Safety and Quality Documentation (EDMS #1549066)...Index •Safety Requirements •Quality...

The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

Safety and Quality Documentation(EDMS #1549066)

Manufacturing and Inspection PlanClaudia Parente (DG-DI), Hector Garcia Gavela (DG-DI)

https://edms.cern.ch/ui/#!master/navigator/document?D:1666167783:1666167783:subDocs

Index

• Safety Requirements

• Quality Documentation during F.A.V phase

(Fabrication, Assembly & Verification)

• MIP/MTF

• HOM Couplers - Example

• Summary

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H.Garcia Gavela - 05 Nov 2015

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Safety requirements• To be defined by HSE unit

• Discussion among WP Leader, PSO and HSE-CO to beheld to assess hazards and later issue the Launch SafetyAgreement (LSA)

• These requirements may impose that compliancewith the Essential Safety Requirements (ESR) of thePressure Equipment Directive (PED) is guaranteed(example of Crab Cavities – WP4)

• Requirement for compliance with the PED ESRscomes from the Safety rules for mechanicalequipment operated at CERN, applicable across thewhole organization


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Construction standards (1/3)

• Ideal case: use of PED harmonized standards for construction of pressure equipment

• Presumption of conformity with PED ESR is granted (no specific demonstration of compliance has to be made)

Unfired pressure equipment

Guidance on the use of the PED conformity

assessment procedures CR 13445-7

General requirements EN 13445-1

Materials EN 13445-2 ASME BPVC Section II

Design EN 13445-3 ASME BPVC Section VIII

Fabrication EN 13445-4 ASME BPVC Section IX

Inspection & testing EN 13445-5 ASME BPVC Section V

Pressure vessels and pressure parts constructed

from spheroidal graphite cast iron EN 13445-6

Additional requirements for pressure vessels

of aluminium and aluminium alloys EN 13445-8

Pressure vessels and pressure parts constructed

from cast iron (elongation after fracture ≤ 15 %) EN 15776

Glass reinforced plastic (GRP) pressure vessels EN 13923 ASME BPVC Section X

Harmonized standards

Pressure Equipment Directive (97/23/EC)

Pressure vessels - EDMS #1360482


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Thermal performance EN 12213 ISO 21014 EN 13648-x ISO 21013

Cleanliness EN 12300 ISO 23208

Materials EN 1252-x ISO 21028

Gas/material compatibility EN 1797 ISO 21010

VI: Vacuum insulated

Non-VI Non-VI

≤ 1 m3 > 1 m3

EN 13458-x ISO 21009-x EN 14197 EN 1251-x EN 13530-x EN 14398-x EN 13480-x

ISO 21029 ISO 20421 ASME B31.3

Valves Couplings Pumps

EN 12434 ISO 21012 EN 1626 EN 13371 EN 13275

ISO 21011 ISO 24490

Safety systems & devicesGeneral requirements

EN 13445-x

ISO 4126-xx

Components

EN 764-7

PipingVessels

Static Transportable

VIVI

ASME BPVC

CEN/TR 14585-2

Metal hoses

EN 14917

Expansion joints

EN 14585-1

Cryogenic equipment - EDMS #1360483

Harmonized standards

Pressure Equipment Directive (97/23/EC)

Referenced standards

Transportable Pressure Equipment (2010/35/EU), ADR


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• Other construction standards for pressure equipmentare used• Assess how conformity with PED ESR can be met. Technical

requirements defined in the engineering specifications haveto be such that compliance can be later demonstrated.Most critical aspects:• Conformity of pressure-bearing materials• Acceptance of pressure-bearing permanent joints (non-

destructive controls acceptance levels and quality criteria)• Pressure test at TBDx the maximum allowable pressure

An assessment has been made for the Crab Cavities prototype Cryomodule (WP4),

partially constructed according to ASME BPVC (not a PED harmonized standard)

and is available on EDMS #1494776 . This proposal on how compliance with

PED ESR will be attained has been approved by HSE unit (EDMS #1541969 )




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Approved austenitic stainless steels for use in pressure equipment

According to EN 13445-2 (PED harmonized standard)

For not approved materials a Particular Material Appraisal (PMA) has to be made. For the case of the crab cavities prototype Cryomodule, the PMA for niobium (non-ferrous material) has been retrieved from XFEL project (based on the same material specification).


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From Design to ProductionMinimum requirements are collected on the Engineering

Specification. Once Design is settled and approved, the

F.A.V (Fabrication, Assembly & Verification) phase will start

Baseline documentation

to be provided at each

stage of the project (Ref.

Doc: 1361462)


https://edms.cern.ch/document/1361462/LAST_RELEASED

Documentation Required during Production (1)

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MATERIAL AND FILLER METAL CERTIFICATES & TRACEABILITY SHEET:If material certificate is missing, documents related to materialqualification (chemical/mechanical/metallographic tests) to beprovided

WPS: Welding Procedures Specification

WPQR: Welding Procedure Qualification Record

WOPQ: Welding Operator Performance Qualification

WELDING MAP & WELDING BOOK: Identification for each weld tokeep the traceability with WPS & Tests performed

MANUFACTURING PROCEDURES: Detailed ManufacturingTechniques carried out during production

NDT PERSONNEL QUALIFICATIONS

Documents to be issued when applicable, depending on the nature of the equipment and how they will be manufactured



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MIP (Manufacturing & Inspection Plan): List of all Manufacturingand QC Operations

QC REPORTS generated after Quality Checks (Metrological Controls,NDT Reports, Mechanical Tests, Surface Treatments, ElectricalChecks, Leak Tightness Test, etc.…)

TRIAL FITTINGS: Applicable to any equipment that will not beshipped completely assembled to CERN

CERTIFICATE OF CALIBRATION: for the tools/equipment used formeasurements

ELECTRICAL DRAWINGS: Single Line Diagram, Developed Diagrams,Interconnection Diagrams

WIRE LISTS: Power Cables and Control Cables

SOFTWARE: Data map list, PLC Program, Control System ProgramSCADA…




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TEST PROCEDURES

FACTORY ACCEPTANCE TEST (FAT)

AS-BUILT DOCUMENTATION: Reflecting all changes made in thespecifications and working drawings during the production, showingthe exact dimension, geometry and location of all elements



Manufacturing and Inspection Plan (MIP)

• Detailed Manufacturing Steps of production

+• Quality Controls to

be performed during manufacturing

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• Follow-up the Production & Project Progress

• Keep track of Inspections

• Foresee the Critical Points

• Record of Verifications and Manufacturing Data

• Identification of Deviations (NCR)

MIP


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• MIP must contain the required fabrication steps and QC checks to ensure that theequipment meets the project requirements

• Each operation and check has to be referred to the drawings/applicable documents.It is compulsory to keep the traceability between the manufacturing steps/QCchecks and the project documentation

• Operations must be supported by standards and manufacturing/test procedures

• Each point of the MIP will be classified by CERN such as:• N (Notification Point): CERN, or its authorized representative, is informed X* working days in advance

that a specific step has been completed and that the following step in the approved work-flow will beperformed. A Notification Point does not affect the work-flow. Work can continue without CERN, or itsauthorized representative, reply

• H (Hold Point): CERN, or its authorized representative, is informed that a specific step has beencompleted. The work-flow is stopped until CERN, or its authorized representative, provides a Hold PointClearance. The clearance is provided within X working days upon submission of the QC documentationrelative to the performed step. In case of clearance the work-flow can continue. In case of rejection, arecovery plan shall be discussed with CERN and submitted to CERN for final approval

• R (Review): The quality records will be reviewed

• Depending on the nature of the manufacturing step/quality control (Hold point orNotified point) the supplier can or cannot continue with the next fabrication step

How to build the MIP


From MIP to MTF• Before starting the production, Manufacturing and Inspection Plan is prepared by the manufacturer

• MIP contains all the Manufacturing Steps and Quality Controls required to produce the equipment

• From the MIP, the QC points (to ensure that the equipment meets the requirements) are extracted

• MTF Folder is created with the sequence of Quality Controls to be performed during manufacturing

• MTF to be fed with the documents required along the Fabrication, Assembly & Verification (F.A.V) phase

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Step ID Step description1.0 Metrology Control before welding (HOOK Nb parts 1 and 2)1.1 Welding inspection W010 (HOOK Nb parts 1 and 2)1.2 Metrology Control after welding (HOOK Nb parts 1 and 2)1.3 Metrology Control before welding (HOOK Nb part 3)1.4 Welding inspection W040 (HOOK Nb parts 2 and 3)2.0 Metrology Control before welding (DN63 Nb parts 4 and 5)2.1 Welding inspection W020 (DN63 parts 4 and 5)2.2 Welding inspection W030 (DN63 parts 4 and 5)2.3 Metrology Control after welding (HOOK Nb parts 1 and 2)2.4 Leak tightness test (DN63- Nb part 4-part 5-S.S flange)

3.0Welding inspection W050 (DN63: Nb part 4-5-flange - HOOK: Nb part 1-2-3)

4.0Metrology Control before welding (DN35 Nb parts 6 and SS flange)

4.1 Welding inspection W110 (DN35 parts 6 and SS flange)4.2 Metrology Control after welding (DN35 Nb parts 6 and SS flange)5.0 TTH Bellows Stiffener6.0 Welding inspection W120 (Bellow-DN35 Flange)7.0 Welding inspection W080 (BODY parts 1 and 2)8.0 Welding inspection W080-W090 (BODY-DN63 flange)9.0 Welding inspection W08010.0 Welding inspection W100 (BODY parts 1&2 and 3)11.0 Welding inspection W130 (DN63 part 5-DN35 part 6)12.0 Leak tightness test W130 (DN63 part 5-DN35 part 6)13.0 Visual inspection W140 (Bellow-BODY part 4)14.0 Final Metrology control (HOM)15.0 Final leak tightness test (HOM)16.0 Manufacturing and inspection plan (record)17.0 Welding Book (record)


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• MTF Folder of each asset is created based on its corresponding MIP

• Each step is approved upon performing the check, and the report

generated is uploaded

From MIP to MTF


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• All quality documents associated to each asset are stored on MTF as

part of the Quality Documentation of the project:

• Dimensional/Metrological Reports

• Mechanical Tests

• Electrical Tests

• Tightness Tests

• Non Destructive Tests (NDTs)

• Non-Conformity Reports (NCRs)

• Surface Treatments

• Welding Book

• Traceability sheet

• MIP signed by parties involved

From MIP to MTF


RF superconducting crab cavities (ACF__)

Cryomodule

(ACFGA)

Dressed cavities

(ACFDC)

Tuning system

(ACFTU)

HOM couplers

(ACFHC)

Cold magnetic shield (ACFMS)

RF services

(ACFSV)

Example WP4 - Using present equipment codes

Items breakdown criteria: 1) Acquisitions launched by CERN(covered by a unique specification, design file, MIP) AND• Internal (in-house)• External

• Collaborations (in-kind)• Industry

2) To which entities are applicable Quality Controls

LHC Equipment Codes should be only definedwhen the items breakdown is established for a given system

An item generates one or more assets based on the item design file(i.e., item specifications, engineering validation reports, functional and manufacturing drawings, manufacturing procedures, and MIP)

CERN(EN-MME)

US-LARP Collab.

CERN(EN-MME)

CERN(EN-MME)

UKCollab.

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Active part

Example - HOM Couplers


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1. All Fabrication Steps + All QC verifications are identified before starting the

production Manufacturing and Inspection Plan is issued (EDMS # 1520850)

2. From MIP QC Checks Sequence

3. MTF Folder is created and fed during production

Step ID Step description1.0 Metrology Control before welding (HOOK Nb parts 1 and 2)1.1 Welding inspection W010 (HOOK Nb parts 1 and 2)1.2 Metrology Control after welding (HOOK Nb parts 1 and 2)1.3 Metrology Control before welding (HOOK Nb part 3)1.4 Welding inspection W040 (HOOK Nb parts 2 and 3)2.0 Metrology Control before welding (DN63 Nb parts 4 and 5)2.1 Welding inspection W020 (DN63 parts 4 and 5)2.2 Welding inspection W030 (DN63 parts 4 and 5)2.3 Metrology Control after welding (HOOK Nb parts 1 and 2)2.4 Leak tightness test (DN63- Nb part 4-part 5-S.S flange)3.0 Welding inspection W050 (DN63: Nb part 4-5-flange - HOOK: Nb part 1-2-3)4.0 Metrology Control before welding (DN35 Nb parts 6 and SS flange)4.1 Welding inspection W110 (DN35 parts 6 and SS flange)4.2 Metrology Control after welding (DN35 Nb parts 6 and SS flange)

Step ID Step description5.0 TTH Bellows Stiffener6.0 Welding inspection W120 (Bellow-DN35 Flange)7.0 Welding inspection W080 (BODY parts 1 and 2)8.0 Welding inspection W080-W090 (BODY-DN63 flange)9.0 Welding inspection W08010.0 Welding inspection W100 (BODY parts 1&2 and 3)11.0 Welding inspection W130 (DN63 part 5-DN35 part 6)12.0 Leak tightness test W130 (DN63 part 5-DN35 part 6)13.0 Visual inspection W140 (Bellow-BODY part 4)14.0 Final Metrology control (HOM)15.0 Final leak tightness test (HOM)16.0 Manufacturing and inspection plan (record)17.0 Welding Book (record)

https://edms.cern.ch/edmsui/#!master/navigator/document?D:1830773741:1830773741:subDocs

Summary• Safety Requirements may impose the compliance with certain standards and this

will have an impact on the design, manufacturing and testing of the equipment

• For not approved materials a Particular Material Appraisal (PMA) has to be made

• Documentation is one of the most important points required by the Project inorder to ensure that requirements are fulfilled and to establish traceability withregard to what has been done, how it has been done, who has done it and when itwas done

• Any supplier (In-House or External) has to provide the compulsory documentsrequired during the production of any equipment before the final installation ofsuch equipment on the LHC

• Manufacturing and Inspection Plans will allow CERN to follow up the production,monitoring the progress of project and keep track of the necessary inspections tobe carried out during fabrication

• From the MIP, the MTF Folder of each asset shall be built (MTF – CERN Repository)

• All manufacturing data will be stored (QC Reports, NCR, etc.…) on MTF as part ofthe quality documentation of the project

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The HiLumi LHC Design Study is included in the High Luminosity LHC project and is partly funded by the European Commission within the Framework Programme 7 Capacities Specific Programme, Grant Agreement 284404.

A good work bad documented becomes a bad work

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