APPLICATION OF EDMS TO XFEL CRYOMODULE ASSSEMBLY AT CEA Christelle CLOUE - Catherine MADEC.

APPLICATION OF EDMS TO XFEL CRYOMODULE ASSSEMBLY AT CEA

Christelle CLOUE - Catherine MADEC

XFELX-Ray Free-Electron Laser

QUICK OVERVIEW

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i r f u

yalcas

i r f u

yalcas

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yalcas

http://www.mi.infn.it/indexIT.shtml

http://www.su.se/english/

http://www.uu.se/

http://www.portal.pwr.wroc.pl/index,242.dhtml


GOAL OF THE ASSEMBLY OF CRYOMODULES

To assemble 100 accelerator cryomodules with a throughput of 1 per week !

operated by an industrial contractoron the Saclay site and CEA infrastructures

with CEA supervision

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CRYOMODULE MBOM

In the process of assembling cryomodule, it is mandatory for traceability to gather, record, process and archive the complete configuration and fabrication information for each cryomodule

MBOM

The MBOM also includes inspection to be performed, the tests to be recorded, the assembly procedures etc... The XFEL cryomodule MBOM contains roughly 500 lines

It uses DESY’s Engineering Data Management System (EDMS).

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EXAMPLE : XM-2 MBOM

The MBOM defines how a specific part type (fabrication part) is produced and from which components.The part gets fabricated in a physical part and assembled to other physical parts to form one cryomodule. This is recorded in the Bill of Material

BOM

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EXAMPLE : XM-2 BOM

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EXAMPLE : NON-CONFORMANCE REPORTS


EXAMPLE : PHYSICAL PARTS


DEDICATED ASSEMBLY BUILDINGS

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XFel Village ~ 1350 m2

3

2

46

5

Bldg 124 North25x15 m²

Bldg 126 North40x11 m²

7

Bldg 126 South 30x17 m²

8

1

CourtYard

6

©GoogleMap

Clean rooms

Assembly halls

Offices

Warehouse


WORKSTATIONS IN ASSY HALLS

the XFEL VillageShipment

Area SH-WS1 & 2

Warehouse

Reception AreaREC-WS1

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Clean room Area

CO-WS1 & 2SA-WS1 & 2

Alignment Area AL-WS1 & 2Roll-out AreaRO-WS1 & 2

Coupler Area CO-WS1 & 2

Cantilever Area CA-WS1


ORGANISATION WITH ALSYOM

Alsyom has been subcontracted to assemble the 100CM under the supervision of CEA. For all exchanges, Cea-Alsyom shared folders

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TRAVELER 1/2

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Cryomodule reference:

Task # Task identification GOM Reference GOM Version Date Operators Report File reference FAQ NCR Comments / Main results

Couplers Reception (ISO5-REC-WS)

Other Components Reception (REC-WS)

Cavities Reception (REC-WS + ISO5-REC-WS)

ISO4 Entry

Coupler & Cavity Assembly (ISO4-CC-WS)

ISO4-CC 1 Couplers pumping, leak test, ventingASS_CR_26_Coupler venting for coupler cold part assembly

06/01/14LE GOFF M. / LECUONA T. / CHATILLON F.

QR_LC2_CCP THRI-CP315 - THRI-CP394_140107.xlsx

ISO4-CC 2 Cavity positioning on coupler assembly stationASS_CR_19_Cavity positioning on coupler assembly station

06/01/14 LE GOFF M. / LECUONA T.

ISO4-CC 4 Cavity pumping and venting ASS_CR_25_Cavity venting for coupler cold part assembly, n=[1;8]

06/01/14LE GOFF M. / LECUONA T. / CHATILLON F.

QR_LC2_CAV_FE00556_140107.xlsx

ISO4-CC 3 Cleaning of parts ( screw, nuts, washer…)ASS_CR_28_Cleaning procedure of parts (screw, nuts, washers)

ISO4-CC 5 Coupler cavity cold part assembly ASS_CR_36_Coupler cold part assembly

ISO4-CC 6 Leak check and RGA of the assemblyASS_CR_27_Leak check and RGA of cavity and coupler cold part assembly

08/01/14 LECUONA T. / BOULCH C.QR_LC-RGA_CCC556_140108.xlsxRGA_CAV556_140108 .png

ISO4-CC 7 Cavity positioning on string assembly stationASS_CR_18_Cavity positioning on string assembly station

05/02/14 LECUONA.T / LE GOFF.M

ISO4-CC 27 Couplers pumping, leak test, ventingASS_CR_26_Coupler venting for coupler cold part assembly

07/01/14LECUONA.T / LE GOFF.M / CHATILLON.F

QR_LC2_CCP THRI-CP315 - THRI-CP394_140107.xlsx

TRAVELER CLEAN ROOMXFEL

AR_XM4_CCC556_140108.xlsx08/01/14 LE GOFF M. / LECUONA T.


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Task # Task identification DateProd.

Control point

Alsyom

Quality Control

point Alsyom

Doc. control point CEA

Hold point CEA CEA Comments

Couplers Reception (ISO5-REC-WS)

Other Components Reception (REC-WS)

Cavities Reception (REC-WS + ISO5-REC-WS)

ISO4 Entry

Coupler & Cavity Assembly (ISO4-CC-WS)

ISO4-CC 1 Couplers pumping, leak test, venting 06/01/14 X NOK TRUBLET T.Valeur de pression avant d'ouvrir

la vanne en rouge (TT)

ISO4-CC 2 Cavity positioning on coupler assembly station 06/01/14

ISO4-CC 4 Cavity pumping and venting 06/01/14 X X OK BOULCH C.

ISO4-CC 3 Cleaning of parts ( screw, nuts, washer…)

ISO4-CC 5 Coupler cavity cold part assembly

ISO4-CC 6 Leak check and RGA of the assembly 08/01/14 X X OK BOULCH C.

ISO4-CC 7 Cavity positioning on string assembly station 05/02/14

TRUBLET T.OKX08/01/14

XM4XFEL

Validation CEAValidation Alsyom

TRAVELER 2/2


FAQ (FICHE D’AMÉLIORATION QUALITÉ) / NCR (NON CONFORMITY REPORT)

All non-conformities are generating a FAQ which is processed internally (Alsyom/CEA). The CEA area manager decides if it needs to escalate to NCR through EDMS.


DECISION PROCESS FOR NON CONFORMITY

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QUICK DECISION PROCESS FOR NCR

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NON-CONFORMITY PROCESSED ON EDMS (1/2)

After the processing of the NCR on EDMS, the corrective and preventive actions should be filled


NON-CONFORMITY PROCESSED ON EDMS (2/2)

Reference : CEA-XFEL-RNC-13-103-1

Page : 1

Date : 17/06/2013

Physical Part EDMS-ID :

Fab. Part Name : Fab. Part EDMS-ID : D00000000583027 Physical Part Serial No. XM-2_CMS

Recorded by : Location :

TITLE :

Reference documents :

Minor : Action on Part :

Major : Documentation :

Clearance for actions

Unit responsible for involved product :

Accelerator Consortium Manager :

Date : 09.10.20xx Reviewer :

Date : xx.xx.20xx Reviewer :

Date : xx.xx.20xx By : VISA :

DESCRIPTION :

PREVENTIVE ACTIONS (on Fabrication Part, or Equipment) : Responsible (s)

Change tooling used in SA WS (torque wrench) to prevent to hit bellows during the string assembly S. BERRY / M. MBELEG3

X

The Coordinator can fill-in the names of reviewers/approver(s), but does not have to because they are listed in the "History", or on the "Reviewer/Approver" tab (names might change there).

The Coordinator can fill-in the names of reviewers/approver(s), but does not have to because they are listed in the "History", or on the "Reviewer/Approver" tab (names might change there).

2nd distribution:

Use As Is

1st distribution :

CEA XFEL Rollout Area

Quality ManagerFabrication Engineer (Technical Manager) Project Manager (WPL)

Responsible (s)

During operations in Roll Out WS, some dents have been observed on cavity bellow between cavities in position 1/2 (see Picture 1), and on cavity bellow between cavities in position 7/8 (see Picture 2).

TECHNICAL INVESTIGATIONS :

Shocks probably generated during string assembly operations (bellows connections on cavities)

C. Cloué O. Napoly

Closing :

NON CONFORMANCE REPORT

XM-2_CMS: Cold Mass + String

C. CLOUE / P. PLUVY

Dents on cavity bellows between cavities 1/2 and cavities 7/8

Enter either the "Physical Part EDMS-ID" , or the "Fab. Part Name" + "Fab. Part EDMS-ID" + "Physical Part Serial Number" .

S.BERRY

CORRECTIVE ACTIONS (on Physical Part, or Equipment) : Responsible (s)

NA S.BERRY

CATEGORY : FINAL DECISIONS :

A. MATHEISEN, L. LILJE

The NCR document is uploaded on EDMS which is used for coordination, review and approval of the its content, namely description of the NC, its corrective and preventive actions.

Reference : CEA-XFEL-RNC-13-103-1

Page : 2

Date : 17/06/2013NON CONFORMANCE REPORT

CONTINUATION SHEET

Picture 1 Picture 2


HOLD POINTS (1/2)

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Task # Task identification DateProd.

Control point

Alsyom

Quality Control

point Alsyom

Doc. control point CEA

Hold point CEA CEA Comments

String Assembly (ISO4-SA-WS)

ISO4-SA 14 Cavity 7 - 8 assembly 26/02/14 X OK TRUBLET

ISO4-SA 3 Qpole unit positioning 26/02/14

ISO4-SA 4 Qpole unit alignment 26/02/14 TRUBLET

ISO4-SA 15 Qpole unit venting 26/02/14 X OK TRUBLET

ISO4-SA 16 Qpôle unit to string cavity assembly 27/02/14 X X OK TRUBLET

ISO4-SA 17 Final leak check cavity string 28/02/14 X X OK TRUBLET

ISO4-SA 18 Distance adjustment 28/02/14 X

ISO4 CTRL 1 Cavity string outgoing inspection 28/02/14 X X NOK TRUBLET

ISO4 CTRL 2 cavity string roll out 28/02/14 OK TRUBLET

TRUBLETXISO4-SA 17 RGA verification OK

XFEL

X

XM4

Validation Alsyom Validation CEA

28/02/14

Time when CEA is inspecting both the documentation and the module and authorized to proceed to the next assembly steps.


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1

2

Part PP Serial No

Part 1 XM4

Template_QR_MecTest1_XMn_STR_yymmdd_V2

General Information (for protocol upload)

Part Information

CEA XFEL String Assembly Area in ISO4 Cleanroom

Project

Team Folder

D00000000572107

Document Type:

Mecanical CheckTeam

Manufacturer Name Commissar. À l'énergie atomique

Manufacturer ID FRA-CEA-SAC

Location

XFEL_WP03_Alsyom

XFEL_WP03_Alsyom_Team

1_STR

Check Report: Mechanical Test on Cavity String before Roll-Out

Fabr. Part Name

STR: Cavity String

Fabr. Part EDMS ID

Cavity 1 Cavity 2 Cavity 3 Cavity 4 Cavity 5 Cavity 6 Cavity 7 Cavity 8

17 626 607 556 597 606 621 592 594

18 337 382 394 315 366 399 349 213

19 077 071 096 052 069 079 067 086

20 OK OK OK OK OK OK NOK NOK

21 OK OK OK OK OK OK OK OK



Numéro de série des coupleurs THRI-CP-

CAVITES

Vérifier que les cavités sont bien posées sur les posts côté coupleur :

Vérifier que le système de maintien du tube He est bien fixé :

Vérifier que les tiges filetées ne sont pas débouchantes :

Vérifier que les cavités sont bien posées sur les posts côté opposé coupleur :

Numéro de série des cavités : CAV_FE00

Numéro de série des soufflets : FEL VB1 000002-

HOLD POINTS (2/2)


C. Madec | SRF13-THIOA02 | 26/09/2013

FURTHERMORE ….. PED :

Welding documents : commments from Lars HaggeA script extracts the files (conformance report from manufacturer or WP – already on EDMS) related to the physical parts that are installed and are parts of the PED

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Titre | Date

DSM

Irfu

SACM

LIDC2

Commissariat à l’énergie atomique et aux énergies alternatives

Centre de Saclay | 91191 Gif-sur-Yvette Cedex

T. +33 (0)1 69 08 69 39

Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019

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Thanks for your attention


EXAMPLE OF ASSEMBLY PROCEDURES

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APPLICATION OF EDMS TO XFEL CRYOMODULE ASSSEMBLY AT CEA Christelle CLOUE - Catherine MADEC.

Documents

ncr page

conformity page

cea supervision page

assembly buildings page

cryomodule assembly

xfel cryomodule mbom

ceaalsyom shared folders

bill of material bom