1. I&T and Operating and Support Hazards Martin Nordby Chief Mechanical Engineer LSST Camera Safety Review August 18, 2015 R1

2. 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

3. 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

4. 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

5. 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 Cases
Access/Secure Camera Body
Access Back Flange
Maintain Mechanisms
Access/Secure Utility Trunk
Remove/Replace Mechanisms
Leak Check Cryostat
Inspect Components in Camera Body
Service, Leak Check Vacuum Systems
Access Front of Camera
Replace System Electronics
Swap Out Filter
Component in Utility Trunk

6. 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 Components
L1-L2 Assembly and L1 and L2 lens
Auto Changer
Carousel clamps and actuators
Shutter
Filters
Raft Tower Modules
Power Supply Boards
Refrigeration system heat exchangers

7. Provisions for camera maintenance
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
Back flange bay covers removed
SMRs are accessible for ground- or telescope-based survey and alignment, as needed
All back flange mounting bolts are accessible for torque checking
Portholes provide access to carousel clamps
Shroud panels detach
Camera access points for maintenance

8. 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

9. 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

10. 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

11. 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 …