Installation Binder / IRR – an example Felix Schlander Lead Engineer European Spallation Source ERIC Date

Example Install cryomodule on supports IMPORTANT: Only mechanical transfer of module Not a single connection (RF, instr., …) … the other ’installations/connections’ are handled in other binders! (not in direct scope of ESS SRF)

Design information I need Input from Design Preparation of Installation Binder Check by: Discipline Lead Engineer QC Engineer IRR

6 DRAWINGS Only related to the immediate installation to be performed! Equipment Layout Piping Layouts Isometric drawings Mechanical drawings Cable layout Electrical drawings / diagrams P&ID Etc.

11 QC – Installation & Test Documentation Inspection plans Mechanical installations Electrical installations Pressure Test Programs Protocols Welding protocol X-ray Protocol UT protocol Pressure test report PT protocol Material certificates Couplings installation protocol Anchor installation protocol Bending of pipe protocol Visual inspection protocol Marking Identification Corrosion protection Installation Certificate of compliance The plates will bend max 0.25mm when loaded …

12 – List of components and material List of Materials List of Objects List of Supports List of Name Plates Equipment list Valve list Motor list Instrument list Cable list Line-list Pipe Spec Pipe insulation Penetration list, fire, ventilation, radiation Etc. 1 cryomodule 1 set of support stands ESS-00XXXXX Tungalyft cart + toolings tools X Mxy bolts + nuts + washers …

13 Reference material Sketches Manuals Data sheets Supporting/reference documents, needed during installation

Summary Documentation required for the instalation binders from IPNO/CEA is – depending on task – not too much Be aware: the example given mainly is ’only’ nuts & bolts plus some handling procedure For other installations (cryogenic connection welding etc.) there may be more information needed from IPNO/CEA, will be requested either through ESS SRF Section or directly

Installation Binder 00. List of Documents Table of content including document revision Issuer: Installation Package Leader Reviewer: Discipline Lead Engineer (WUL / WPM) + QC Approver: Installation / Area Coordinator Link to General site information and templates

Installation Binder 01. Scope of work Description of work in general terms Interfaces Boundaries and Extent of activities to be performed (E.g. test/commissioning activities to be included.) Responsibility matrix

Installation Binder ESS Site Organization Project Site Organisation 02. Organisation / List of Contacts ESS Site Organization Project Site Organisation In-kind / Contractor Site Organisation Telephone / mail list to all site personnel

Installation Binder 03. Time Schedule Installation Time Schedule for the work described in this binder

04. RAMS Risk Assessment Method Statement Installation Binder 04. RAMS Risk Assessment Method Statement Installation sequence Transportation route interference check Job Hazard Analysis Equipment & resources Etc.

05. Temporary Service Installation Binder Scaffolding Laydown Areas (Storage) Site logistics Lifting Temporary power and fluids List of concrete boring and drilling Etc.

Installation Binder 06. Drawings Only installation drawings! Equipment Layout Piping Layouts Isometric drawings Mechanical drawings Cable layout Electrical drawings / diagrams P&ID Etc. Drawings used for prefab. etc. are placed in: 13. Reference documents

Installation Binder 07. Installation Procedures Welding Procedure Specification Electrical procedures Cold bending Anchor bolt installation procedure Coupling installation procedure Etc.

08. Work Permits Installation Binder Certificates Permits Hot work Fork lift Crane Etc. Permits Electrical work Lock out tag out Ladder

Installation Binder 09. Daily diary Meeting notes from e.g. Pre Job Briefing. Notes of importance / Main activities during the day. Is also used for reporting to management or as turn-over notes to other shifts.

Installation Binder 10. NCR Non Conformity Report Non conformity reports Follow up list

Installation Binder 11. QC - Installation & Test Documentation Inspection plans Mechanical installations Electrical installations Pressure Test Programs Protocols Welding protocol X-ray Protocol UT protocol Pressure test report PT protocol Material certificates Couplings installation protocol Anchor installation protocol Bending of pipe protocol Visual inspection protocol Marking Identification Corrosion protection Installation Certificate of compliance

12. List of Components & Material Installation Binder 12. List of Components & Material List of Materials List of Objects List of Supports List of Name Plates Equipment list Valve list Motor list Instrument list Cable list Line-list Pipe Spec Pipe insulation Penetration list, fire, ventilation, radiation Etc.

Installation Binder 13. Reference Documents Sketches Manuals Data sheets Supporting/reference documents, needed during installation

Installation Binder 14. TRR- Test Readiness Review Demonstrate and handover finalized installation to Commissioning Verification / Validation plans state what’s needed! (Functional test, System test, Integrated system test) Output: Quality documentation Installation Certificate of compliance List of outstanding activities and NCRs As built doc:s or Red lined drawings Signed Test Readiness Review