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

2. 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)

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

4. 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.

5. 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 …

6. 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 …

7. 13 Reference material Sketches Manuals Data sheets
Supporting/reference documents, needed during installation

8. 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

9. 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

10. 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

11. 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

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

13. 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.

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

15. 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

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

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

18. 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.

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

20. 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

21. 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.

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

23. 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