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 Safety and Quality Documentation (EDMS # ) Manufacturing and Inspection Plan Claudia Parente (DG-DI), Hector Garcia Gavela (DG-DI)

Index Safety Requirements Quality Documentation during F.A.V phase (Fabrication, Assembly & Verification) MIP/MTF HOM Couplers - Example Summary 2 H.Garcia Gavela - 05 Nov 2015

3 Safety requirements To be defined by HSE unit Discussion among WP Leader, PSO and HSE-CO to be held to assess hazards and later issue the Launch Safety Agreement (LSA) These requirements may impose that compliance with the Essential Safety Requirements (ESR) of the Pressure Equipment Directive (PED) is guaranteed (example of Crab Cavities – WP4) Requirement for compliance with the PED ESRs comes from the Safety rules for mechanical equipment operated at CERN, applicable across the whole organization H.Garcia Gavela - 05 Nov 2015

4 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) Pressure vessels - EDMS # H.Garcia Gavela - 05 Nov 2015

5 Construction standards (2/3) Cryogenic equipment - EDMS # H.Garcia Gavela - 05 Nov 2015

6 Construction standards (3/3) Other construction standards for pressure equipment are used Assess how conformity with PED ESR can be met. Technical requirements defined in the engineering specifications have to 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 # This proposal on how compliance withEDMS # PED ESR will be attained has been approved by HSE unit (EDMS # )EDMS # H.Garcia Gavela - 05 Nov 2015

7 Approved austenitic stainless steels for use in pressure equipment According to EN (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). H.Garcia Gavela - 05 Nov 2015

8 From Design to Production Minimum 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: ) H.Garcia Gavela - 05 Nov 2015

Documentation Required during Production (1) 9  MATERIAL AND FILLER METAL CERTIFICATES & TRACEABILITY SHEET: If material certificate is missing, documents related to material qualification (chemical/mechanical/metallographic tests) to be provided  WPS: Welding Procedures Specification  WPQR: Welding Procedure Qualification Record  WOPQ: Welding Operator Performance Qualification  WELDING MAP & WELDING BOOK: Identification for each weld to keep the traceability with WPS & Tests performed  MANUFACTURING PROCEDURES: Detailed Manufacturing Techniques 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 H.Garcia Gavela - 05 Nov 2015

Documentation Required during Production (2) 10  MIP (Manufacturing & Inspection Plan): List of all Manufacturing and QC Operations  QC REPORTS generated after Quality Checks (Metrological Controls, NDT Reports, Mechanical Tests, Surface Treatments, Electrical Checks, Leak Tightness Test, etc.…)  TRIAL FITTINGS: Applicable to any equipment that will not be shipped completely assembled to CERN  CERTIFICATE OF CALIBRATION: for the tools/equipment used for measurements  ELECTRICAL DRAWINGS: Single Line Diagram, Developed Diagrams, Interconnection Diagrams  WIRE LISTS: Power Cables and Control Cables  SOFTWARE: Data map list, PLC Program, Control System Program SCADA… Documents to be issued when applicable, depending on the nature of the equipment and how they will be manufactured H.Garcia Gavela - 05 Nov 2015

Documentation Required during Production (3) 11  TEST PROCEDURES  FACTORY ACCEPTANCE TEST (FAT)  AS-BUILT DOCUMENTATION: Reflecting all changes made in the specifications and working drawings during the production, showing the exact dimension, geometry and location of all elements Documents to be issued when applicable, depending on the nature of the equipment and how they will be manufactured H.Garcia Gavela - 05 Nov 2015

Manufacturing and Inspection Plan (MIP) Detailed Manufacturing Steps of production + Quality Controls to be performed during manufacturing 12 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 H.Garcia Gavela - 05 Nov 2015

13 MIP must contain the required fabrication steps and QC checks to ensure that the equipment 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/QC checks 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 be performed. A Notification Point does not affect the work-flow. Work can continue without CERN, or its authorized representative, reply H (Hold Point): CERN, or its authorized representative, is informed that a specific step has been completed. The work-flow is stopped until CERN, or its authorized representative, provides a Hold Point Clearance. The clearance is provided within X working days upon submission of the QC documentation relative to the performed step. In case of clearance the work-flow can continue. In case of rejection, a recovery 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 or Notified point) the supplier can or cannot continue with the next fabrication step How to build the MIP H.Garcia Gavela - 05 Nov 2015

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 14 Step IDStep description 1.0Metrology Control before welding (HOOK Nb parts 1 and 2) 1.1Welding inspection W010 (HOOK Nb parts 1 and 2) 1.2Metrology Control after welding (HOOK Nb parts 1 and 2) 1.3Metrology Control before welding (HOOK Nb part 3) 1.4Welding inspection W040 (HOOK Nb parts 2 and 3) 2.0Metrology Control before welding (DN63 Nb parts 4 and 5) 2.1Welding inspection W020 (DN63 parts 4 and 5) 2.2Welding inspection W030 (DN63 parts 4 and 5) 2.3Metrology Control after welding (HOOK Nb parts 1 and 2) 2.4Leak 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) 4.1Welding inspection W110 (DN35 parts 6 and SS flange) 4.2Metrology Control after welding (DN35 Nb parts 6 and SS flange) 5.0TTH Bellows Stiffener 6.0Welding inspection W120 (Bellow-DN35 Flange) 7.0Welding inspection W080 (BODY parts 1 and 2) 8.0Welding inspection W080-W090 (BODY-DN63 flange) 9.0Welding inspection W Welding inspection W100 (BODY parts 1&2 and 3) 11.0Welding inspection W130 (DN63 part 5-DN35 part 6) 12.0Leak tightness test W130 (DN63 part 5-DN35 part 6) 13.0Visual inspection W140 (Bellow-BODY part 4) 14.0Final Metrology control (HOM) 15.0Final leak tightness test (HOM) 16.0Manufacturing and inspection plan (record) 17.0Welding Book (record) H.Garcia Gavela - 05 Nov 2015

15 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 H.Garcia Gavela - 05 Nov 2015

16 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 H.Garcia Gavela - 05 Nov 2015

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 defined when 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) UK Collab. 17 Active part Example - HOM Couplers H.Garcia Gavela - 05 Nov 2015

18 Example - HOM Couplers

19 1.All Fabrication Steps + All QC verifications are identified before starting the production  Manufacturing and Inspection Plan is issued (EDMS # ) From MIP  QC Checks Sequence 3.MTF Folder is created and fed during production Step IDStep description 1.0Metrology Control before welding (HOOK Nb parts 1 and 2) 1.1Welding inspection W010 (HOOK Nb parts 1 and 2) 1.2Metrology Control after welding (HOOK Nb parts 1 and 2) 1.3Metrology Control before welding (HOOK Nb part 3) 1.4Welding inspection W040 (HOOK Nb parts 2 and 3) 2.0Metrology Control before welding (DN63 Nb parts 4 and 5) 2.1Welding inspection W020 (DN63 parts 4 and 5) 2.2Welding inspection W030 (DN63 parts 4 and 5) 2.3Metrology Control after welding (HOOK Nb parts 1 and 2) 2.4Leak 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) 4.1Welding inspection W110 (DN35 parts 6 and SS flange) 4.2Metrology Control after welding (DN35 Nb parts 6 and SS flange) Step IDStep description 5.0 TTH Bellows Stiffener 6.0 Welding inspection W120 (Bellow-DN35 Flange) 7.0Welding inspection W080 (BODY parts 1 and 2) 8.0Welding inspection W080-W090 (BODY-DN63 flange) 9.0Welding inspection W Welding inspection W100 (BODY parts 1&2 and 3) 11.0Welding 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) 17.0Welding Book (record)

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 in order to ensure that requirements are fulfilled and to establish traceability with regard to what has been done, how it has been done, who has done it and when it was done Any supplier (In-House or External) has to provide the compulsory documents required during the production of any equipment before the final installation of such 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 to be 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 of the quality documentation of the project 20 H.Garcia Gavela - 05 Nov 2015

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 A good work bad documented becomes a bad work Thanks for your attention Questions?