1. Cryomodule Product Breakdown Structure and configuration traceability
ESS Quality workshop at Saclay 30/06/2016 | Anaïs BRUNIQUEL

2. PRODUCT BREAKDOWN STRUCTURE - PBS of the cryomodules

3. Product breakdown structure –PBS (1/4)
Description of the cryomodule PBS
Schematic view of the cryomodules and its sub-systems as a “product tree”
The PBS includes the material needs of each project phase (from the design to the final delivery)
CEA Saclay/Irfu ESSI project | 30/06/2016

4. Product breakdown structure –PBS (2/4)
First principle
The product tree is based on the functions of the cryomodule, on the generic steps of cryomodule assembly and on the organization of the product responsible (including IPNO team).
Second principle
A generic PBS is defined for all type of cryomodules. It determines the PBS code for each component whether for m-beta or h-beta.
There are 4 types of cryomodule which correspond to:
M-ECCTD,
H-ECCTD,
HBL,
MBL.
Each type of cryomodule has a dedicated PBS.
This generic PBS is reproduced and adapted for each type of cryomodule.
Consequently, 5 kinds of PBS are defined.
Serial cryomodules
Principals functions of a cryomodule : to accelerate particles
To accelerate particles you need RF power. So you need cavities and couplers.
In order to the cavities and the couplers worked, you need an package with thermal, magnetic and cryogenic propriety.
From an PBS to another, each component keep the same PBS code.
CEA Saclay/Irfu ESSI project | 30/06/2016

5. Product breakdown structure –PBS (3/4)
Third principle
The PBS is composed of 7 levels associated to a code with 7 digits.
Level 1: kind of cryomodule (M-ECCTD, H-ECCTD, MBL or HBL)
Level 2: systems associated to the principal functions of cryomodule, and ancillary items required to the tests and the assembly (tooling and installation)
Level 3: subsystem of the last level
Levels 4 to 7: all components and elements associated to the subsystem of the third level. These levels include the fixing parts.
Fourth principle
The tools for assembly and tests (of cryomodule or subsystems) are only managed in the tooling section (not with the component which uses it). These tooling are not included in the delivery for ESS Lund.
The temporary elements (e.g. cap to protect the seal surfaces) are included in the component which need it.
Fifth principle
The component which is assembled to another component, brings the fixing parts permitting the assembly (e.g.: nuts, screws, gaskets). It depends to the assembly scenario.
This third part is decomposed according the step of assembly in order to do appear the interface between components.
CEA Saclay/Irfu ESSI project | 30/06/2016

6. Product breakdown structure –PBS (4/4)
1. M-ECCTD
2. H-ECCTD
3. MBL (serial cryomodule)
4. HBL (serial cryomodule)
Deliverables to ESS
CRYOMODULES
LEVEL 1 x
LEVEL 2
CAVITIES
RF COUPLERS
CRYOSTAT
TOOLING
ASSEMBLY, TEST INSTALLATIONS
x.1.
x.2.
x.3.
x.4.
x.5.
Niobium
RF window & Antenna
Cavity string (Clean room)
LEVEL 3
x.1.1.
x.2.1.
Cavity tooling
x.3.1.
x.4.1.
M-beta cavity
Double-wall Tube M-beta
Coupler tooling
x.1.2.
x.2.2.
Cavity string (Out of clean room)
x.4.2.
x.3.2.
H-beta cavity
Tooling for coupler conditioning
x.1.3.
Double-wall Tube H-beta
x.2.3.
Cryogenic circuits
x.3.3.
x.4.3.
RF pick up
x.1.4.
Assembly tooling for cavity/coupler
Doorknob
Thermal shield
x.2.4.
x.3.4.
x.4.4.
Coupler instrumentation (ready for assembly)
Spaceframe
Assembly tooling for cryomodule
x.3.5.
x.4.5.
For the cavity section of the PBS, the niobium is managed only for ECCTD. It is the same thing for RF pick up
x.2.5.
Vacuum vessel
x.3.6.
Test tooling
x.4.6.
« Coupler bell »
x.3.7.
External instrumentation
x.3.8
CEA Saclay/Irfu ESSI project | 30/06/2016

7. Traceability of the configuration
CEA Saclay/Irfu ESSI project | 30/06/2016

8. Traceability of the configuration (1/3)
Principles
The PBS is the configuration reference.
The PBS is integrated in a table which includes :
Product tree (levels) associated to a PBS code (x.1….);
Name of components;
Material of the component (steel, niobium…);
Drawing reference;
Quantities needed for the final assembly;
Identification of the component (according to the rules of the ESSI project).
 There are 5 tables (exactly 5 sheets in the same Excel folder)
Traceability
The table is in two parts:
The first is the decomposition of the PBS
The second part is the manufacturing details (name of the manufacturer, batch number, …) until the reception.
CEA Saclay/Irfu ESSI project | 30/06/2016

9. Traceability of the configuration (2/3)
First part
PBS code
PRODUCT TREE 
Tri
Code N1 N2 N3 N4 N5 N6 N7
Drawing
Edition of drawing
Rep.
qty /unity
Totale Qty X X.
3.1.
Cavity string (out of cleanroom) 1 X 1.
Bellow between cavities
24G0620 A 3
Second part
SUPPLY 
ID ESS
ID ESSI
Supply group
Supplier
Reference of supplier
Document for supply
Statut
date
Qty received
Storage place
réf. ESS
réf. IRFU
ABC
xxx -
Technical specifications
CEA-ESS-CMD-ST
In manufacturing
UXX-24G0620-XA-X..
CEA Saclay/Irfu ESSI project | 30/06/2016

10. Traceability of the configuration (3/3)
The PBS is finalised from level 1 to level 3. It is only in French.
A note which describes the PBS, is being written and will be sent to ESS as soon as possible.
The present table for following the configuration of the cryomodule, is only used for ECCTD cryomodule.
There are over 1000 items to be followed (excluding the tooling). For the serial cryomodules, there should be a software to do it.
CEA Saclay/Irfu ESSI project | 30/06/2016

11. Thank you for your attention.
CEA Saclay/Irfu ESSI project | 30/06/2016

12. CEA Saclay/Irfu ESSI project | 30/06/2016
Commissariat à l’énergie atomique et aux énergies alternatives
Centre de Saclay | Gif-sur-Yvette Cedex
T. +33 (0) xx xx | F. +33 (0)
Etablissement public à caractère industriel et commercial | RCS Paris B
DSM Irfu
CEA Saclay/Irfu ESSI project | 30/06/2016