks: US-HiLumi-doc-79 5 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
Risk Registry Post-mitigation open risks: US-HiLumi-doc-79 6 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
Risk Assessment Post-mitigation risks: US-HiLumi-doc-79 RI-ID Threats RT-302-2-08-001 Critical BNL Personnel Unavailable for Magnet Testing RT-302-2-08-002 BNL Vertical Test Facility Breakdown RT-302-2-08-003 Loss of He Gas RT-302-2-08-004 Shipping and Handling of Magnets From AUP Risk Register Document: US-HiLumi-doc-79 Also reference to Risk Management Plan Document: US-HiLumi-doc-339 Title Risk Rank 1 (Low) 2 (Medium) 1 (Low) 1 (Low) Breakdown above means delay of greater than 1 week. Above risks are understood and being actively managed. 7
Risk Assessment in Detail Facility Breakdown VERTICAL TEST FACILITY CRITICAL DEVICES FOR BREAKDOWN RISK Equipment Power Supply Thyristors Power Supply IGBTs Power Supply Thyristor Fuses 480VAC Power line fuses Freewheeling Diodes Filter Capacitors Down time 3 Weeks 5 Weeks 3 weeks 3 days 1 Week 3 Days Schedule Impact Probability severe Severe Severe Low Low Low Cost of Repair Available Spares $15,000 No Spares $18,000 Some Spares $9,000 No Spares $2,000 No Spares $5,000 Some Spares $5,000 Some spares very low Medium Very low Very Low Low Very low Quench Detector Chassis Quench Detector Modules Fast logger Chassis Fast Logger modules Slow logger 1 week 2 Days 2 Weeks 2 Days 3 days low low Moderate low low low low Low low low $3,000 No Spare $2,500 All Spare available $8,000 No spare $1,500 Some spare available $5,000 No spare Quench Heater power supply Cryo Valve controller Nash Pump Controller Mycom Controller HUEB Refregerator Controller 4 days 5 days 4 days 5 days 5 days low low low low low low low low low low $4,000 Some spare available $5,000 Some spare available $6,000 Some spare available $6,000 Some spare available $8,000 Some spare available Soft Starts for Compressors Funding for spares above may be covered by future funding requests or by BCR. 4 Weeks Severe Medium $8,000 No Spare 8
BNL Risk Management Risk #1 Critical Personnel Unavailable for Magnet Testing Critical personnel include - Supervisor/physicist: J. Muratore Cryogenics operator: W. McKeon Electrical engineer: P. Joshi Electrical/test technician: S. Dimaiuta Backups for critical personnel have been specified - Supervisor/physicist: P. Joshi & P. Wanderer (SMD) Cryogenics operator: New staff member to be hired and trained for production testing; this will also allow for two work shifts per day in order to maintain 3 quenches per day rate Electrical engineer: G. Ganetis, J. Escallier, W. Louie (formerly at SMD), and D. Bergman (NSLSII) see following slide Electrical/test technician: J. D Ambra, D. Sullivan (SMD) NOTE: Personnel from NSLSII would need some time to become familiar with the SMD Vertical Test Facility 9 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
BNL Risk Management Risk #1 Critical Personnel Unavailable for Magnet Testing 10 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
BNL Risk Management Risk #2 BNL Vertical Test Facility Breakdown Breakdown here means more than 1 week delay in test schedule In preparation for such an event, there has been stockpiled an inventory of critical spare parts for compressors and other components of the facility Sullair 500 compressor is available as a backup for Mycomm (main compressor) Planned 2-week cryogenics maintenance periods between series magnet tests (production testing) Linde Model 1610 He Liquefier is being shipped to BNL from PNNL at minimal Project cost this will serve as a backup to CTI Model 4000 Refrigerator if needed (available after next test) BNL funding request ($378,066) has been submitted for FY19 for cryogenics system critical parts, in addition to upgrades already implemented BNL funding request ($203,871) has been submitted for FY19 for crane critical parts 11 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
BNL Risk Management Risk #3 Loss of Helium Gas Loss of significant amount of He gas (power outage, lightning hit, valve failure, etc.) necessitates the purchase of more gas Impact is the cost to replace gas and a test schedule delay of several days to a week The facility is over 40 years old, but many parts, including valves and plumbing, have been replaced and modernized There is a continuing effort to enlarge the inventory of critical spare parts There is a continuing effort to locate leaks and repair Future addition of two more buffer tanks (29874 L each) to mitigate He gas loss at quench (available after next test) Newly designed relief valve assembly to mitigate burst disc problem and decrease loss of He gas at quench Use of Test Cryostat 3 as a cold buffer tank next to Test Cryostat 2 under test to mitigate He gas loss at quench all parts (including newly designed transfer line) are ready for use in next test (Aug 2018) 12 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
Summary Three risks have been identified for the WBS Magnets Vertical Testing at BNL All 3 risks are classified as threats, and are rated low (2) to medium (1) There are mitigations in place in case one of these risks develops during testing Risks are being managed, at BNL and at AUP Thanks for your attention 13 Review for the HL-LHC AUP Vertical Magnet Test Stand at BNL August 1 2, 2018
