F. Savary Industrial service contracts for HL-LHC MSC Technical Meeting on 2013-12-12.

F. Savary

Industrial service contracts for HL-LHCMSC Technical Meeting on 2013-12-12

MSC Technical Meeting 2

Outlook

2013-12-12

• Motivation• Magnet development process• Concept• Objectives• Procurement process• Requirements• Outcome• Examples


Motivation

2013-12-12

Courtesy L. Rossi

Today

LS1 LS2 LS3


Two main projectsThe 11 T Dipole is a two in one dipole magnet with an aperture of 60 mm, a coil length of 5.5 m, and an approximate weight of 12 t

The large aperture quad. is a single aperture quad. with an aperture of 150 mm, a coil length of 4 to 7 m, and an approximate weight of 8 to 14 t

2013-12-12

New ideas / developments needed!

• Nb3Sn superconductorNew challenges:

• Reaction treatment• Impregnation• Insulation,• Hybrid joints, …


Magnet development process

2013-12-12

Physics CommunityFrom needs, formulate functional requirements

Functional & operation requirements Prototyping• Engineering design of an accelerator magnet (full-length, with

all necessary features for “accelerator”: bus bars, protection, geometry and alignment, vacuum, cooling, cold mass envelope, interfaces, …)

• Analysis, tooling, integration-interfaces, constraints• Full-length prototype fabrication and testing in real

operation conditions, in view of validating the design• Interactions with physicists, and partner technologies (vacuum,

cryogenics, cryostating, power supply, protection, …)

Prototyping Final Design• For series production• Taking into account industrial constraints• Interaction with industry

New, and

innovative

concept

Functional requirements Conceptual Design• Research & Development• Cable development• Electro-magnetic & mechanical analyses• Material selection and testing• Tooling development• Short model fabrication and testing

in view of validatingthe concept

• Demonstrator


Concept• Have companies experienced in the field of

superconducting accelerator magnet technology working with/at CERN on the prototyping and industrialization of Nb3Sn magnets for HL-LHC

• Through special industrial service contracts

• The standard Field Support Unit (FSU) contracts do not provide answer to our specific needs because they are too generic

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Objectives1. Compensate the temporary lack of resources due to the LS1

Project (consolidation of the LHC machine)2. Understand better, at an early stage, the inevitable constraints

of the industrial world, and adapt the final design as needed, wherever possible

3. Make use of the know-how and specific expertise of specialized firms

4. Anticipate technology transfer towards industrya) To avoid unnecessary margins aimed covering

unknowns/uncertainties @ bidding stageb) To prepare industry for the future series production of a new type of

superconducting magnetsc) To shorten, as much as possible, the duration of the learning phase

in the beginning of the production

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Procurement process

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Market Survey [to well known companies, #10]• Technical description [short], tech. questionnaire, and qual. criteria• Identification of suitable bidders within the CERN member states

Invitation to tender [to qualified bidders, #7]• Technical specification, and annexes [checked by TS Committee]• Work packages, and qualifications of personnel defined• Tender form, hourly rates, offers for 3600 hours/year over 2 years

Offers [#5] and contracts award [#4]• Adjudication based on lowest bid• Submission to CERN Finance Committee for approval (3 contracts proposed)• Finally, 4 contracts were given to 4 different firms in 4 different countries

Brainstorming: how do we do it?• What do we need/ask? What scope? What adjudication criteria? Risk?• How to ensure we get quality service, how to evaluate our level of

satisfaction, what quality indicators, how to keep things under control?• Preliminary discussions conducted with the firms to ‘measure’ interest


Definition of the work packages• As per technical specification EDMS 1261927• 11 T Dipole:

• WP1: Cable insulation, winding, and binder curing• WP2: Reaction heat treatment, coil instrumentation, impregnation• WP3: Construction of the collared-coil dipole• WP6: Active part construction for collared-coil dipole• WP9: Finishing of the cold mass assembly• Added later: WP10: Coil fabrication for the short models of the 11T

dipole magnet• Large Aperture Quadrupole

• WP1: Cable insulation, winding, and binder curing• WP2: Reaction heat treatment, coil instrumentation, impregnation• WP5: Construction of the coil-pack quadrupole• WP8: Active part construction for shell, bladders and keys quadrupole• WP9: Finishing of the cold mass assembly• Added later: WP11: Coil fabrication for the short models of the MQXF

quadrupole magnet

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Qualification of personnel• At least three members of the contractor’s personnel with the

following profiles• Academic engineer (will be the ref. person, shall always be present on site

when there are activities)• Technical Engineer (type “magnet designer”)• Draftsman (to work @ the contractor’s premises)• Experienced practitioner

• Proven experience in the design, manufacturing and testing of superconducting magnets for accelerators, in particular Nb3Sn reaction

heat treatment, coil insulation and vacuum impregnation techniques• Proven experience in the design, procurement and commissioning of

special tooling for the manufacture of superconducting magnets, preferably made of Nb3Sn superconductor

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Functions – two examples• Academic engineer

• Supervises the team;• Interfaces with CERN, and reports to the contractor, in particular ensures that the CERN

schedule requirements are met;• Carries out magnet design;• Carries out mechanical, thermal, and electro-magnetic analyses;• Writes technical reports, and technical specifications, or check these documents if

prepared by the technical engineer or higher technician• Assists the technical engineer, the draftsman, and the practitioner, for the execution of the

hands on activities and of the design work, in particular ensures that the CAD design standards are respected

• Experienced practitioner• Carries out hands on work at the shop floor level, e.g. assemble tooling or magnet parts

and magnet sub-assemblies;• Under the supervision of the technical engineer, or higher technician, develops

manufacturing and assembly procedures, or manufacture and assemble parts according to existing procedures;

• Prepares and install instrumentation systems;• Carries out welds on parts of the cold mass envelope made of austenitic stainless steel

grade AISI 316L and AISI 316LN, e.g. fillet welds and full penetration welds, single or multi-pass welds, with or without filler material;

• Carries out inspections as per available procedures or helps in developing inspection procedures, e.g. high voltage electrical tests and 3D geometry measurements

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Outcome

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• S158/TE• 3 work packages• ~ 5600* hours• 2 years• Start May 2014

• S156/TE• 5 work packages• ~ 7300 hours• 2 years• Start Jan. 2014

• S157/TE• 3 work packages• ~ 6000 hours• 2 years• Start Sept. 2013

• S159/TE• 1 work package• ~ 2000 hours• 1 year• Start Nov. 2013

Babcock Noell GmbH

*of which 2000 are for short models in B927

*all for short models in B927


7300

6000

5600

2000Babcock Noell

Alstom

ASG Superconductors

Oxford Instruments

810

560

630

Oxford Instruments

2433

12171217

2433

Babcock Noell

Academic Engineer

Technical Engineer

Drafstman

Experienced Practitioner

Work distribution

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Contract Nr Contractor Work Packages

S156/TE Babcock Noell [DE] 11T Dip.: WP2Quad.: WP1, 5, 8, 9

S157/TE Alstom Power Systems [FR] 11T Dip.: WP1, 9Quad.: WP2

S158/TE ASG Superconductors [IT] 11T Dip.: WP3, 6Quad.: WP11 [B927]

S159/TE OI Nanotechnology Tools [UK] 11T Dip.: WP10 [B927]

2000

10001000

2000

Alstom1867

933933

1867ASG Superconductors

2000 hours

7600 hours 5600 hours7300 hours

Overall 29000 hours


Critical item: Intellectual property• In application of the CERN General Conditions of Contract, all intellectual

property generated during the execution of the contract will belong to CERN. Accordingly, CERN is free to give access to the results generated during the execution of the contract to third parties at its sole discretion. The contractor thus acknowledges that the results of work related to the prototyping and industrialization of Nb3Sn magnets will be made available to the successful bidder(s) for the series production.

• Furthermore, the contractor hereby agrees to grant CERN a royalty-free license on its pre-existing intellectual property needed to make use of the results generated during the execution of the contract, sub-licensable to third parties within the scope of CERN’s activities.

• The contractor shall provide to CERN a list of its pre-existing intellectual property needed to make use of the results generated during the execution of the contract within 60 days after signature of the contract.

• CERN hereby agrees to grant the contractor a license on the results for the commercial exploitation of the results beyond HL-LHC procurement at preferential conditions.

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… Copied from the contract …


What do we save on schedule?2014 2015 2016 2017 2018

Tooling preparation

Practice coils

Real coil #1

Real coils #2 to #5

Collared coil #1

Collared coil #2

Two in one cold mass

Cryostating and cold test

11T Dipole #1 & 2 for IR2

11T Dipole #3 & 4 for IR2

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Prototype

Production

LS2

Technology transfer to be done (> 2 years) if we do

not do it as presented


Examples / on-going work / Alstom

2013-12-12

F. Savary Industrial service contracts for HL-LHC MSC Technical Meeting on 2013-12-12.

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