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

Outlook MSC Technical Meeting2 Motivation Magnet development process Concept Objectives Procurement process Requirements Outcome Examples

Motivation MSC Technical Meeting3 Courtesy L. Rossi Today LS1LS2LS3

Two main projects The 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 MSC Technical Meeting4 Nb 3 Sn superconductor New challenges: Reaction treatment Impregnation Insulation, Hybrid joints, …

Magnet development process MSC Technical Meeting5 Physics Community From 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 validating the concept Demonstrator

Concept Have companies experienced in the field of superconducting accelerator magnet technology working with/at CERN on the prototyping and industrialization of Nb 3 Sn 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 MSC Technical Meeting6

Objectives 1. 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 industry a) To avoid unnecessary margins aimed covering bidding stage b) To prepare industry for the future series production of a new type of superconducting magnets c) To shorten, as much as possible, the duration of the learning phase in the beginning of the production MSC Technical Meeting7

Procurement process MSC Technical Meeting8 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 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 MSC Technical Meeting9

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 the contractor’s premises) Experienced practitioner Proven experience in the design, manufacturing and testing of superconducting magnets for accelerators, in particular Nb 3 Sn 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 Nb 3 Sn superconductor MSC Technical Meeting10

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 MSC Technical Meeting11

Outcome MSC Technical Meeting12 S158/TE 3 work packages ~ 5600* hours 2 years Start May 2014 S156/TE 5 work packages ~ 7300 hours 2 years Start Jan S157/TE 3 work packages ~ 6000 hours 2 years Start Sept S159/TE 1 work package ~ 2000 hours 1 year Start Nov Babcock Noell GmbH *of which 2000 are for short models in B927 *all for short models in B927

Work distribution MSC Technical Meeting13 Contrac t Nr ContractorWork Packages S156/TEBabcock Noell [DE] 11T Dip.:WP2 Quad.:WP1, 5, 8, 9 S157/TEAlstom Power Systems [FR] 11T Dip.:WP1, 9 Quad.:WP2 S158/TEASG Superconductors [IT] 11T Dip.:WP3, 6 Quad.:WP11 [B927] S159/TEOI Nanotechnology Tools [UK]11T Dip.:WP10 [B927] 2000 hours 7600 hours 5600 hours 7300 hours Overall 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 Nb 3 Sn 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 MSC Technical Meeting14

What do we save on schedule? 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 IR MSC Technical Meeting15 Prototype Production LS2 Technology transfer to be done (> 2 years) if we do not do it as presented

Examples / on-going work / Alstom MSC Technical Meeting16