A Quality and Technology Network
ISQ
Potencial involvement on ESS
and the CERN experience
Instituto de Soldadura
e Qualidade
José Oliveira Santos
29 January 2009
 1. ISQ
 2. Services
 3. ESS – Vision
 4. Objectives and Motivation
 5. Strategy
 6. ISQ Participation @ the LHC Project
 7. Other Projects
 8. The Future
Technological Development, Quality and innovation since 1965
1. ISQ – Instituto de Soldadura e
 Privately
owned, non-profit technical and scientific
Qualidade
organisation
 Founded in 1965 as Welding Institute
 Around 1000 co-workers in Portugal and 500 abroad
 Operating in more than 20 countries
 Turnover (2009)
– ISQ Group: 80 M€ (49% abroad)
– ISQ : 62 M€
 Accumulated investment in R&D during the last 10 years:
55M€
 Headquarter:
– Total Area: 40 000 m2
– Covered Area: 15 000 m2
 Activity and services in technical areas covering a wide
range Industrial Activities
2. ISQ – Services
 Non Destructive Evaluation
 Testing Engineering and Performance
 Thermodynamics, Materials, Mechanical testing, Electromagnetic
Compatibility and Finite Element Modeling
 Production Technologies (welding and brasing)
 Project Revision and Follow Up
 Quality Assurance : QA/QC
 Technical Inspections
 Health and Safety
 Maintenance and Structural Integrity
 Risk Based Inspection : RBI
 Metrology
 Training
 Research and Development
 ...
3. ESS - Vision
 ISQ strategy as proved that scientific international
cooperation projects are profitable by themselves and provide
the levering for technological developments that allow to enter
new business markets producing simultaneously a marketing
effect capable of generating business on the traditional markets.
-Some examples in ISQ recent history include: CERN, ESO,
ESA, CNES/ARIANSPACE, FLPP, E- ELT, CHERNOBYL
Opportunities:
 Visibility of ISQ as an R&D partner for industry solutions
 A market per si.
 An outstanding and unique opportunity to be present at the
development stage of new technological solutions that can
place ISQ as a market leader in particular segments of industry.
4. Objectives and Motivation
Development of new Non Destructive
Evaluation and Production
Technologies Solutions
ISQ as an international reference, helping on the
Internationalization strategy – based on services
of high value and technologically unique.
Development of Test procedures for
the qualification of new Materials and
new usage conditions for known
materials
Placing ISQ as an engineering and testing
house for the Automotive, Aero and Nuclear
Industries
Participation, as third party, in the
Quality Assurance / Quality Control of
Mechanical and Electrical
Components and Assemble
Marketing of ISQ image, allowing a different
approach on the international market of big Oil
and Gas and Public Works
Create “critical mass” to enter a new
business area in the “nuclear” field
Positioning ISQ towards an industry that has
never emerged in Portugal, but that can be
decisive on the Internationalization strategy in
Spain, Brazil, Emirates, China, etc...
5. Strategy
Benchmarking the services provided at CERN
Benchmarking the
CNES/ARIANSPACE
QA/QC
services
provided
at
 Collaboration with the Portuguese Scientific community
allowing mutual interest development of competences and
positioning in the market
 To act as service integrator for Portuguese SMEs that can
integrate consortium's led by ISQ
6. ISQ Participation @ the LHC Project
Introduction
Start – September 2001
End - 2007
Inspectors
– Integrate a CERN Project Team
– Training period in the beginning
– Inspections activities coordinated
by the Project Team
Number of inspectors from 16 till 26
6. ISQ Participation @ the LHC Project
General Framework
CERN
– Assures technical management of Inspectors
– Programs Inspector’s activities
ISQ
– Manages inspector logistics, travels, visas,...
– Provides technical support to inspector
Working with CERN engineers, ISQ inspector’s functions are:
– Follow manufacturing at suppliers or onsite (installation)
– Incoming reception of materials at manufacturer
– Attend tests according to ITP and at random
– Report and follow-up of non conformities
– Facilitate interface CERN- Manufacturer
– Prepare or supervise the preparation of Travelers at manufacturer
– Reporting to CERN Engineers
6. ISQ Participation @ the LHC Project
Inspections – personnel and locations
6. ISQ Participation @ the LHC Project
Inspections – activities and personnel
6. ISQ Participation @ the LHC Project
Contract Management
Inspector’s selection and allocation
– Competence
– Communication skills
– Integration: CERN, manufacturer, country
– Long term expatriation
Multi locations project
– Legal issues
– Logistics
Personal inspector support
Overall coordination
– Resources
– Project development
– Contractual reports
– Budget control
– Inspector’s performance
6. ISQ Participation @ the LHC Project
Project Outcome
TECHNICAL
Management
New equipment expertise:
– SC Cables
– Magnets
– Vacuum
– Cryogenics, …
New experience and knowledge
– Large scientifi c projects
– High tech project
Important reference for similar
international projects
– SC Cables
– Magnets
– Vacuum
– Cryogenics,
– ITER
Data Management Process
International Environment
Financial
7. Other Projects - Engineering
 1. Study of new Non Destructive Examination Methodologies on
the Poloidal Field Superconductor Jacketing
 2. Qualification of a Non Destructive Examination Solution based
on Automatic UT (Phased Array) for the Toroidal Field Case Closure
Welds – Austenitic materials with high thickness and variable
geometry.
 3. New methodologies for the control of the brasing between
terminations of the superconductors junction (Coper-Coper)
 4. Welding technology and Non destructive Examination training
for F4E
7.1 Other Projects - Engineering
Study of new Non Destructive Examination Methodologies on the
Poloidal Field Superconductor Jacketing
ITER Magnet System
WORK PERFORMED
18 Toroidal Field (TF) coils
Central Solenoid (CS)
 Conventional Radiography with high
sensitivity films
6 Poloidal Field (PF) coils
 Computed Radiography
18 Correction Coils (CC)
 Computed Tomography
H
1
H
2
7.1 Other Projects - Engineering
Flaws
Notch 1
Notch 2
Notch 3
Notch 4
Notch 5
Hole 1
Hole 2
Conventional
Radiography
Detected
Detecte
d
Detected
Detected
Tough
Shallow
Detecte
d
Detecte
d
Computed
Radiography
Detected
Detecte
d
Detected
Detected
Shallow
Detecte
d
Detecte
d
Computed
Tomography
Detected
Detecte
d
Detected
Detected
Detected
Detecte
d
Detecte
d
7.2 Other Projects - Engineering
Qualification of a Non Destructive Examination Solution based on
Automatic UT (Phased Array) for the Toroidal Field Case Closure
Welds – Austenitic materials with high thickness and variable
Receive
Transmitter
geometry.
r
Squint angle
2
0<Z<25
0
Vertical scanning
7.2 Other Projects - Engineering
Qualification of a Non Destructive Examination Solution based on
Automatic UT (Phased Array) for the Toroidal Field Case Closure
Welds – Austenitic materials with high thickness and variable
geometry.
7.3 Other Projects - Engineering
New methodologies for the control of the brasing between
terminations of the superconductors junction (Coper-Coper)
7.3 Other Projects - Engineering
New methodologies for the control of the brasing between
terminations of the superconductors junction (Coper-Coper)
7. Other Projects – Quality Assurance
and Inspections
 QA/QC EFDA
As a result of a collaboration with IPFN, ISQ as placed in EFDA a coworker at the position of QA/QC.
This co-worker has latter changed from EFDA to F4E where he
maintains the same responsibilities, being the the representative of
Quality Assurance at Fusion for Energy
7. Other Projects – Quality Assurance
and Inspections
ESO (European Organisation for Astronomical Research in the
Southern Hemisphere)
Quality Audit of Cryostat Production (for VLT) : 2007
Scope
•Review of ESO relevant documentation
•Definition of Audit scope (objectives, responsibilities, processes and
documentation to be audited)
•Definition of Audit requirements according to the project reference
documentation
•Audit at suppliers premises
•MoM issuing
•Final Audit report issuing (audited processes, personnel contacted,
documentation reviewed, non-conformities, improvement
opportunities)
7. Other Projects – Quality Assurance
and Inspections
ESO (European Organisation for Astronomical Research in the
Southern Hemisphere)
Quality and Product Assurance to the E-ELT Project – 2010 -...
E-ELT - European Extremely Large Telescope, is a revolutionary new
ground-based telescope concept that will be 42 metres in diameter
and will be the world's biggest eye on the sky.
Scope
• Review of ESO PA and QA manuals and procedures in the context
of the various ESO contracts with particular attention to issues that
may become cost drivers.
• Provide a list of suggested modifications to ESO standards
• Review of requirements of the technical specifications in the light of
the quality and product assurance matters
• Review of documentation generated by suppliers
• Reporting to E-ELT project office.
7. Other Projects – Quality Assurance
and Inspections
ESA
GSE & Ground Units Certification in the context of ESA Programs
Scope
Conformity assessment of the ground units that can be used in
different countries (amongst others, France for the Guyana Space
Centre, the USA for the Kennedy Space Center and the Vandenberg
Air Force Base, and Russia for the Plessetsk and Baykonur
Cosmodromes), including:
Listing the systems prone to risk covered in the study and analysing
the regulations of the countries in which these systems may be
implemented,
Cross-analyses of regulations
Definition of certification processes
Specifications drawn up for the various types of ground equipment
and units used by the ESA.
Activities
Consulting
7 Other Projects - Testing
ESA
Consultancy (Technical Assistance) to ESTEC
RESIDUAL STRESS MEASUREMENTS IN WELDED Ti ALLOY PLATES
SUPPORT TO THE METROLOGY LABORATORY ON THE
ACCREDITATION IN ROUNDNESS MEASUREMENTS - Support to ESTEC
Metrology Laboratory on its accreditation with ISO 17025 in roundness
measurements.
FATIGUE TEST OF THREADED A2-70 SIZE M5 FASTENERS - To present a
test program to establish the fatigue strength of “cheese head” M5 size,
fasteners made of A2-70 austenitic stainless steel, according to DIN912.
Scope
Laboratory measurements and measurement tools development;
Consultancy on metrological technology, procurement, equipments
maintenance, installation support and procedures;
Procedures development
Training in specific measurement techniques;
Feasibility Assessment;
7 Other Projects - Testing
Alcatel-Alenia Space: Re-entry simulation test on metallic TPS
To perform several cycles simulating the re-flight of a reasonable re-entry
system.
The tests will be performed in test articles with a maximum temperature on
the test article of 900ºC, with pressure variable from 5hPa up to ambient
pressure.
Data will be gathered from 19 thermocouples, 6 displacement sensors and 1
pressure sensor.
7 Other Projects - Testing
SNECMA PROPOLSION SOLIDE – Windward and Nose C/SiC Assembly
Tests
IXV program is an ESA program, which aim is to study the atmospheric re-entry with a vehicle
named
Intermediate eXperimental Vehicle. Snecma Propulsion Solide is responsible for the Windward
assembly and the Nose assembly
Scope
Mechanic and thermal characterisation of the attachment system:
Mechanical test on the MACOR washers
Mechanical characterization of the standoff
Characterization of the screw with a constant temperature
Thermal characterization
Insulation Tests
Elementary insulation characterization
Insulation interface thermal characterization
Engineering test
thermomechanical characterizations
Insulation stack-up thermal characterization
7 Other Projects - Testing
Thales Alenia Space: FLPP- Future Launchers Preparatory Program
Period 2 Step 1 Cryogenic Upper Stages Technology - CUST 1.1 – In
Progress
Scope
• Test Campaign Definition and Planing
• Test Procedures and Facility Set-up / Test Execution
• Raw Materials and Technology Process Samples
• Mechanical tests
• Thermal tests
• Modal Survey on Full Scale Panel
• Sinusoidal and Random Tests on Full Scale Panel
7 Other Projects - Testing
AIRBUS
EMOC Coupons Tests – in Progress
As part of the Multi Disciplinary Optimised Wing Project WP3.2.1.4, this test campaign
is being carried out to understand the effect of absorbed moisture on composite
materials (EMOC). These tests will provide preliminary information on the effect of
absorbed moisture temperature on strength.
Specimens will undergo environmental conditioning prior to testing and be subject to
strict environment control. The tests themselves will also be carried out across a range
of temperatures.
Scope
• In plane shear tests
• 90º tension tests
• 0º compression tests
• 90º compression tests
• Open hole compression (OHC)
• Filled hole compression (FHC)
7 Other Projects - Nuclear
 Welding Inspection during the fabrication of piping for the French
Nuclear reactor RES – Project launched by the French partner
APAVE
Welding Inspection during the fabrication of piping for the French
Nuclear reactor Flamanville 3 – AREVA EPR - Project launched by
the French partner APAVE
 Non Destructive Examination, performed by ISQ Spain, for
Tecnatom, during the periodic shut-downs of Spanish Nuclear
Facilities in Valencia
8. The Future
 ISQ will maintain its strategy establishing it self as a partner for
research and development during the engineering phase.
 Following the first step, ISQ will approach the industry main
contractors in the perspective of the technology transfer
 Collaboration with the owner of the installation shall try to
encompass services as technical inspections (on mechanical
construction and electrical facilities) and 3rd party Quality Assurance
 Act as a National SME integrator in multi-disciplinary projects that
involve competences not available in-house.
Instituto de Soldadura
e Qualidade
A Quality and Technology Network
ISQ
2010