MANUFACTURING CONTRACTS FOR RFQ

CDR2 RFQ| Vincent Hennion

SYSTEM ENGINEERING ACTIVITIES

CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

TABLE OF CONTENTS

Chapter 01

Rules and purchasing procedures @CEA P.04List of RFQ Contracts P.05Tendering documents file P.06Contracts follow-up strategy P.07

Chapter 02

Focus on the 5 main contracts P.09Questions P.15

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CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CHAPTER 1

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RULES AND PURCHASING PROCEDURES

Fundamental rulesEuropean directives and associated French laws applicable to the procurement proceduresThe principles governing the public purchasing - equity, efficiency and transparency - from the first €uro

CEA Internal rulesPurchases below € 30,000 will be treated in connection with the IRFU budget groupPurchases over € 30,000 will be made with the purchasing department

ProceduresThe simplified procedure (not formalized) for purchases < € 207,000The formalized procedure for purchases > € 207,000- Restricted call for tender (over 5 months)- Open call for tender (over 4 months)

| PAGE 4CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

LIST OF RFQ CONTRACTS

Contract 1: Copper raw material procurement

Contract 2: Ports, sections flanges and dummy plates

Contract 3: RFQ Cavity in copper

Contract 4: RF coupling loops

Contract 5: RF tuners

Contract 6: HIP (High Isostatic Pressing)

Contract 7: Helicoflex seals

Contract 8: Prototype RF tuner

Contract 9: RF test bench equipment

Contract 10: RFQ support

Contract 11: Finition milling of the entry/exit plates

Contract 12: Spares of bolts and nuts

Contract 13: Seals for test activities

Others contracts: Tools, …

| PAGE 5CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

TENDERING DOCUMENTS FILE

ContractRules for the call for tender

Purchasing proceduredeadlinesdeliverablesTechnical and financial offer evaluation

Statement of workTechnical specifications of manufacturing, controlling, cleaning, packing…DeliverablesContent of the manufacturing file

Drawings2D representation of the mechanical partsnomenclatures

3D mock-upCatia V5 or Step file

othersExcel file of the coordinates of points of the modulation

| PAGE 6CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CEA Purchasing Department

IRF

U E

ngineering team and D

O

CONTRACT FOLLOW-UP STRATEGY

Regular progress meeting (face to face or by teleconference)Sensitization of the operators @manufacturer workshops

Mechanical behavior specificity of pure copper as raw materialPure copper oxidation properties (degreasing)Cleanliness (work with gloves)Required tolerances for performancesRequest of collaborative exchanges

Sensitization of the managers @manufacturer workshopsRFQ is an RF equipment before being a complex mechanical systemProcesses qualification is a mandatory step to master RFQ manufacturingControls at intermediate steps are needed, due to the high value of the partsTransparency and collaborative exchanges are mandatory to deal with technical issues and find solutions

Drawings2D drawings from CEA (functional requirements and needs)2D manufacturing and control drawings from the manufacturers to be checked by CEA

3D mock-upCatia V5 or Step file from CEA to help the manufacturer for the control

| PAGE 7CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CHAPTER 2

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THE 5 MAIN CONTRACTS: NEEDED EXPERTISE

Contract 1: Copper raw material procurement

Contract 2: ports, sections flanges and dummy platesMachining of copper blocks and cylindersMachining / Supply of flanges in SSCu/SS brazingMachining and copper/copper brazing of the test cavity

Contract 3: RFQ Cavity in copperDrilling, machining of vanes Cu/Cu brazing of 5 sections

Contract 4: RF coupling loopsMachining and brazing of the ceramic windowManufacturing of the water cooling loopTiN coating characterization

Contract 5: RF tunersMachining of copper blocks and cylindersMachining / Supply of flanges in SSCu/bellows assembly

| PAGE 9CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CONTRACT 1: COPPER RAW MATERIAL

Forging processIsotropic and homogeneous pure copper, with grain size <500µm3D hot forged copper, at 800-800-400°C5mm scalping on each facet

Thermal treatmentAnnealing under vacuum (400°C / 1 hour / 10-5 mbar)Slow cooling under vacuum

Test plates samplingTest plates sampled from the extremity of each bar20mm thick

Purchased quantity: forged bars and blocks for 5+1 sections, spares for portsOption for 1 more section and additional spares for ports

| PAGE 10CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CONTRACT 2: PORTS, SECTION FLANGES

Contract phasingStep 1: qualification of a SS/Cu brazing process without metallic coating; verification on representative ports, validation after Cu/Cu brazing on the manufactured test cavityStep 2: extension of this process to larger quantities: process industrializationStep 3: manufacturing of the series (for the whole RFQ)

Main technical acceptance criteriaSatisfactory vacuum leak test of the brazed jointSatisfactory dimensional criteria (geometry, parallelism…) after brazingManufacturing and control fileShipment of the equipped test cavity Shipment of the ports, sections flanges, and dummy entry/exit plates

No Option| PAGE 11CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CONTRACT 3: RFQ CAVITY

Contract phasingStep 1: qualification of deep drilling and precision milling processes on pure copper; verification on representative parts, including a section 1 minor vane modulations (@full scale)Step 2: qualification of a Cu/Cu brazing process on pure copper ; verification on representative partsStep 3: validation of these processes for the manufacturing of the 1st sectionStep 4: manufacturing and control of the other 4 sections of the RFQ

Main technical acceptance criteriaSatisfactory vacuum leak test and He pressure testSatisfactory dimensional criteria (geometry, surface quality…) before and after brazingSatisfactory RF tuning test (Bead-pull)Manufacturing and control fileShipment of all the sections

Option for one more section | PAGE 12CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CONTRACT 4: RF COUPLING LOOP

Contract phasingStep 1: qualification of the RF window manufacturing process including Ceramic/Cu brazing; verification and validation on a representative dummy RF window, including a LLRF testStep 2: qualification of the water cooling loop manufacturing process; verification on representative parts which may be the subassembly of the 1st RF coupling loopStep 3: qualification of the TiN coating process by characterization measurement on samples (stoichiometry, thickness, homogeneity)Step 4: manufacturing and control of 3 RF coupling loops

Main technical acceptance criteriaSatisfactory dimensional criteria (geometry, RF surface quality…) Satisfactory vacuum leak test and pressure test of the concerned parts of the loopSatisfactory LLRF tests of the RF windowsManufacturing and control fileShipment of the 3 RF coupling loops

Option for one more RF coupling loop | PAGE 13CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CONTRACT 5: RF TUNERS

Contract phasingStep 1: qualification of the manufacturing processes including bellows/Cu assembly; verification and validation on representative dummy parts and one full prototypeStep 2: extension of this process to larger quantities: process industrializationStep 3: manufacturing of the series (for the whole RFQ)

Main technical acceptance criteriaSatisfactory dimensional criteria (geometry, RF surface quality, adjustment flexibility…) Satisfactory vacuum leak test and pressure test of the concerned partsSatisfactory tests on the prototypeManufacturing and control fileShipment of the 60+5 RF tuners

Option for up to 12 more RF tuners | PAGE 14CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

DSM

Irfu

Commissariat à l’énergie atomique et aux énergies alternatives

Centre de Saclay | 91191 Gif-sur-Yvette Cedex

T. +33 (0)1 69 08 xx xx | F. +33 (0)1 69 08 99 89

Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019

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Thank you for your attention!

QUESTIONS?