1. X-FEL linear accelerator
cryomodule integration
LCWS, Strasbourg, the 26th October 2017

2. ALSYOM a subsidiary of ALCEN Group X-FEL cryomodule integration
X-FEL accelerator
Cryomodule description
ALSYOM Industrial mission

3. ALSYOM : a subsidiary of ALCEN Group
An Intermediate Size Company created in 1988 : Industry and Innovation
High Technology activities dedicated to following domains:
Defence and Security
Energies
Aeronautic
Medical Equipment
Large Research Infrastructure
Main figures:
About 31 subsidiaries in France and North Africa
2016 turnover ≈ 215 M€
2016 employees ≈ 1 900
350 in Design Office
1 300 in Production
ALCEN has a permanent innovation policy applied
to its product and services

4. ALSYOM : domains of activities
Experimental Nuclear Fusion Reactors
ITER, RJH
High Power Lasers
Laser Megajoule, PETAL
ELI (Extreme Light Infrastructure)
Accelerator
X-FEL
Astrophysics
Astronomy (CTA)
Aeronautic, Defense and security
Turret, satellite antenna and aero structure tools
« Program Management, Design, Engineering and Manufacturing »
for the production of mechanical and opto-mechanical equipment

5. ALSYOM : main expertise
Development and industrialisation
Mechanical, Opto-mechanical, Optic, electronic, command control Design, in collaboration with SEIV design office
Product and Process Industrialisation
System and Equipment manufacturing
Series equipment and complex system production, including:
High accuracy mechanism, control command electronic,
Optic and cabling
Opto-mechanical system in cleanliness and vacuum environment
Integration and cleaning
Geometrical characterisation
Cleaning and integration in ISO 5 and ISO 8 condition
Assembly, Integration and test
Services
Installation on Customer site, including cleanliness, welding and tests
Optical Surface Treatment « sol-gel »
Maintenance: mechanism, opto-mechanism, vacuum
Unique Industrial entity in France grouping these expertise and combined performances
High accuracy, large Dimension, Cleanliness and Vacuum

6. ALSYOM : location in France
Paris
Tarbes
Le Barp
LASERIS
Bordeaux
Cadarache
VERSAILLES
ALSYOM Headquarter TARBES
Bordeaux LASERIS
& LMJ

7. ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration
X-FEL linear accelerator
Cryomodule description
ALSYOM industrial mission

8. X-FEL linear accelerator
Construction and installation of the European X-ray Free Electron Laser (E-XFEL).
Location : DESY (Deutsch-Elektronen-Synchrotron) in Hamburg (Germany)
Tunnel : ~ 1,6 km length
5 X-ray beams
10 experiment stations (research in biology, chemistry, nanotechnology, …)

9. X-FEL linear accelerator
Description of the X-FEL Accelerator Linac (Energy : 17,5 GeV)

10. X-FEL linear accelerator
Institutes involved in the construction of the E-XFEL accelerator

11. ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration
X-FEL linear accelerator
Cryomodule description
ALSYOM Industrial mission

12. X-FEL Cryomodules
E-XFEL accelerator main components

13. X-FEL Cryomodules 496 types of parts
E-XFEL Cryomodule - Main Components
496 types of parts

14. ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration
X-FEL linear accelerator
Cryomodule description
ALSYOM Industrial mission

15. ALSYOM mission Environment Industrialization ALSYOM Responsabilities
Domain of expertise and responsibilities :
Industrialization and process definition
Assembly, Integration and test activities : production team management
ALSYOM Responsabilities
Environment
Industrialization
Methods
Machines
Deliver 100 cryomodules
Meet deadlines
Manage the documentation (Quality, Traceability…)
Process Improvement
Customer Satisfaction
INTEGRATION
PROCESS
Materials
People

16. ALSYOM mission Integration process organized in 7 workstations
Cold Coupler Area – (ISO4-CC-WS)
Coupler Cold Part assembly + 1 Gate valve
Leak tests / RGA tests (RGA : Residual Gas Analysis)
String Assembly Area – (ISO4-SA-WS1, ISO4-SA-WS2 )
Connection of the 8 cavities + 1 Quadrupole
Leak tests / RGA tests
Roll Out Area – (RO-WS1, RO-WS2)
2 Phase Pipe welding + tests (VT, LT, PT, RT)
Temperature sensors, magnetic shields, 4K & 70K assembly
Tuner systems assembly + RF controls
Cold Mass positioning and hooking
Alignment Area – (AL-WS1, AL-WS2)
Alignment of the cavities/Qpole with the cold mass (~ 100µm)
8mm pipe welding + tests (VT, LT, PT)
Electrical tests (Tuners & piezo systems)
Current leads welding
Thermalization

17. ALSYOM mission Integration process organized in 7 workstations
Cantilever Area – (CA-WS)
4K & 70K shells welding
Cables positioning and thermalisation
Introduction inside the vacuum vessel ; fixing
Alignment Cold Mass / vacuum vessel
Coupler Area – (C0-WS1, CO-WS2)
Coupler warm part assembly + Leak test
Coupler Pumping Line assembly + Leak test
T° sensors and Motors cabling
Current lead connection + Electrical tests
Current lead welding on the vacuum vessel + Leak Tests
Cavity string pumping + final Leak test & RGA
Shipment Area – (SH-WS1, SH-WS2)
End caps positioning on the vacuum vessel
Pumping and Nitrogen flushing
RF controls, Motors controls
Connection of the vacuum recording box for transportation
Loading on truck

18. ALSYOM mission
Integration process organized in 7 workstations

19. ALSYOM mission ALSYOM industrial team Production activities
Up to 33 people
Management and Quality
Integrator in clean room
Welder and coordinator
RF, laser tracker, vacuum test technician
Logistician
Production activities
Supply Chain
Production Flow management
Technical event management : from the problem to the solution
Transverse activities
Quality management
Documentation management
Configuration management

20. RESULTS Complete production cycle for ONE Cryomodule : 7 weeks
Schedule and production rate
4 years divided in 3 Phases
Training and Process definition (3 prototypes)
Ramp Up to reach the rate of 5 days
Series Production (100 cryomodules) with rate acceleration up to 4 days
Complete production cycle for ONE Cryomodule : 7 weeks
Up to ONE Cryomodule every for 4 days, ready for delivery

21. RESULTS Schedule and production rate achieved
Performance achieved for the 100 Cryomodules

22. X-FEL inauguration in Hamburg

23. Welcome in the South West of France
Thank you for your attention
Thierry HOVSEPIAN
Managing Director
Eric GIGUET
Commercial and Development Director
ALSYOM
17 Bis Avenue des Forges
CS Tarbes Cedex - France Tel.: +33 (0)
Fax: +33 (0)
Welcome in the South West of France