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(M9) Engineering
Contractor Assurance

​​​​​​​​​​​​​​​​​​​Management System Owner: Chair, Engineering Advisory Committee

Revision and Date: ​Revision 1.3 - June 21, 2018

1.0 Purp​​​ose

The purpose of the Engineering Management System is to provide consistency to engineering systems, practices, procedures and processes at Fermi National Accelerator Laboratory (FNAL) in order to minimize risk to Fermilab's mission by assuring that engineered components, sub-systems and systems meet specifications, functionality and laboratory requirements. The Engineering Management System consists of a set of documented policies, procedures and processes that are used to plan and carry out engineering design, testing, validation and acceptance, and release to operations of components, sub-systems or systems.

2.0 Roles and Responsi​​bilities

The roles and responsibilities for the Engineering Management System are as follows.

Title Responsibilities
Chief Laboratory Officers
  • Responsible to Laboratory Director for implementing the Laboratory-level requirements for engineering standards and configuration control within their respective Sectors; for ensuring that adequate resources are provided; and for holding their direct reports accountable for their performance.
Division/Section/Project (D/S/P) Heads
  • Line management responsibility for ensuring that engineering processes and expectations are promulgated within their organizations and that engineering design processes are followed.
Department Heads, Group Leaders, Engineering Supervisors
  • Line management responsibility for ensuring that engineering processes and expectations are promulgated within their organizations and that engineering design processes are followed.
Project and System Managers
  • Responsible for ensuring that tasks are completed using good engineering and quality-control methods.
Engineering Employees
  • Responsible for carrying out engineering design activities in accordance with engineering design processes, policies, procedures and standards.
Engineering Management System Owner (MSO)
  • Lead the development, deployment and execution of the Engineering Management System
  • Incorporate advice from the Engineering Policy Committee (EPC) on revisions to the Management System, and execution of the engineering design processes.
Engineering Advisory Committee
  • Advises the laboratory Director on matters of interest to the Laboratory Director, or matters of concern to the Fermilab Engineering community. Provides advice to the MSO on revisions and updates to the Management System. Maintains the Fermilab Engineering Manual, reviewing and updating biennially. Evaluates and incorporates lessons-learned into the Engineering Process.

 

3.0 Primary Requiremen​​​ts

M&O Contract

    •  C.4(b)(3) Office of Science High-Energy Physics Program.

Other DOE orders, regulations, and statutes

    • O 420.2C           07/21/11 Safety of Accelerator Facilities

FRA Contract Clause Mapping to Management Systems

            https://fermipoint.fnal.gov/organization/ood/cas/

4.0 Management System Des​​​cription

4.1               Overview​

The Engineering Management system is intended to provide consistency to engineering systems, practices, procedures and processes to ensure that engineering standards are utilized for Fermi National Accelerator Laboratory (FNAL) engineering activities.  The Management system ensures quality levels appropriate for the work, while protecting the health and safety of employees and users, and protection of the environment.   The Engineering Management System reviews the engineering needs of the laboratory and establishes engineering standards. Those standards, practices, procedures and processes are periodically reviewed to respond to emerging needs.

4.2               Key Functions/Services and Proce​​sses

The Engineering Management System supports FNAL research and development as well as support organizations by providing processes and standards that appropriately consider and/or are compliant with codes and regulations while achieving safe, effective, and efficient operations of FNAL facilities. The Sys​​tem focuses on safe and appropriate engineering standards (i.e., applicable Building Code, ASME Code, ASHRE, National Fire Code, safety design software, security requirements, etc.) integration into engineering design, modification, and operations.

4.3               Engineering Subject Mat​ter Experts

There are certain engineering systems/components at FNAL that require consistent administration. Examples of these are cranes, fire protection, welding, various Authorities Having Jurisdiction (AHJ), receipt inspections and testing, and controlled storage.

4.4               Management System O​​peration

Given the dynamic nature of engineering work at FNAL, the Laboratory Director established the Engineering Advisory Committee to assist the Management System Owner (MSO) in the maintenance and continuous improvement of Fermilab's engineering practices. The EAC provides advice on engineering matters of interest to the Laboratory Director, or matters of concern to the Fermilab Engineering community and helps to foster communication between the Engineering community and the Laboratory Director at Fermilab. EAC membership is established by the MSO and reflects the broad range of engineering disciplines carried out at the laboratory.

 The EAC supports the MSO in identifying emerging engineering issues and concerns and in the application of consistent engineering processes throughout the laboratory.  The EAC is engaged in the following activities:

  • Identifying cross-cutting engineering-related issues that require resolution at the laboratory level
  • Issuing, reviewing and updating laboratory level engineering standards and processes, including the Engineering Manual
  • Reviewing and incorporating applicable engineering-related DOE Orders, codes, regulations to determine appropriate implementation
  • Identify Subject Matter Experts as needed
  • Provide standards that define the desired level of quality and performance requirements for engineering design, construction and operation
  • Foster coordination, communication and awareness about the FNAL Engineering Management System and engineering practices and processes.

4.5               Engineering Process​

The Engineering and Design Process integrates Quality Assurance and ES&H into sound, code-compliant, engineering procedures and practices.  The Engineering Process is described in the Fermi National Accelerator Laboratory Engineering Manual. The Engineering Process utilizes the following steps.

4.5.1    Requirements and Specific​ations

The Lead Engineer prepares engineering specifications based on requirements from the project or system manager.  Considerations in preparing requirements include the scope of work, functional or technical requirements, ESH&Q requirements, relevant codes and standards and interfaces.  Specifications are approved by line management and project management prior to the initiation of design.

4.5.2    Engineering Risk Ass​essment

A risk assessment is conducted in order to assess project risk as well as to determine the appropriate level of engineering documentation and review.  Risks to be considered include technical complexity, potential environmental impact, vendor capabilities and schedules, resource availability, Quality Assurance requirements, safety hazards, manufacturing complexity, schedule, interfaces, experience and capabilities of team members, regulatory requirements, funding availability, reporting requirements, potential public impact, and cost.

4.5.3    Requirements and Specifications Revi​​ew

Review of the requirements and specifications takes a graded approach depending on the evaluated risk of the project.  Low-risk engineering activities may utilize an informal technical review by peer engineers.  High-risk projects require formal technical reviews with SMEs from outside the engineering department or laboratory.  In all cases, the Review of requirements and specifications shall be appropriately documented.

4.5.4    System De​sign

Once Requirements and Specifications are completed and approved, system design is initiated.  An engineering design must be properly documented, including calculations, drawings, operating modes and procedures and maintenance plans.

4.5.5    Engineering De​​sign Review

The purpose of design reviews is to ensure that proper engineering design has been conducted, such that the component, sub-system or system meets the requirements and specifications while adhering to relevant requirements and codes.   Design reviews utilize a graded approach based on the assessment of risk.  Reviews occur at various stages of the engineering process, such as prototyping, conceptual design, preliminary design and final design. Reviews may be sponsored by the Department Head, the Project Management or Division/Section Management.

4.5.6    Procurement and Imple​mentation

Procurement of goods and services is in accordance with Fermilab Procurement Policies. In the implementation phase, the lead engineer regularly provides cost and schedule progress to the line and project management. Quality assurance verification is obtained for delivered parts and components. The lead engineer coordinates with support staff to ensure proper fabrication and installation of the project components.

4.5.7    Testing and Valida​​​tion

Testing and validation demonstrate that the component or system satisfies the project requirements and component specifications, based on documented acceptance criteria. The level of testing and validation varies considerably in a graded approach depending on project risk. Testing and validation results shall be documented, prior to release to operations.

4.5.8    Release to ​Operations

Operating and maintenance documents and procedures are prepared, as appropriate.

4.5.9    Final Documentation

The lead engineer creates, controls, and archives documentation in order to complete a project.  This process uses a graded approach as determined by the department head and lead engineer following the guidance of the Engineering Risk Assessment. The final documentation includes all documents from prior steps in the process.

5.0 Reports, Audits, Assessmen​​ts and Required Records

There are no formal requirements for assessment of the Engineering Management System. Periodic self-assessment ensures that the management system is providing consistency to engineering systems, practices, procedures and processes at Fermilab, and minimizing risk to the laboratory from a failure in the engineering process. A self-assessment shall be carried out on a biennial basis. Action items from these self-assessments are to be posted, assigned and tracked through the iTrack system.

6.0 Additional R​​eferences

    • ANSI O1.1   Woodworking machinery
    • ANSI Z136.1            Lasers 2000
    • AWS Z 49.1 (American Welding Standard) Cutting, Welding and Hot Work Activities 1999 version
    • ANSI/ASHRAE 15     Mechanical refrigeration
    • ANSI/ASME B30.10   Hooks 2005
    • ANSI/ASME B30.11   Monorails and Underhung Cranes 2004
    • ANSI/ASME B30.16   Overhead Hoists (Underhung) 2003
    • ANSI/ASME B30.17   Overhead and Gantry Cranes (Top Running Bridge, Single Girder, Underhung Hoist) 2003
    • ANSI/ASME B30.2    Overhead and gantry cranes 2005
    • ANSI/ASME B30.20   Below the hook lifting devices 2006
    • ANSI/ASME B30.21   Manually Lever Operated Hoists 2005
    • ANSI/ASME B30.22   Articulating Boom Cranes 2002
    • ANSI/ASME B30.5    Mobile and locomotive truck cranes 2004
    • ANSI/ASME B30.9    Slings 2003
    • ANSI/ASME B31.3    Process Piping 2004
    • ANSI/ASME B31.5    Refrigeration piping 2001
    • ASME Pressure Vessel Code - Section VIII
    • ASME B20.1-1996     Safety Standard for Conveyors & Related Equipment
    • FESHM 5031            Pressure vessels
    • FESHM 5031.1         Pressure piping systems
    • FESHM 5032            Cryogenic system review
    • FESHM 5032.1         Liquid nitrogen dewar installation rules
    • FESHM 5032.2         Guidelines For the Design, Fabrication, Testing, Installation, and Operation of LH2 Targets
    • FESHM 5033            Vacuum vessel safety
    • FESHM 5033.1         Vacuum window safety
    • FESHM 5035            Mechanical refrigeration systems
    • IEC 61511   Functional Safety, Safety Instrumented Systems for the Process Industry Sector
    • Pressure Equipment Directive (PED) 97/23
    • 10 CFR 435 RDR  Energy Conservation Voluntary Performance Standards for New Buildings; Mandatory for Federal Buildings. (The hazards that this law addresses are not directly related to ES&H issues but applicable to engineering design.)
    • 10 CFR 436 RDR  Federal Energy Management and Planning Programs. (The hazards that this law addresses are not directly related to ES&H issues but applicable to engineering design.)
    • ANSI B30.9 (1992) RDR  Slings (equipment design specification only)
    • ANSI N14.6-1993 RDR  Radioactive Materials, Special Lifting Devices for Shipping Containers Weighing 10,000 pounds (4500 kg) or More
    • AWS B2.1 RDR  Specification for Welding Procedure and Performance Qualification
    • AWS D1.1 RDR  Welding Code-Steel
    • AWS D1.2 RDR  Structural Welding Code-Aluminum
    • AWS D1.3 RDR  Structural Welding Code-Sheet Steel 
    • AWS D1.6 RDR  Structural Welding Code-Stainless Steel 
    • AWS D9.1 RDR  Sheet Metal Welding Code 
    • AWS QC-1 RDR  Specification for Qualification and Certification of Welding Inspectors 
    • AWWA D100 RDR  Welded Steel Tanks for Water Storage 
    • DOE-STD-1090-2007 with exceptions RDR  Hoisting and Rigging Standard (Formerly Hoisting and Rigging Manual)
    • FED-STD-795 RDR  Uniform Federal Accessibility Standards
    • Instrument Society of America (ISA) S5.1 RDR  Instrum. Symbols & Ident, 1993
    • Instrument Society of America (ISA) S5.4 RDR  Instrumentation Loop Symbols, 1996
    • International Building Code (IBC) 2009 RDR  (Exceptions: Replace all references to the ICC Electrical Code with the NFPA 70 National Electric Code, latest edition; All appendices; See additional exceptions identified in the WSS ID Team Report, Attachment B IBC matrix) 
    • International Fire Code (IFC) 2009 RDR  (Include Appendix B through I as reference only; Exception: Appendix A â€" Board of Appeals)
    • International Fuel Gas Code (IFGC) 2009 RDR  (Include Appendix B through I as reference only)
    • International Mechanical Code (IMC) 2009 RDR  (Exceptions: All Appendices)
    • International Plumbing Code (IPC) 2009 RDR  (Include Appendix B through G as reference only)
    • NBIC RDR  National Board Inspection Code (for existing and new pressure vessels) (The latest edition of the NBIC is to be used (see NBIC Foreword for specific applicability).
    • Fermi National Accelerator Laboratory Engineering Manual

7.0​ Definitions of Acronym​​s and Terms

Acronym Definition
CFOChief Financial Officer
COOChief Operating Officer
CSOCognizant Safety Officer
D/S/P HeadsSenior managers responsible for each of Fermilab's major organizations (Division, Section, or Project)
EACEngineering Advisory Committee
FNALFermi National Accelerator Laboratory, also known as Fermilab
FRAFermi Research Alliance, LLC
FSOFermi Site Office of the U.S. Department of Energy
Lead EngineerEngineer assigned to lead the design of a components, sub-system or system
NEPANational Environmental Protection Act
 
​​ 

8.0            Extension of Management System To South Dakota

This section formally captures the extension of this management system to Fermilab activities and roles at SURF. (Add appropriate text below and change font back to black when finished)

In this new section, please make appropriate declarations about equivalencies AND note areas where the management system would operate differently.  Importantly, also note how your M.S. will provide assurances about performance at SURF (e.g., visits, inspections, monthly reports,  SDSD personnel oversight, and so on). 

ES&H has completed an analysis that generated a graphic identifying what requirements where for what work.  A reference to this analysis would be appropriate to include in this section.   In another example, the Legal Management System might observe formally that the Prime Contract applies to all legal matters identically to FRA-sponsored work in South Dakota as it does in Batavia and the same points of contact should be used. 

  
  
  
  
Fermilab Engineering Manual (pdf).aspx
  
12/16/2014 4:43 PMMatt Crawford
Fermilab Engineering Manual Appendices (pdf).aspx
  
12/17/2014 10:28 AMMatt Crawford