- Generals for PED matters - Definition of pressure vessel and classes - Who is who according to PED - Definition of pressure vessel + codes for XFEL - PED handling of the DESY/ XFEL cavities PED (Pressure Equipment Directives ) for XFEL (Some of them (!) that are related to Modules and Cavities) Axel Matheisen DESY

2 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Generals for PED matters In normal cases process is as follows - Check legal rules/ codes of areas where product will be operated (ASME, ISO; CE;..) Short excurse ASTM has extended range of tolerances in material  thicker walls ISO tight tolerances field on material and design  thinner walks possible - Define pressure vessel and operation conditions (See page 4) * Define maximum pressure, maximum temperature, the volume (for equipment and accessories) or the nominal diameter DN (for piping and accessories) * Check if additional information is required to be selected to determine possible exceptions to the classification tables (See later page 9)

Generals for PED matters cont. 3 Delete this text and put in here: Date of the Talk, location, … (max: 1 line) Put in here: Name of the speaker, function, affiliation, … (max. 1 line) What else  Design according to legal PED rules  Select material;  wall thicknesses; materials; weld joints…  Select licensed fabricators  (welders qualification; QA systems etc.  Set up a quality control system  Set up documentation system for full traceability

Definition of pressure vessel and classes 4 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Conformist diagram classification Input: Pressure; Temperature; Type (pipe or heat exchanger) ; Volume; Tube diameter

Definition of pressure vessel and classes 5 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2

Who is who according to PED 6 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Define “who is who” Manufactures- Takes the risk for safe design Responsible for safety for pressure vessel Can/ has to fix sequences, materials and tests.. for a safe product. But guides the whole production and is the only one that can produce replicas of the product ! Manufacturing enterprise (fabricator)- Has to hold and guaranty all qualification's requested by the manufacturer Hast to follow strictly the directives of manufacturer Has to deliver all data from production requested. “Customer” location defines the PED code to be applied

Definition of pressure vessel and codes for XFEL 7 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 General definition of the pressure vessel by PED “Pressure vessel is the volume that can not be sealed and insulated” From the XFEL lay out of tests and infrastructure 1 st volume than can be insulated ONE module / string during test in module test at AMTF 2 nd volume than can be insulated Linac/ coupling of modules (330 mm tube;2 phase HE lines;..

Definition of pressure vessel and codes for XFEL 8 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Individual Module = KAT II

Definition of pressure vessel and codes for XFEL 9 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 BUT XFEL Modules are coupled in the tunnel n times 256 L => Classification pressure vessel Kat IV From this it results that All pressure bearing components (Druckbehälter Bauteile) have to be fabricated and tested according to Kat IV (Cavities; He distribution tubes etc.)

Definition of pressure vessel and codes for XFEL 10 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Manufactures can select “Test Modules” We as manufacturer have selected Module B and F for the cavity production (we don’t hold a license as pressure device manufactures)

Definition of pressure vessel and codes for XFEL 11 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG several pages

PED handling of the DESY / XFEL cavities 12 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Consequences: Module B / Module B1 - Check all documents concerning design; calculation and fabrication - Cross check design by finite element calculations - Cross check fabricators manufacturing drawings on accordance with original design /drawings and FEM calculations -Cross check material for applicability -Cross check qualifications of companies; (welders; weld procedures,…) -Cross check accordance and fabrication on test objects by destructive and non destructive test

PED handling of the DESY/ XFEL cavities 13 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 # Cavity design does not base on the PED requirements # Cavity material and application temperature not in the PED 2K 2K # Kat.IV  cut complete cavities for analysis # Material qualification test apparatus not applicable (Yield- an tensile tests and Impact test at 2 K) # Material tests for serial production at low temperatures do not exist in industry

PED handling of the DESY/ XFEL cavities 14 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 Way out for DESY Operational experiences over 15 years About 160 cavities build  long term experiences in cold operation Experiences on pressure + crash 2K on Cavity C 26 and Module 3* Traceability of drawings, fabrication, materials and preparation Produce accordingly to the experiences! No changes are allowed Full traceability has to be given Install notified body installed for tests and proves

PED handling of the DESY/ XFEL cavities 15 TTC Meeting Milano Italy Axel Matheisen DESY Hamburg WG -2 PED Module B / B1 for the XFEL Cavities - DESY is defined as the manufacturer - Fabricate a “test piece” (pre production welding test acc. to ISO 15613) for destructive tests - Manufacture n Cavities with notified body on place and do non destructive testing on them (DCV - RCV cavities for XFEL Cavity production) - Set up PMA material for materials (as in use) and follow this PMA strictly! (PMA= Particular Material Appraisal Acc. PED(97/23/EC) annex I, Sec 4.2) - Perform a pressure test on completed cavity for each cavity build

PED handling of the DESY/ XFEL cavities 16 Delete this text and put in here: Date of the Talk, location, … (max: 1 line) Put in here: Name of the speaker, function, affiliation, … (max. 1 line)

PED handling of the DESY/ XFEL cavities 17 Delete this text and put in here: Date of the Talk, location, … (max: 1 line) Put in here: Name of the speaker, function, affiliation, … (max. 1 line)