F. Savary Industrial service contracts for HL-LHC MSC Technical Meeting on 2013-12-12.
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Transcript of 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
MSC Technical Meeting 3
Motivation
2013-12-12
Courtesy L. Rossi
Today
LS1 LS2 LS3
MSC Technical Meeting 4
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, …
MSC Technical Meeting 5
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
MSC Technical Meeting 6
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
2013-12-12
MSC Technical Meeting 7
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
2013-12-12
MSC Technical Meeting 8
Procurement process
2013-12-12
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
MSC Technical Meeting 9
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
2013-12-12
MSC Technical Meeting 10
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
2013-12-12
MSC Technical Meeting 11
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
2013-12-12
MSC Technical Meeting 12
Outcome
2013-12-12
• 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
MSC Technical Meeting 13
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
2013-12-12
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
MSC Technical Meeting 14
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.
2013-12-12
… Copied from the contract …
MSC Technical Meeting 15
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
2013-12-12
Prototype
Production
LS2
Technology transfer to be done (> 2 years) if we do
not do it as presented
MSC Technical Meeting 16
Examples / on-going work / Alstom
2013-12-12