Quality Assurance Overview Ranko Ostojic 12 Nov 2012

Quality Assurance Overview Ranko Ostojic 12 Nov 2012

Outline • • • Mandate Basic principles Organization Documentation Summary

Long Shutdown 1 F. Bordry SMACC: J-Ph. Tock Open/Close IC & DN 200 A. Musso - Opening/ Closure of IC Partial and complete W bellows & ther. shields - Installation of DN 200 Special interventions N. Bourcey - Cryomagnets exchange - Connect. Cryostat cons. - PIMs - Specific issues - Heavy NC Main arc splices consolidation F. Savary - Sleeves cutting - Splice de/resoldering - BB surfacing - Shunt installation TIG welding S. Atieh ELQA K. Dahlerup - Orbital & manual - Continuity - HV test DFBA A. Perin Quality Assurance R. Ostojic - Electrical QC: C Scheuerlein - Welding QC: JM Dalin - Beam vacuum QC: C Garion - Open/close IC QC: D Bodart - QA support - Splices and BB Leak Tests P. Cruikshank - Beam lines - Cryogenics lines - Insulation vacuum Project Office M. Pojer - Radiation protection - Safety - Access - Coordination with Survey, Instrumentation, Transport, LS 1 planning, QPS, cryogenics, … Test teams on a chain of IC - Reporting tools

Quality Assurance: Mandate • Coordinate the QA activities linked to the consolidation of superconducting magnets and circuits during LS 1, especially: – – – QC of the main splices (including those in the DFBAs) TIG welds QC Beam vacuum QC Opening and closure of interconnection QC Electrical Quality Assurance Leak testing • Ensure that an adequate level of QA is applied, especially in terms of documentation and traceability. • Ensure a timely management of the non-conformities, minimizing the impact on the overall schedule. • Ensure that production parameters are analysed in time to give an early warning in case of drift. • Identify as early as possible critical issues that could jeopardize the consolidation work. • Report to the SMACC Project Leader, to the LS 1 Project Leader and when necessary, to the LHC Machine Committee (LMC).

Quality Assurance: Basic Principles • • • Independence Flexibility Simplicity and clarity of criteria Continuity of activities Interaction and communication with production teams and project coordination

Quality Assurance: Organization Production Inspections Actor: Operators and supervisors Level: Interconnection Documents: MIP for each activity CERN Audit Quality Control Actor: Team of experienced CERN staff Level: All Documents: MIPs, QCPs, CERN rules Actor: QC team Level: Interconnection, Subsector Documents: QC Procedures QA Team Actor: QA team Level: All Documents: MIPs, QC Procedures Actions: • • • Review and decision on NCs and border-line cases Follow-up of audits and production trends Follow-up and timely completion of production and test reports and MTF entries

MIPs and QC Procedures • MIPs and QC Procedures are fundamental documents for all production and QC activities. • Prepared by responsible teams, circulated to all relevant experts, and approved by SMACC Project leader and LS 1 Project leader. • Documents to be used in the tunnel by trained (but non-expert) staff: – Concise and simple wording – Step-through sequence – Unambiguous criteria and clear report – Unique naming convention

QC Procedures - Status • Procedures and criteria for QC of 13 k. A splices and shunts are the result of extensive testing since S 34 reinstallation and have been fully validated in 2012. The core element of these procedures are the resistance measurements at RT (R 8/R 16), which are considerably more reliable than mechanical and visual inspections. The procedures are under approval. • Procedures for mechanical, welding and vacuum QC are based on the experience of LHC installation. Updated documents have been circulated and reviewed and are ready for approval. • ELQA at RT will follow the testing procedure and criteria developed for the last shutdowns. Updated documents are ready for approval.

Supporting Documents • An effort has been made in 2012 to update all relevant documents with the latest data, and to document design and other margins assimilated in the acceptance criteria so that NCs and border-line cases can be treated coherently and on time. • A structure containing all relevant documents is being setup as part of SMACC-WBS.

Summary • The QA for SMACC relies on the production teams, on the QC team, and a team of CERN auditors. In addition to accumulated experience in tunnel work, they all base their activities on a set of QC Procedures, which are well understood and their methods thoroughly validated. • The quality of LHC electrical interconnects is known to be non-uniform, and a number of NCs and border-line cases are expected. These will be treated coherently and on time by the QA team. • Feedback to the production teams on the significant deviations will be reported promptly by the QA team. If necessary, some acceptance criteria may be modified following the experience of the first LHC sector.