1. S. Barbanotti - DESY Requirements Conformance for SRF Cryomodules Workshop 16/10/2014 – ESS, Lund XFEL cryostat main components: Quality Assurance and Control

2. 2 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Summary Main components in an XFEL cryostat Quality assurance and control of cold masses and vacuum vessels  Lessons learned Quality assurance and control of other components

3. 3 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti What are we speaking about?

4. 4 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Components under the WP03 responsibility Cryostats and cold masses produced in China and delivered to DESY  Quality control at the company and at DESY Cryostats and cold masses produced in Italy and delivered to CEA-Saclay  Quality control at the company Ti end-connections, quadrupole-pipes, filling lines, flanges produced or assembled in house by DESY  Quality control at DESY

5. 5 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Part 1 COLD MASS AND VACUUM VESSEL

6. 6 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti It all starts like this…

7. 7 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti …then it‘s more like this…

8. 8 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti.. and at the end it looks like this.

9. 9 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti And how do we control what we get? (1/2) Specifications, drawings, additional procedures (shipping conditions, painting, required dimensional controls) are defined at the very beginning of the work. The production is mainly regulated by the requirements for the PED certification; this means:  Verification by the manufacturer of production drawings and procedures  Use of certified materials, with traceability of the material certification on the single components  Approval by the manufacturer of the welding documentation:  weld design  welding procedures  welding personnel certification  The type and “quantity” of NDT tests on pressurized components are defined by the norm  NDT personnel has to be certified

10. 10 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti And how do we control what we get? (2/2) Additional requirements are set by DESY as manufacturer:  Dimensional control of some sensitive components  Traction test of cold mass supports  Spot visual and destructive tests on pipes and welds (endoscope)  Regular visit to the production site during fabrication

11. 11 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Examples (1) Verification of welds

12. 12 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Examples (2) Tranction test Distuctive test on weld

13. 13 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Examples (3) Dimensional survey

14. 14 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Additional incoming controls at DESY Repetition of dimensional control with laser tracker Verification of main flange surfaces (no transport damages) Check of part list Verification of position of main pipes  many hours needed only for the QC

15. 15 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Documentation For each CM and VV assembly, the complete documentation includes all the PED relevant certificates, test records, procedures, and the additional test records required by DESY The package is handled as follow:  The documentation of the main components is uploaded directly by the producer into the EDMS system  The documents are reviewed internally by DESY experts  The documentation is accepted (or rejected) by the WP03 co-leader responsible for the procurement This procedure has to be repeated for 100 components  quite time consuming Missing documentation delays acceptance of the components and PED certification  the delivery of a complete documentation is not just a “detail”, it’s a part of the whole production process

16. 16 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti How did it work so far? Main non-conformities discovered:  11 cold masses not conform at incoming dimensional control in DESY  Rework at companies needed  Requires a lot of extra work (unpacking, packing, transport, …) and it‘s very time consuming  Components of the cavity support system (needle blocks and plates, bushes...) not acceptable (threads not working, parts dirty, …)  Sent back to companies  Effort needed to agree with the companies of the quality level required  Lot of „small“ non-conformities discovered in DESY, i.e. thermal shield profile, flanges not leak-tight, copper braids too short …  Fixed in house  Major NCs fixed by company personnel on DESY/Saclay site  Also very time consuming (small work for 100 times)

17. 17 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Lessons learned – big subassemblies QA/QC process should be defined before the delivery of the first components  guarantee uniformity of the verified products, no “special cases”  allow the estimation of the time to be allocated for the QC The producer should be informed of the main QC points before the beginning of the production  awareness of the producer on the critical points of the product  possibility to do internal checks at the company before long transports Documentation is not a side aspect, it’s an integral part of the production In house verification of the delivered parts is very time consuming  alternative solution: quality control personnel permanently present at the producer during fabrication (at least for the first few components)

18. 18 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Part 2 OTHER COMPONENTS

19. 19 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti QA / QC of components assembled in house (1) Preparation of documentation:  Complete set of drawings  Welding documentation  Specifications for all ND tests (VT, LT, PT or RT)  Reports of ND tests Execution of assembly (cutting, welding, feedthrough assembling) performed following the specifications

20. 20 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti QA / QC of components assembled in house (2) Traceability of the documentation: everything is uploaded in the EDMS and connected to the physical parts Inspection reports and Conformity declarations are issued by DESY as manufacturer  Parts ready for use in a PED assembly

21. 21 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Other components Components delivered to DESY ready for used are either CE stamped or certified as “part of a pressure vessel” After a quick visual inspection and documentation check, these components are directly integrated in the main assembly Examples:  Ti-bellows  Ti-pipes for the cavity repair activity  Transition joints  Gate valve supports

22. 22 Requirements Conformance for SRF cryomodules Workshop, ESS, Lund – 16/09/2014 S. Barbanotti Thank you for your attention!