Overview of PED Compliance Requirements for RFD Crab Cavities Fabrication at FNAL
The process of ensuring PED compliance for RFD crab cavities fabricated by FNAL involves a review of EN and ASME Codes, with additional requirements set by CERN HSE. A formal agreement is being finalized, with a document defining essential safety requirements, risk assessment, and more. Additional requirements include hazard assessment prior to fabrication. The PED compliance agreement for cold masses is nearing signoff, with similar requirements expected for crab cavities. Specific details and progress are outlined in the provided documents.
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PED Compliance Thomas Page Fermilab HL-LHC AUP System Integration Engineer HL-LHC AUP RFD Design Review June 20 - 21, 2018
PED Compliance RFD crab cavities fabricated by FNAL must meet the CERN HSE requirement of being PED (Pressure Equipment Directive) compliant. FNAL and CERN reviewed the EN and ASME Codes to determine the differences in the Codes as it relates to the RFD crab cavities. The ASME BPVC meets most of the requirements but there are a few additional requirements we must meet. A formal agreement between CERN HSE and the HL- LHC AUP will be created to define the additional requirements. This process is in the final stages for the AUP cold mass fabrication. The process for ther RFD crab cavities is not as far along but it is well advanced with only one issue to resolve. HL-LHC AUP RFD Design Review June 20-21, 2018 2
Status CERN is developing a PED Compliance document which defines the requirements for the RFD Crab Cavities. This document applies to all RFD crab cavities regardless of where they are fabricated. The document lists the EN Codes and the ASME equivalent where applicable. In cases where the ASME code is not equivalent, the requirement is listed which typically points to a European Code or Standard. HL-LHC AUP RFD Design Review June 20-21, 2018 3
PED Compliance Document Document can be found in: US-HiLumi-doc-1049. HL-LHC AUP RFD Design Review June 20-21, 2018 4
PED Compliance Document summary TOC PED Essential Safety Requirements Risk assessment Design requirements Materials Manufacturing Inspection and test Traceability Safety file contents (CERN documentation requirements) HL-LHC AUP RFD Design Review June 20-21, 2018 5
Agreement The PED compliance agreement for the cold masses is in final draft, signoff is imminent. The PED compliance agreement for the RFD crab cavities will be very similar. Listed on the next few slides are the additional requirements that are foreseen to be in the agreement. HL-LHC AUP RFD Design Review June 20-21, 2018 6
Additional Requirements Hazard Assessment PED requires a hazard assessment be completed prior to the start of fabrication. FNAL typically completes this as part of the engineering note which gets reviewed near the end of fabrication. US HL-LHC-AUP shall perform a hazard assessment, in the form of a Failure Mode and Effects Analysis (FMEA) for the RFD crab cavities. HL-LHC AUP RFD Design Review June 20-21, 2018 7
Additional Requirements Material: Material for the RFD crab cavities must meet the requirements given in the PED compliance document. AUP plans to order the materials per the CERN specifications. This includes the Niobium, Niobium- titanium and Grade 2 Titanium. HL-LHC AUP RFD Design Review June 20-21, 2018 8
Additional Requirements Weld Inspection The PED compliance document lists the requirements and provides a table of acceptable levels of imperfections. AUP will use the table shown in the document. HL-LHC AUP RFD Design Review June 20-21, 2018 9
Additional Requirements Brazing There are differences between the EN and ASME Codes on the level of inspection for brazed joints: both qualifications and production NDT. Argonne National Lab is currently the source for the brazed joints. They follow the ASME Code. Sample documentation from ANL of the braze procedure, qualification and testing has been sent to CERN for review. The requirements for the braze joints are still under negotiation. Plan: Discuss the brazing requirements with Argonne and see if meeting the EN Codes is possible. Revise procedures as necessary. HL-LHC AUP RFD Design Review June 20-21, 2018 10
Additional Requirements Pressure test The test pressure differs between the EN and ASME Codes for a pneumatic pressure test. ASME: 1.1x MAWP EN: 1.25x MAWP FNAL will adopt the higher test pressure of 1.25x MAWP. HL-LHC AUP RFD Design Review June 20-21, 2018 11
Fabrication and Documentation All other design and fabrication requirements come from the Fermilab ES&H Manual (FESHM) and the ASME Code which is standard practice at FNAL for RF cavities. Cavities will be tested at FNAL so FNAL requirements must also be satisfied. Documentation will be uploaded to the CERN system on a regular basis, TBD. (This is happening for the magnets now.) We will work with Jamie Blowers and CERN HSE to upload all of the documentation. HL-LHC AUP RFD Design Review June 20-21, 2018 12
Summary Progress towards a PED Compliance agreement is well underway. We see no show stoppers in meeting the CERN requirements. RFD crab cavity fabrication will meet both the FNAL and CERN safety requirements. HL-LHC AUP RFD Design Review June 20-21, 2018 13
