1. ESS Spoke Cryomodules: QA / QC Plans Workshop on Requirements Conformance for SRF Cryomodules, 15 th -16 th October 2014 Denis Reynet, Veronique Poux Sebastien Bousson

2.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 QA / QC Plans for the ESS spoke production Main goal and path: Develop all the necessary tools and documentation to insure a high quality/traceability of the fabrication and assembly of the ESS spoke cryomodule parts. Take benefit of the ongoing prototyping phase to draft and later on modify/correct these tools Once ready, transfer and/or adapt to the overall ESS QA system that will be developed. We started to set our QA/QC plans only a few months ago, the basis is here, but it’s only a start… Based on our past contributions to LHC, SPIRAL-2…

3.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 QA / QC Plans for the ESS spoke production HOW ? Based on the following pillars: A Product Breakdown Structure to list all components, equipments, tooling to be used for the spoke production A detailed life cycle of the components that could also serve as a Work Breakdown Structure to list in details all the production/preparation/assembly/test of the components and associate the required input/output A component identification/naming convention to be able to identify all basic component / assembly

4.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 QA / QC Plans for the ESS spoke production HOW ? Based on the following pillars: A set-up of documentation (procedure, travelers, reports, legal/purchase documents, publications…) to properly insure a reliable, stable, not company or people-dependent quality of production A document management system to insure access, ordering, sorting, traceability of all documentation produced. A configuration table to trace which sub-system is installed in each cryomodule.

5.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 QA / QC Plans for the ESS spoke production Series production ? Number of components: 13 spoke cryomodules 26 cavities, power couplers, cold tuners 13 valve boxes Depending on each personal background, could be considered either as a big series or a small series, but in any case, it deserves a proper QA/QC system !

6. General overview & Component life cycle

7.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule overall life cycle Appro Niobium Fabrication Cavité Traitement surface Cavité Assemblage cavité Salle blanche Test en CV COMPONENT PHASE Export / delivery Test / validation Préparation/ assembly SUpply/ Production NiobiumCavitiesCouplers vessel Vacuum Cryomod. Full. compon.. Cryomod. string Cavity CTS… Transport -> site assemblage Transport -> Fabriquant cavités … … … … Fabrication Enceinte Cryomodule Transport -> site assemblage Appro Compos. cryomodule Transport -> site assemblage Assemblage train cavités Transport -> site assemblage Fabrication SAF Assemblage SAF Test à chaud SAF Transport -> site assemblage Assemblage cryomodule Test à chaud Transport -> Uppsala Fabrication Coupleur Préparation salle blanche coupleurs Conditionn- ement coupleurs Transport -> site assemblage

8.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule detailed life cycle Phase_Name Validation stage -> Go / No Go Stage name (number Phase and stages Names, shapes and colors

9.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule detailed life cycle Names, shapes and colors Requirement Administrative / Contractual Milestone Technical Report Minutes Contractual/legal document Input /Output documents Document type Color convention

10.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule detailed life cycle 1 st example: Niobium production

11.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule detailed life cycle 2 nd example: Cavity production

12.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule detailed life cycle 3 rd example: Cavity preparation

13. Component naming convention (internal IPN Orsay)

14.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule naming convention 1. Project ID: ESS WP4 Cryomodule Spoke = 24A (prototype) 2. Component / Sub-assembly ID: Cavity = 00, Coupler = 01, CTS = 02, Cavity string = 25… 3. Phase ID: Explicit (in french !) A = Supply / Fabrication, P = Prreparation / Assembly T = Test/Validation X= eXport / transport 4. Identification Etape : Lié au Flow chart Deux chiffres à définir par WP Leader

15.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule naming convention 5. Document type ID: PV = Procès verbal (Technical Minutes) RA = Rapport (Report) PR = Procedure DC = Contractual Document TR = Traveller SP = Spécification tech. (Requirement) PU = Publication, Poster 6. Component ID: 2 caracters for company ID 2 digits : rank in the series production Exemple: ZA01 = Cavity #1 from Zanon

16.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule naming convention 24A : ESS project, Spoke cryomodule prototype 00 : Document concerning cavities T : Document linked to the testing phase 35 : stage #35 defined in the life cycle PV : it’s a technical minutes SD01 : Document concerning the cavity #1 produced by SDMScompany 24A-00T35-PV-SD01 For instance:

17. Document Management System

18.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 IPNO organization for ESS contribution Documentation management at IPNO for ESS CATIA V5 + Smarteam EDMS Soon to be replaced by ATRIUM…

19. Product Breakdown Structure (for the prototype)

20.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Spoke cryomodule prototype PBS 7 levels identified PBS Détaillé (03/02/2014) L0L 1L2L3L4L5L6L7L8 ESS CNRS WP4 Fourniture Equiped spoke cryomodule Double Spoke Cavity Magnetic shielding Power Coupler Line Cold Tuning System Assembly Vacuum vessel MLI Thermal shield Supporting rods Cables/wire Alignment devices Instrumentation Inter cavity bellow C/W transition assembly Cryo piping Vacuum devices valves gauge Interface to the ground Jumper Valve Box Toolings Clean room toolings For cavity alone for cavity string For power coupler alone cryomodule assembly tooling surface treatment toolings heat treatment toolings Transport devices cavity transport device coupler transport device cryomodule transport device PLC Hardware Software Coupler conditionning test bench conditionning cavity RF line/equipment Electronics software

21. Document standardization

22.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Document Standardization Production of templates for each document type TemplatesDocuments Procedure for cavity weighting

23.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Example : cryomodule assembly procedure Will be updated and completed with the prototype assembly

24.  S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15 th Oct. 2014 Just a start… A huge work still ahead: Complete the life cycle Complete all procedures Transfer to ESS Properly define all QC procedure - During fabrication (what sampling ?) - During assembly (required instruments ?) Define with ESS how a cryomodule will be considered as validated for installation