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This document provides information on the rules, procedures, and main contracts involved in the manufacturing process for RFQ CDR2. It covers topics such as purchasing procedures, tendering documents, contract follow-up strategy, and expertise needed for the main contracts.
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Manufacturingcontracts for RFQ CDR2 RFQ| Vincent Hennion System engineering activities
Pour personnaliser le pied de page et la date : « Insertion / En-tête et pied de page » Personnaliser la zone de de pied de page Cliquer sur appliquer partout Table of contents • Chapter 01 • Rules and purchasingprocedures @CEA P.04List of RFQ ContractsP.05 • Tendering documents file P.06 • Contractsfollow-up strategyP.07 • Chapter 02 • Focus on the 5 main contractsP.09 • Questions P.15 CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Chapter 1 CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Rules and purchasingprocedures • Fundamental rules • European directives and associated French laws applicable to the procurement procedures • The principles governing the public purchasing - equity, efficiency and transparency - from the first €uro • CEA Internal rules • Purchases below € 30,000 will be treated in connection with the IRFU budget group • Purchases over € 30,000 will be made with the purchasing department • Procedures • The simplifiedprocedure (not formalized) for purchases< € 207,000 • The formalizedprocedure for purchases > € 207,000 • Restricted call for tender (over 5 months) • Open call for tender (over 4 months) CEA 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 couplingloops • Contract 5: RF tuners • Contract 6: HIP (High Isostatic Pressing) • Contract 7: Helicoflexseals • Contract 8: Prototype RF tuner • Contract 9: RF test benchequipment • 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 • Otherscontracts: Tools, … CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Tendering documents file • Contract • Rules for the call for tender • Purchasing procedure • deadlines • deliverables • Technical and financial offer evaluation • Statement of work • Technical specifications of manufacturing, controlling, cleaning, packing… • Deliverables • Content of the manufacturing file • Drawings • 2D representation of the mechanical parts • nomenclatures • 3D mock-up • Catia V5 or Step file • others • Excel file of the coordinates of points of the modulation CEA PurchasingDepartment IRFU Engineering team and DO CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Contractfollow-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 material • Pure copper oxidation properties (degreasing) • Cleanliness (work with gloves) • Required tolerances for performances • Request of collaborative exchanges • Sensitization of the managers @manufacturer workshops • RFQ is an RF equipment before being a complex mechanical system • Processes qualification is a mandatory step to master RFQ manufacturing • Controls at intermediate steps are needed, due to the high value of the parts • Transparency and collaborative exchanges are mandatory to deal with technical issues and find solutions • Drawings • 2D drawings from CEA (functional requirements and needs) • 2D manufacturing and control drawings from the manufacturers to be checked by CEA • 3D mock-up • Catia V5 or Step file from CEA to help the manufacturer for the control CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Chapter 2 CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
the 5 main contracts: needed expertise • Contract 1: Copper raw material procurement • Contract 2: ports, sections flanges and dummy plates • Machining of copper blocks and cylinders • Machining / Supply of flanges in SS • Cu/SS brazing • Machining and copper/copper brazing of the test cavity • Contract 3: RFQ Cavity in copper • Drilling, machining of vanes • Cu/Cu brazing of 5 sections • Contract 4: RF couplingloops • Machining and brazing of the ceramicwindow • Manufacturing of the water coolingloop • TiNcoatingcharacterization • Contract5: RF tuners • Machining of copper blocks and cylinders • Machining / Supply of flanges in SS • Cu/bellows assembly CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Contract 1: copperrawmaterial • Forging process • Isotropic and homogeneous pure copper, with grain size <500µm • 3D hot forged copper, at 800-800-400°C • 5mm scalping on each facet • Thermal treatment • Annealing under vacuum (400°C / 1 hour / 10-5 mbar) • Slow cooling under vacuum • Test plates sampling • Test plates sampledfrom the extremity of each bar • 20mm thick • Purchased quantity: forged bars and blocks for 5+1 sections, spares for ports • Option for 1 more section and additional spares for ports CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Contract 2: ports, section flanges • Contract phasing • Step 1: qualification of a SS/Cu brazing process without metallic coating; verification on representative ports, validation after Cu/Cu brazing on the manufactured test cavity • Step 2: extension of this process to larger quantities: process industrialization • Step 3: manufacturing of the series (for the whole RFQ) • Main technical acceptance criteria • Satisfactory vacuum leak test of the brazed joint • Satisfactory dimensional criteria (geometry, parallelism…) after brazing • Manufacturing and control file • Shipment of the equipped test cavity • Shipment of the ports, sections flanges, and dummy entry/exit plates • No Option CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Contract 3: RFQ cavity • Contract phasing • Step 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 parts • Step 3: validation of these processes for the manufacturing of the 1st section • Step 4: manufacturing and control of the other 4 sections of the RFQ • Main technical acceptance criteria • Satisfactory vacuum leak test and He pressure test • Satisfactory dimensional criteria (geometry, surface quality…) before and after brazing • Satisfactory RF tuning test (Bead-pull) • Manufacturing and control file • Shipment of all the sections • Option for one more section CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Contract 4: RF couplingloop • Contract phasing • Step 1: qualification of the RF window manufacturing process including Ceramic/Cu brazing; verification and validation on a representative dummy RF window, including a LLRF test • Step 2: qualification of the water cooling loop manufacturing process; verification on representative parts which may be the subassembly of the 1st RF coupling loop • Step 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 criteria • Satisfactory dimensional criteria (geometry, RF surface quality…) • Satisfactory vacuum leak test and pressure test of the concerned parts of the loop • Satisfactory LLRF tests of the RF windows • Manufacturing and control file • Shipment of the 3 RF coupling loops • Option for one more RF coupling loop CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Contract 5: RF tuners • Contract phasing • Step 1: qualification of the manufacturing processes including bellows/Cu assembly; verification and validation on representative dummy parts and one full prototype • Step 2: extension of this process to larger quantities: process industrialization • Step 3: manufacturing of the series (for the whole RFQ) • Main technical acceptance criteria • Satisfactory dimensional criteria (geometry, RF surface quality, adjustment flexibility…) • Satisfactory vacuum leak test and pressure test of the concerned parts • Satisfactory tests on the prototype • Manufacturing and control file • Shipment of the 60+5 RF tuners • Option for up to 12 more RF tuners CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15
Thankyou for your attention! QUESTIONS? 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 DSM Irfu CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15