PRELIMINARY VERSIONESS RFQ CDR 2TIME SCHEDULE,

PROJECT RISKS, RAMI AND SAFETY

Anne-Catherine CHAUVEAU 8th and 9th december 2015

PRELIMINARY VERSION

TIME SCHEDULE

TUNER

COUPLERS

TEST CAVITY and AUXILIARIES

PROTOTYPING COUPLER CONDITIONING

COPPER

RFQ MANUFACTURING

RFQ ASSEMBLY and TESTS

RFQ RE-ASSEMBLY and CONDITIONING

RFQ PACKING and TRANSPORTMPP planning is more than 200 lines

Manufacturer’s planning awaits confirmation| PAGE 2

Delivery to Lund due 13/03/18Formal Handover due 16/07/18

Assembly in Saclay will start in parallel with sections manufacturing

PRELIMINARY VERSION03/16

Pre-prod 08/16

Proto 06/16

TENDERS PLANNING CONNECTIONS

Vannes Copper

RFQ tenderProcess Qualif.

11/15 04/16

09/15

HIP

03/16 04/16

07/16 09/16

Sec.1 Machining

Sec.1 ass. Brazing

12/16

Sec.2 ass. Brazing

02/17

RFQ Assembly

RF testsDe-ass. Packing

RFQ partial SAR

TransportRe-

AssemblyConditioning

RFQ Handover

03/17 01/18 01/18 02/18 03/18 03/18 03/18 04/18 07/18

Tuner tender

11/15

Tuner manufact.

05/16

Aux. Copper Manuf.

Ports and test cavity

tender

10/15 04/16

09/15 01/16

Test cavity & Ports

manufact.

04/16 10/16

08/16∆= 6wks

Serie 11/16

Tuner Proto manufact.

Test cavity leak tests

06/1606/16

11/16∆= 10wks

06/16

Test cavity assembly

05/16 12/16

12/15 03/16

Sec.1. Pre-assembly.

Sec.2 Pre-assembly01/17

03/17

Preserie 09/16

Serie 12/16

07/16 02/17

Coupler tender

11/15

Coupler manufact.

05/16 05/16 02/17

02/17

12/16

02/17∆= 12mths

Coupler conditioning

02/17 03/17

20162015 2017 2018

09/1

6

∆= 13wks

∆= 17wks

Tight meeting points between tenders target dates.

RFQ cavity is the critical path

| PAGE 3

Production Ports needed for assembly and brazing on the

remaining cavity sections.10 weeks margin.

Pre-production ports needed for assembly and brazing on

the first cavity section.6 weeks margin only.

Tuner production needed for assembly of the remaining sections after delivery at

Saclay17 weeks margin.

Couplers needed for RF tuning tests

12 months margin.

Tuner pre-production needed for assembly of the first section after delivery at

Saclay13 weeks margin.

PRELIMINARY VERSIONLund delivery on february 2019 Lund delivery on march 2018

Whole RFQ fully tested.Partial tests done on single sections to 4

assembled sections. Partial tests on full RFQ

Assembly tools validation Assembly tools validation

Alignment

Tuners RF tuning Tuners RF tuning

Leak tests under full vacuum Partial Leak test

Vacuum system and control validation First full assembly of vacuum system done in Lund

Bead Pull measurement and voltage law Bead Pull measurement and voltage law

Cooling system and control validation FAT for the SKID under simulated load drops

Cooling piping system congestion verification First assembly of cooling system done in Lund

Verification of mechanical behavior under vacuumRFQ first time under operational vacuum will be done in Lund.

IO plates brazed finger RF verification IO plates with brazed fingers will be checked in Lund.

Lund delivery on february 2019 Lund delivery on march 2018

Whole RFQ fully tested.Partial tests done on single sections to 4

assembled sections. Partial tests on full RFQ

Assembly tools validation Assembly tools validation

Alignment

Tuners RF tuning Tuners RF tuning

Leak tests under full vacuum Partial Leak test

Vacuum system and control validation First full assembly of vacuum system done in Lund

Bead Pull measurement and voltage law Bead Pull measurement and voltage law

Cooling system and control validation FAT for the SKID under simulated load drops

Cooling piping system congestion verification First assembly of cooling system done in Lund

Verification of mechanical behavior under vacuumRFQ first time under operational vacuum will be done in Lund.

IO plates brazed finger RF verification IO plates with brazed fingers will be checked in Lund.

CHALLENGING TIME SCHEDULE

In order to meet the ESS target date for delivery, CEA has worked on reducing the project planning.Test planning has been reduced by 6 months and manufacturing by 4 months thus adding risks on the time schedule

| PAGE 4

PRELIMINARY VERSION

0, 0, 22, 0, 5, 57, 22, 57 IdentificationRating Pre-Mitigation

DispositionRating Post-

Mitigation

Risk LabelLevel Treatment Mitigation Strategy / main actions Level

("As a result of...") ("There is a risk that...") ("Resulting in...")

Time schedule reduction of RFQ contract

Auxilairies + Tuner + couplers contracts nor reaching RFQ contract on target time (from schedule point of view)

Interruption in RFQ cavity manufacturing (assembly step) + RFQ final assembly

64VERY HIGH

Mitigation

Set sub-critical contracts as priority in order to put them outside the critical path : ressources allocations, special adlinstrative procedure, pre-selection of bidders. Close follow-up of adminstrative durations

32 HIGH

Time schedule reduction of RFQ contract

No single manufacturer able to sustain the schedule constraint

No offer avaialble > Schedule 32 HIGH Transfert Delay to be tranfered to ESS 32 HIGH

Time schedule reductionProcurement financial offers should be higher than expected

Overcost 32 HIGH Transfert Additional cost to be transfered to ESS 32 HIGH

Time schedule reduction > Cooling system FAT only, no SAT (leak test, skid performance test)

Cooling system performance not reaching its specifications during check-out at Saclay

Investigation to be done directly in Acceleraor tunnel - defaut to be corrected > time schedule

32 HIGH Mitigation

Mitigation : Water loss of pressure simulations in FAT (new in contract), Transfert : Cooling system assembly and leak test to be performed directly by ESS / Delays and additional cost to be tranfered to ESS to correct problem after shipment

32 HIGH

Only partial tests at sacalyMore manmpower needed in Lund to finish CEA contribution

Overcost 32 HIGH MitigationChange contract approach (with limitation in ressources according to intial cost) + all correcivtes cost to be supported by ESS => Cost & fee

32 HIGH

Time schedule reduction > End plate final assembly no RF tested (only dummy finger tested)

End plate RF specification not achieved (with final components)

End plate parts (gaskets ,fingers, assembly process) defaut to be corrected > time schedule

16 HIGH Transfert Delays and additional cost to be tranfered to ESS 16 HIGH

Time schedule reduction > No final vacuum system integrated and tested @ Saclay

Vacuum system performance not reaching its specifications (RFQ vacuum integrity still tested ) during validations at Saclay

Investigation to be done directly in Acceleraor tunnel - defaut to be corrected > time schedule

16 HIGH TransfertDelays and additional cost to be transfered to ESS if issues arise after shipment.

16 HIGH

Time schedule reduction > No final vacuum control system integrated and tested @ Saclay

Vacuum control system not reaching its specifications during validations at Saclay

Investigation to be done directly in Acceleraor tunnel - defaut to be corrected > time schedule

16 HIGH Mitigation

Vacuum CS partially tested on vacuum chamber (Control system could be partially tested on 1 RFQ section ONLY if this can be done on hidden time thus not impacting time schedule.

8MEDIUM

Set sub-critical contracts as priority in order to put them outside the critical path (ie: tuner prototype)No mitigation

No mitigation Mitigation : Water loss of pressure simulations in

FAT Issues discovered in Lund

will take longer to solve

Change contract approach with limitation in

ressources according to intial cost and correctives cost to be supported by

ESS

More CEA manpower needed in Lund to finish

CEA contribution.Overcost

Cooling system performance not reaching its specifications first time

Procurement financial offers should be higher

than expected

Auxilairies + Tuner + couplers contracts not

reaching RFQ contract on target time (from schedule

point of view)

No single manufacturer able to sustain the

schedule constraint of 20 months

CHALLENGING TIME SCHEDULE RISKS

| PAGE 5

PRELIMINARY VERSION

IdentificationRating Pre-Mitigation

Disposition Rating Post-Mitigation

Risk LabelLevel Treatment Mitigation Strategy / main actions Level

("As a result of...") ("There is a risk that...")

Organization / Specific managerial aspects              

ERIC finalisationUnknown admistrative process with potential impact on-going call for tenders and schedule

32 HIGH Mitigation Mitigations at management level (see Management RR) 16 HIGH

Accelerator System team not stabilized. Engineering process not stable

External RFQ interfaces not frozen in due time (CDR2) to finalize Tech Specs

64 VERY HIGH Mitigation

CDR2 before manufacturing with high priority interfaces specification.Interface specification reviewed both by CEA and ESS

8 MEDIUM

Individual components performance              

Beam Dynamics design issues …RFQ RF design does not match the all the performance requirements

32 HIGH Mitigation CDR0 has reviewed all design topics / Qualification plan / Bead pull / 16 HIGH

Peak power very high, design based on SP2 under installation, Couplers not reaching specifications (800 kW)

64 VERY HIGH Mitigation

The couplers will be tested on the test cavity / One coupler spare / Additional windows spares / Qualification plan (progressive steps)

32 HIGH

Procurements              

Not enough applicants, over cost from tenderers, bad tendering process

tenders process not concluded in due time 32 HIGH MitigationAnticipate as much as possible call for tenders even if specifications are not completely defined.The markets are closely followed.

8 MEDIUM

Several company to deliver the auxiliairies parts, technological challenges (SS/Cu brazing), process qualification to reach, manufacturing schedules slippage

Auxiliaries parts (esp. RFQ ports) to braze delivered too late to RFQ manufacturer

32 HIGH Mitigation Close follow-up of manufacturers, Enhanced QA 4 MEDIUM

Manufacturing workload and internal bad arbitration from the manufacturer

RFQ manufacturer late delivery 32 HIGH Mitigation

Define precise steps with the manufacturer to follow process datesWe will request frequent meetings with manufacturer to follow process.Higher delivery penalties / incitationsMarket survey (Industry proper selection)

16 HIGH

ESS issuesVacuum and its control system not delivered on time by ESS

16 HIGH Mitigation

Enhance communication with vacuum and control teams. If possible, the pump used for all anticipated tests during prototyping and RFQ assembly will be identical to the final pumps in order to prove mechanical adjustment.Send 3D to vacuum team ASAP

16 HIGH

Manufacturing process              

Bad behaviour of materials during brazing, senstive and new process for the selected company

Difficulties to perform RFQ sections brazing

64 VERY HIGH Mitigation

Check brazing experience prior to tender approval / Follow up process during manufacturing / Brazing process qualification / Cu Spare parts / Brazor expert is working with us to help on and follow brazing procedure.

16 HIGH

Difficult manufacturing process (ceramic window brazing …)No manufacturing acceptance of Couplers (leaks, conditioning barriers, …)

64 VERY HIGH Mitigation

One coupler spare + Manufacturing process with validation steps (NOT considered in current risk analysis : 2 or 3 spares in option / pre-serie qualification inc conditioning / Contract provisions)

32 HIGH

Acceptance              

RF archs damaging critical parts of the cavity RFQ compromised during conditioning 64 VERY HIGH Mitigation

Progressive RF power ramp / Cleanliness cautions during manufacturing and assembly at Lund / RF expert for conditionning

16 HIGH

Progressive RF power ramp.Cleanliness cautions during

manufacturing and assembly. RF expert for

conditioning

One coupler spare + Manufacturing process with validation steps.

Brazor expert is working with us to help on and

follow brazing procedure.

The couplers will be tested on the test cavity /

One coupler spare

Interface specification reviewed both by CEA

and ESS

RFQ compromised during conditioning (RF arcs

damaging cavity)

Manufacturing process issues for the couplers

(ceramic window)

Difficulties to perform RFQ sections brazing

Couplers not reaching specifications because peak power is very high

External RFQ interfaces not frozen in due time

(CDR2) to finalize Tech Specs

OTHER RISKS

| PAGE 6

PRELIMINARY VERSION

| PAGE 7

PROJECT RISKS SUMMARY

Level 64 Level 32 Level 16 Level 8 level 40123456789

10

6

9

4

0 0

RISKS LEVEL BEFORE MITIGATION

Risk level

Num

ber

of r

isks

Level 64 Level 32 Level 16 Level 8 level 40

1

2

3

4

5

6

7

8

9

0

78

3

1

RISKS LEVEL AFTER MITIGATION

Risk level

Num

ber

of r

isks

No “Very High” level risks after mitigation

Most risks concern the time schedule as it contains no margin.

Most critical technical part is the coupler because it is a complex part and the power required is very high.

Risk Workshop due in Lund on the 14th of january

PRELIMINARY VERSION

| PAGE 8

RAMI AND SAFETY

RAMI: Reliability – Availability – Maintainability – Inspectability

Very little maintenance on the RFQ itself if kept under vacuum (hydraulic channels cleaning), most are on the coupler (EPDM gasket, view ports replacement).

No statistics on RFQ life time. Cooling system will be delivered with maintenance manual.

CEA will provide technical inputs for the RAMI workshop.

SAFETYNo specific hazard under CEA responsibility on the RFQ.

CEA applies the standard European safety rules and regulations.During work in Sweden, CEA will follow the Swedish rules and regulations.List of materials used will be provided to ESS (>90% consists in copper and

stainless steel)

CEA Saclay/Irfu projet ESS | DATECommissariat 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

| PAGE 9

有點不耐煩毀掉一個偉大工程

A small impatience ruins a great project.

En liten otålighet ruiner ett stort projekt

Confucius

PRELIMINARY VERSION

APPENDIX: RISK QUOTATION

| PAGE 10