Codes & Standards
and
Quality Assurance
M. Ferrari
EFDA Close Support Unit Barcelona
ELE Preparation Project
IL PROGETTO ITER
Giornata di Presentazione del Progetto ITER all’Industria Italiana
Frascati, 19 gennaio 2007 – Villa Tuscolana
1
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
of 25 slides
Outline
• Rules & Regulations in France for
safety and licensing
• Codes & Standards for nuclear
safety
– Pressure Equipment
– Buildings
• Quality Assurance
2
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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ITER Organization
Project Typology
– International collaboration with “inkind” procurement
– “First-of-a-kind” device/plant
3
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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Actors & Responsibilities
• ITER-org (owner, operator)  The User
–
–
–
–
Is the responsible for safety
Ensures quality
May appoint directly qualified & skilled staff
Observes national laws in the fields of public and occupational
health & safety, nuclear safety, radiation protection,
environmental protection,…
• Domestic Agencies (suppliers)
– Procure “in-kind” components & systems according to the
ITER-org technical and quality requirements
– In same case perform design activity based on ITER-org
functional and performance requirements
4
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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Regulation System in France
Licensing, QA
Laws
Radioprotection
Environmental
requirements
Pressure Vessel
Decrees
Orders
Ministerial
Letters
Basic Safety Rules
Design and Construction Rules
Internal Rules and Specifications
of Industry and NPP-Operators
Issued by Safety Authorities
Issued by Industry or NPP-Operators and
approved by Safety Authorities
RCC, IEC, ISO/NF standards,
ASME, ASTM, handling,
electricity,…
5
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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C&S per
ITER
What is the logic?
 Design and safety requirements
 Regulations (IAEA/ICPR  EU  France)
 Essential Safety Requirements (ESRs)
 Available calculation codes, codes and standards
 ITER, according to the procurement sharing and other inputs,
will specify what should be followed to fulfill essential safety
requirements; this will usually be a unique set of C&S for one
component.
 Field Teams in contact with Domestic Agencies will insure that
the final set used by end-supplier complies with ITER
specification
6
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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French Rules & Regulations on PE
ESPN
7
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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ESRs for Pressure Equipment
•
General obligations for manufacturer
– e.g. to carry out hazard analysis incl. reasonably foreseeable misuse
– to establish technical documentation file
•
Design and calculation
– Design for adequate strength
– Take into account sources of hazard, e.g., handling and operation, examination, draining and
venting, corrosion, chemical attack, wear, filling and discharge, exceeding allowable limits, safety
accessories, external fire
•
Manufacturing
– Manufacturing procedures, e.g., preparation of components, permanent joining, heat treatment,
traceability
– Final assessment, e.g., final inspection incl. safety devices, proof test
– Marking and labelling
– Operating instructions
•
•
Materials
Specific requirements
– for fired or otherwise heated pressure equipment
– for piping
•
Specific quantitative requirements (general rule)
8
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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Pressure Equipment
Pressure hazard
ESPN
Cat. IV
Cat. II
Cat. I
Cat. 0
------ PED ------
Cat. III
level N1
ESPN
ESPN
level N3
level N2
0,5 bar
-------- no pressure equipment requirement ---------370 MBq
370 GBq
Nuclear hazard
9
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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C&S for ITER
• Licensing and site specific requirements:
– French regulations and conformity to national laws and EU
directives
– Nuclear or non-nuclear? (nuclear codes developed for fission
reactors)
– Experimental nature of the device (or of some components)
• Technical specific feature of the components
(not addressed by existing codes):
– Basic geometry of components (toroidal geometry, double
shell structure, several geometrical discontinuities, etc.)
– Non-standard manufacturing, inspection and testing
processes
– Special materials
– Specific design loads (type of design loads, experimental
nature of the machine, etc.)
10
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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C&S Activities
• On going activities:
–
–
–
–
–
–
Adaptation of codes to site specific requirement (national laws)
Modification/addition to RCC-MR for ITER VV metallic parts
Technical specifications for ITER VV non-metallic parts
Selection of building code
Implications of using ASME for components installed in Europe
Review of the Structural Design Criteria (SDC) for ITER Magnets
• Short–medium term activities:
– Further development of design criteria for In-vessel Components
(SDC-IC)
– Selection of standard for manufacturing of in-vessel components
– Revision of the code selection for ITER components based on
procurement sharing
– Verify compatibility between different codes
11
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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ASME & Others
• ASME or other codes could not be recognized directly as
conforming to all requirements of European regulations, i.e., as
directly satisfying the Essential Safety Requirements (ESRs)
• Use of ASME or other codes is possible, provided that:
– sufficient evidence is given (by the Manufacturer) of conformance to
ESRs,
– conformance to ESRs is assessed by a Notified Body,
– procedures & personnel for welding and for NDT are approved
according to the European regulations
This means that use of ASME or other codes cannot only be dealt with by
some additional conformity assessment, involving only a Notified Body.
The manufacturer has also to perform some additional tasks, like for instance
welding qualifications according to European rules.
12
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Code Selection
• General strategy for components code selection:
– Minimize number of Codes
– 1 Code for 1 component (or system)
– Minimize number of interfaces where different codes are used
• Vacuum Vessel: the EUPT (EFDA) has proposed RCC-MR with a
specific new addendum
• The Addendum includes some modifications to adapt the code to
the ITER special features and shall be finalised shortly in
accordance with French rules (PED-based & ESPN)
• The Conformity to PED and ESPN is in progress in France:
– RCC-M modification to conform PED and ESPN during 2007
– RCC-MR afterward (date not defined)
13
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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DRAFT - Courtesy by ITER
Classification of ITER Components
WBS
WBS Element
No.
TOKAMAK BASIC MACHINE
Manufacturing Standards
SDC - magnet
ASME, ITER technical spec
EU, JA, RF, US, CH, KO; + FUND
No
RCC-MR + ITER Addendum
SDC-IC
RCC-MR + ITER Addendum
ASME or RCC-MR, ITER
technical spec
ASME or RCC-MR, ITER
technical spec
ASME or RCC-MR, ITER
technical spec
No specific criteria
No specific criteria
ASME
EU, RF, KO, IN
EU, JA, RF, US, CH, KO; + FUND
Yes
No - TBC
EU, JA, RF
No - TBC
1.1
MAGNETS
1.5
1.6
VACUUM VESSEL
BLANKET SYSTEM
1.7
DIVERTOR
SDC-IC
1.8
FUELLING AND WALL CONDITIONING
SDC-IC
2.2
2.3
2.4
MACHINE ASSEMBLY AND TOOLING
REMOTE HANDLING (RH) EQUIPMENT, Hot Cell
CRYOSTAT
No specific criteria
No specific criteria
ASME Sec, VIII Div 2; ASME
B31.3
Sharing of Procurement
Nuclear (ESPN)
Design Code
EU, CN, US; + FUND
Yes
KO; + FUND
EU, CN, JA; + FUND
IN
No
No
No - TBC
No - TBC
2.4bis VACUUM VESSEL PRESURE SUPPRESION SYSTEM
ASME Sec, VIII Div 2; ASME
B31.3
ASME
IN
2.6
COOLING WATER SYSTEM
ASME Sec, VIII Div 2; ASME
B31.3, Cat M
ASME
US, IN; + FUND
Yes
2.7
THERMAL SHIELDS
ASME Sec, VIII Div 2; ASME
B31.3,
ASME
KO
No
3.1
VACUUM PUMPING
ASME
EU, CN, US; + FUND
ASME
EU, JA, KO, US; + FUND
Yes
ASME
EU, IN; + FUND
No
3.2
3.4
5.1
5.2
5.3
5.4
5.5
5.6
6.5
ASME Sec, VIII Div 2; ASME
B31.3,
TRITIUM PLANT
ASME Sec, VIII Div 2; ASME
B31.3, ASME B73.1/B73.2M,
ASME B16.34
CRYOPLANT AND CRYODISTRIBUTION
ASME Sec, VIII Div 2; ASME
B31.3, ASME B73.1/B73.2M,
ASME B16.34
ION CYCLOTRON HEATING & CURRENT DRIVE (IC H&CD) SDC-IC, ASME Sec. VIII, Div 2,
SYSTEM
ASME B31.3
ELECTRON CYCLOTRON HEATING & CURRENT DRIVE
SDC-IC, ASME Sec. VIII, Div 2,
(EC H&CD) SYSTEM
ASME B31.3
NEUTRAL BEAM HEATING & CURRENT DRIVE (NB H&CD) SDC-IC, ASME Sec. VIII, Div 2,
SYSTEM
ASME B31.3
LOWER HYBRID HEATING & CURRENT DRIVE (LH H&CD) SDC-IC, ASME Sec. VIII, Div 2,
SYSTEM
ASME B31.3
DIAGNOSTICS
SDC-IC, ASME Sec. VIII, Div 2,
ASME B31.3
TEST BLANKETS
SDC-IC - new version for TBM
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
LIQUID AND GAS DISTRIBUTION
conventional
No - TBC
ASME, ITER technical spec
EU, IN, US; + FUND
No - TBC
ASME, ITER technical spec
EU, JA, KIN, RF, US; + FUND
No - TBC
ASME, ITER technical spec
EU, JA, IN
No - TBC
ASME, ITER technical spec
ASME, ITER technical spec
ITER technical spec
conventional
No - TBC
EU, IN, JA, RF, US, CH, KO; + FUND
No - TBC
EU, IN, JA, RF, US, CH, KO
Yes
EU
of 25 slides
No
14
C&S for Buildings (1)
The ITER nuclear complex shall be designed and fabricated
according to ITC-C (ITER Technical Code for Civil Works)
fully compliant with Eurocodes
Nuclear Buildings
11 Tokamak Hall & Pit
12 Laydown Hall
14 Tritium Building
21 Hot Cell Building
22 Tokamak Access Control
Structure
23 Radwaste Building
24 Personnel Access
Control Building
Industrial Structures
Operations Buildings
Industrial Buildings
Outdoor Storage
Nuclear Buildings
Staff Buildings
Marco Ferrari – Codici, Standards & QA – Frascati,
19 gennaio
2007
Reserved
Area
for New/Expanded Buildings
Paved Road Way
15
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C&S for Buildings (2)
• ITC-C derived from ETC-C, the Technical Code for
European Pressurized Reactor (EPR) Civil Works
• ETC-C constitutes the code used as base for the
design and for the fabrication of the safety classified
civil-engineering works for EPR
• The design rules for civil engineering structures in
ETC-C and ITC-C are based on Eurocodes approach &
philosophy
• ETC-C and ITC-C may be considered as practice
guidelines on how apply Eurocodes for specific
projects (EPR and ITER respectively)
16
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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Eurocodes
1990:2002
Eurocode: Basis of structural design
2002-04
EN 1990/A1:2005
Eurocode: Basis of structural design (Amendament)
2005-12
EN 1991-1-1:2002
Eurocode 1: Actions on structures -Part 1-1: General actions -Densities, self-weight and imposed loads
for buildings
2002-04
EN 1991-1-2:2002
Eurocode 1: Actions on structures -Part 1-2: General actions - Actions on structures exposed to fire
2002-11
EN 1991-1-3:2003
Eurocode 1 - Actions on structures -Part 1-3: General actions - Snow loads
2003-07
EN 1991-1-4:2005
Eurocode 1: Actions on structures -Part 1-4: General actions - Wind actions
2005-04
EN 1991-1-5:2003
Eurocode 1: Actions on structures -Part 1-5: General actions - Thermal actions
2003-11
EN 1991-1-6:2005
Eurocode 1 - Actions on structures Part 1-6: General actions - Actions during execution
2005-06
EN 1991-1-7
Eurocode 1 - Actions on structures -Part 1-7: General actions -Accidental actions
EN 1991-4
Eurocode 1 - Actions on structures -Part 4: Silos and tanks
2006-05
EN 1992-1-1:2004
Eurocode 2: Design of concrete structures - Part 1-1: General rules and rules for buildings
2004-12
EN 1992-1-2:2004
Eurocode 2: Design of concrete structures - Part 1-2: General rules -Structural fire design
2004-12
EN 1993-1-1:2005
Eurocode 3: Design of steel structures - Part 1-1: General rules and rules for buildings
2005-05
EN 1993-1-1:2005/AC:2005
Eurocode 3: Design of steel structures - Part 1-1: General rules and rules for buildings
2005-12
EN 1993-1-2:2005
Eurocode 3: Design of steel structures - Part 1-2: General rules -Structural fire design
2005-04
EN 1993-1-2:2005/AC:2005
Eurocode 3: Design of steel structures - Part 1-2: General rules -Structural fire design
2005-12
EN 1993-1-3
Eurocode 3 - Design of steel structures - Part 1-3: General rules -Supplementary rules for cold-formed
members and sheeting
(2006-07)
EN 1993-1-4
Eurocode 3 - Design of steel structures - Part 1-4: General rules -Supplementary rules for stainless
steels
(2006-07)
EN 1993-1-5
Eurocode 3 - Design of steel structures - Part 1-5: Plated structural elements
(2006-07)
EN 1993-1-8:2005
Eurocode 3: Design of steel structures - Part 1-8: Design of joints
2005-05
EN 1993-1-8:2005/AC:2005
Eurocode 3: Design of steel structures - Part 1-8: Design of joints
2005-12
EN 1993-1-9:2005
Eurocode 3: Design of steel structures - Part 1-9: Fatigue
2005-05
EN 1993-1-9:2005/AC:2005
Eurocode 3: Design of steel structures - Part 1-9: Fatigue
2005-12
EN 1993-1-10
Eurocode 3: Design of steel structures - Part 1-10: Material toughness and through-thickness
properties
2005-05
EN 1993-1-10:2005/AC:2005
Eurocode 3: Design of steel structures - Part 1-10: Material toughness and through-thickness
properties
2005-12
EN 1993-1-11
Eurocode 3 - Design of steel structures - Part 1-11: Design of structures with tension components
(2006-07)
EN 1993-1-12
Eurocode 3 - Design of steel structures - Part 1-12: Additional rules for the extension of EN 1993 up to
steel grades S 700
(2006-11)
EN 1994-1-1:2004
Eurocode 4: Design of composite steel and concrete structures - Part 1-1: General rules and rules for
buildings
EN 1997-1:2004
Eurocode 7: Geotechnical design -Part 1: General rules
EN 1997-2
Eurocode 7 - Geotechnical design -Part 2: Ground investigation and testing
EN 1998-1:2004
Eurocode 8: Design of structures for earthquake resistance - Part 1: General rules, seismic actions and
rules for buildings
2004-12
EN 1998-3:2005
Eurocode 8: Design of structures for earthquake resistance - Part 3: Assessment and retrofitting of
buildings
2005-06
EN 1998-4
Eurocode 8 - Design of structures for earthquake resistance - Part 4: Silos, tanks and pipelines
Marco Ferrari – Codici, Standards
QA – Frascati, 19 gennaio 2007 Eurocode 8: Design of structures for earthquake resistance Part 5: Foundations, retaining structures
EN &
1998-5:2004
and geotechnical aspects
EUROCODE 1
(2006-07)
2004-12
2004-11
(2006-10)
(2006-07)
2004-11
EUROCODE 2
EUROCODE 3
EUROCODE 4
EUROCODE 7
EUROCODE 8
17
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Quality Assurance
• EFDA, as one of the main contributors to ITER design
and R&D activities, has started the development of a
QA System compatible with licensing requirements in
France
• The structure of this QA system is considered as a
basis for the QA System for the EU-DA
• As one of the ITER organization main suppliers, the
EU-DA will implement a Quality Management System
which main objective is to ensure ITER that the
delivered items fulfill the ITER requirements in the
agreed time, by:
– Controlling the EU-DA internal activities
– Controlling the EU suppliers activities
18
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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QA Regulatory/Legal Requirements
• The reference for QA, for Safety Important Components (SIC),
is given by French law, with the Order of August 10, 1984
concerning ‘Basic Nuclear Installation design, construction and
operation quality’ , and the associated explicatory note that
gives more extensive explanation on its application
• The legal requirements are fulfilled by a QA system that
complies with the rules of IAEA Series 50-C-Q, and the
instructions contained in the related Safety Guides, 50-SG-Q1
to Q14
• IAEA Series 50-CQ is largely equivalent to ISO 9001:2000 with
a limited number of deviations and integrations explained in
the IAEA publication Safety Report- Series No.22 Quality
Standards: Comparison between IAEA50-C/SG-Q and
ISO9001:2000’
19
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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EFDA QA System – Generalities
• A QA documentation for EFDA for ITER related
activities (not approved for implementation) is
available.
• Set of quality documents based on IAEA
Safety series 50-C/SG-Q and
compatible/complemented with ISO 9001
(2000).
• The general structure has been presented to
ITER and other Parties (QA Meeting March
2006)
• All the QA is written on the assumption that
Procurement management for ITER is the
main EFDA (and ELE) process implemented
(no internal design activity is foreseen)
Quality Manual
Organization
Responsibilities
Documentation
& info
management
Non-conf.
management
Resources
management
Procurement
management
Audit &
int. control
Config.
management
20
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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EFDA QA System for Procurement
• The control of the activities of EFDA suppliers (including Associations) is
made through three contractual documents dedicated and tailored for
each contract placed by EFDA to European industry or laboratories.
– The technical specification defines the object of the contract (the
« as specified » configuration of the product)
– The management specification defines the quality requirements
to be met by the supplier.
– The contract defines the commercial and legal requirements and
provisions that are applicable
• These documents are issued by EFDA, reviewed and approved by ITER.
They are tailored according to ITER requirements including quality
classification
• To achieve these requirements, the Supplier shall provide a dedicated
Quality Plan describing the quality provisions it will implement to
perform the work
21
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Technical Specification
• This document collects all the design
input data.
It specifies completely and
unambiguously the product to design
and the details to achieve (preliminary
or detailed design). The technical
specification details the quality
requirements of the product’s design
and defines precisely the deliverables
and their associated documentation.
• For the supplier of the design
activities, these inputs are assumed to
be fully completed and approved.
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
Scope of the supply
Items supplied by ITER
Technical requirements
Functional requirements
Interfaces requirements
Safety and regulation requirements
Environmental requirements
Physical requirements
Operational requirements
Human factor requirements
Integrated logistic support requirements
Product assurance requirements
Configuration requirements
Codes and standards
Verification and approval requirements
Documentation requirements
Identification requirements
22
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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Management Specification
–
–
–
–
Introduction
Subject
Reference and applicable documents
Management requirements
• Responsibilities requirements
–
This document outlines all the
quality requirements of the design
process management.
The purpose is to ensure that all
personnel involved in the
procurement process use the
same management rules and to
allow the EFDA Work Package
Manager to monitor properly the
contract.
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
The bidder shall identify the different organizations involved to perform the
contract and detail the breakdown of responsibilities.
•
Project management
•
Work plan
•
Resources requirements
•
Non-conformance requirements
–
–
–
–
Frequency and location of the progress meetings
Content and frequency of the progress report
Sequences of the work, milestones, key points, reviews,
Work Breakdown Structure (WBS)
–
–
Specific training for personnel
Specific qualification for particular operations
–
Transfer to EFDA non-conformance report before any actions for all major
non-conformances
Communicate to EFDA the list of all the non-conformances and the
associated actions on a regular basis
–
•
Change and configuration requirements
•
•
Time schedule requirements
Information and documentation requirements
•
Risk management
•
Procurement requirements
•
Assessment and validation requirements
•
Acceptance and delivery requirements
–
Ensure changes are approved by EFDA before any implementation.
–
–
Language to use
List of the documents and records to be issued and controlled
–
Preliminary risk analysis
–
–
–
–
–
–
Evidence of effectiveness of the subcontractor quality system
EFDA approval of the proposed suppliers or subcontractors
Signature and dating of progress reports for each completed operation
Issue and up-dating of a conformity matrix
Review of the documentation (Acceptance Data Package) to be provided
Provide a formal Contractor Release Note
23
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The Quality Plan as a tool
for QA implementation
• The Supplier shall be requested to provide a Quality Plan indicating
how the requirements set in the Management specification are
actually fulfilled
• At the tender level, the bidder shall provide a meaningful summary of
the overall content of the final Quality Plan. This Quality Plan is one
criterion of the bid assessment. In response to the management
specification, it describes the quality disposals that the bidder will
implement for the work.
• The content of the Quality Plan depends on the nature and criticality
of the work (including quality classification).
• Guidance notes will be sent to the bidders in order to help them to
issue their Quality Plan according to the work to be performed:
–
–
–
–
–
–
Quality
Quality
Quality
Quality
Quality
Quality
management
management
management
management
management
management
in
in
in
in
in
in
Design contracts
R&D contracts
Manufacture contracts
Integration contracts
Test and Acceptance contracts
Construction contracts
• The compliance with the Quality Plan shall replace certifications and
shall be limited to the actual part (division, department, workshop,
laboratory) of the Industry that is performing the work.
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
24
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Conclusion on QA
• No specific problem appears in the implementation of
QA procedures compatible with lTER actual
requirements
but
• The ITER QA documentation shall be progressively
complemented with a series of internal standards and
codes of practice reviewing and integrating
documents like
–
–
–
–
–
CAD Manual
Vacuum Handbook
Remote Handling Manual
Radiation Hardness Manual
Etc..
25
Marco Ferrari – Codici, Standards & QA – Frascati, 19 gennaio 2007
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