Download A prototyping and industrialization phase

HEPTech and ESS Innovation Procurement Workshop
Lund
Procurement at CERN and innovative
procurement:
Practical use cases
7 May 2013
Dante Gregorio & Myriam Ayass
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CERN conducts direct procurement based on CERN’s intrinsic
needs deriving from curiosity driven research.
CERN’s requirements can be sub-divided into three categories:
1) Standard industrial products (off-the-shelf);
2) Non-standard products which can be produced with existing
manufacturing techniques and/or technologies, but industry has
no experience of manufacturing the products;
3) New high-tech products requiring a conceptual design phase. The
manufacturing methodology has to be developed.
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Practical Use Cases
 X-band accelerating structures for CLIC project (2);
 Hybrid circuits for the CMS Tracker Upgrade (3);
 Nb3Sn Magnets for HL-LHC (3).
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X-band Accelerating Structures for CLIC Project
 During the technical design phase in the years 2013 – 2017, one of
the objectives will be to demonstrate a cost effective series
production of the X-band accelerating structures, which are two of
the most critical components of CLIC;
 The aim of the programme is the validation of the different steps of
the production process: from the engineering design to the
complete assembly as well as the optimisation of the production
process yielding a lower and more reliable cost estimate for the
series production;
 The X-band structures are composed of two components:
- Accelerating Structures (AS);
- Power Extraction and Transfer Structures (PETS).
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Typical Two-Beam Module
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Accelerating Structures (AS)
 Each AS contains about 30 copper discs, which form the accelerating
cavity and are bonded together to form a stack. Each disc has an
external diameter of 80 mm and extremely stringent geometry,
dimensions and tolerances due to the RF requirements (e.g. the
shape tolerance of the RF cells is ± 2.5 μm and the surface
roughness is 0.025 μm);
 The fabrication of the accelerating structure is based on the following
main conventional technologies:
- diamond machining;
- surface treatment including chemical etching;
- joining of the disks by diffusion bonding at about 1000C
under hydrogen atmosphere;
- brazing of the vacuum manifolds to the disk stack;
- vacuum baking at 650C.
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Main Tolerances for Accelerating Structure Disc
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Power Extraction and Transfer Structures (PETS)
 A PETS unit comprises the assembly of two PETS, together with the
corresponding mini-tank, and output coupler;
 The components of the PETS units are fabricated using conventional
machining technologies and are assembled at a final stage using the
electro-beam welding (EBW).
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General View of a PETS Unit
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Procurement Strategy
The overall procurement will be divided into two phases:
 Qualification phase (2013-2015): a Market Survey will be issued to
qualify firms and small quantities of prototype X-band AS and PETS
will be ordered from these firms;
 Production phase (2015-2017): only those firms which have been
qualified as a result of the qualification phase will be contacted for the
invitation to tender(s) for a small series production.
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Procurement Strategy – Qualification Phase
Qualification phase
 A market survey will be issued based on a typical set of
qualification criteria. The most important qualification criterion will
be the successful production of small sample prototypes, which will
be ordered as part of the market survey from firms;
 Feedback to be given by CERN to firms on measurement results;
 After the market survey, small quantities of prototype X-band AS
and PETS will be ordered from the selected firms, based on
different manufacturing processes and technologies.
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Procurement Strategy – Production Phase
Production phase
 Only those firms that have been qualified during the qualification
phase will be contacted for the invitation for tender(s) for the
production of X-band AS and PETS;
 The corresponding invitation to tender will be based on a detailed
technical specification, which will include the experience gained
from the results of the qualification phase stated above;
 Following each invitation to tender, a contract will be placed with
the lowest compliant bidder.
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Intellectual Property Scheme
 General Conditions of CERN Contracts shall apply;
 Firms develop expertise and know-how to bring their processes in
line with CERN specifications.
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Hybrid Circuits for the CMS Tracker Upgrade
 The CMS Tracker is one of the many sub-detectors that constitute
the CMS detector;
 In view of the High Luminosity LHC, the CMS tracker needs to be
upgraded in 2022 to match the new and more demanding physics
requirements;
 The CMS tracker sensor elements are built as modules, consisting
of silicon sensors, connected to hybrid circuits carrying readout
and control electronics and supported by a lightweight mechanical
structure providing structural support and efficient cooling;
 The modules, assembled at CERN, will have to work reliably in a
harsh radiation and magnetic field environment with no possibility
of maintenance over an expected time frame of more than a
decade.
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CMS Tracker Module and its Components
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Hybrid Circuits for the CMS Tracker Upgrade
 Different module types are under development, matching different
regions of the tracker, which implies different degrees of complexity
and will require different technological solutions;
 These requirements restrict the suppliers to those typically involved
in the packaging of integrated circuits;
 Furthermore, suitable packaging firms offer proprietary
technologies and processes (design rules) that will eventually
result in substantially different implementations while achieving the
same functional result.
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Hybrid Circuits for the CMS Tracker Upgrade
 In order to be compatible with several processes, the final CERN
design of the hybrid circuits must be flexible enough to cope with
the differences between technologies;
 Also, the definition of the acceptance criteria can only be made
after the successful design, fabrication and validation of fully
assembled module prototypes, evaluated under realistic operating
conditions;
 The knowledge required to finalise the specification and
acceptance criteria can only be gained from a robust development
programme and will only be applicable to the processes of those
firms which will have participated in the programme.
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Procurement Strategy
The overall procurement will be divided into two phases:
 A development phase (2013-2015): small quantities of prototypes will
be developed with different firms, technologies and processes (in
parallel):
- Each set of prototypes willl be assembled into modules at CERN,
evaluated and compared under realistic operating conditions;
- The knowledge gained from this integration effort will form the
basis for finalising the specification and acceptance criteria to be
used in the production phase(s);
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Procurement Strategy
 Production phase(s) (2016 onwards): only those firms which have
been qualified as a result of the development phase will be contacted
for the invitation to tender(s) for the series production;
 Since each type of hybrid circuit will be based on its own specification
and acceptance criteria, the production phase of each hybrid circuit will
be the subject of a separate invitation to tender;
 Volumes in the order of 10’000 – 20’000 circuits are expected per
production phase. The delivery schedule of each production phase will
typically extend over one year.
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Procurement Strategy – Development Phase
Development phase
 A market survey to be issued, based on a typical set of qualification
criteria. Among the qualification criteria, firms must demonstrate their
capability to meet the basic technical requirements by providing freeissue hybrid samples developed for other customers;
 After the market survey, a price enquiry will be issued for the
manufacturing of prototype hybrid circuits, based on a preliminary
specification for a specific type. The adjudication will be based on:
- the development cost for the prototype hybrid circuits;
- a ceiling price for a small series production of 1000 pieces;
 A collaboration contract will be placed with 2 to 5 firms, as a result of
the price enquiry. To ensure that firms respect the ceiling price, the
series production will be included as a purchase option in the contract.
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Procurement Strategy – Production Phase
Production phase
 The corresponding invitation to tender will be based on a detailed
technical specification, which will include a generic design based
on the experience gained from the results of the development
phase stated above;
 Bidders will be requested to quote prices using their specific
technologies and processes (design rules);
 Following each invitation to tender, a contract will be placed with
the lowest compliant bidder.
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Intellectual Property Scheme
 The General Conditions of CERN Contracts shall apply; i.e. all
intellectual property generated during the execution of the contract
will belong to CERN;
 The hybrid circuits will be developed using technologies and
processes (design rules) specific to the firms;
 CERN’s generic designs will comply with the specific design rules
of the firms i.e. they will be open enough to allow each firm to work
with its own design rules;
 The designs, the resulting products and the specifications will be
the entire property of CERN;
 CERN to offer a licence on Foreground for other applications, at
preferential rates.
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Nb3Sn Magnets for HL-LHC
 The High Luminosity Project (HL-LHC) aims at upgrading the LHC
machine currently in operation. The aim will be to increase its
luminosity (i.e. the number of particle collisions) by a factor five;
 This will be reached by installing, in particular:
- New 11-T Dipole magnets i.e. a two in one magnet with an
aperture of 60 mm, a coil length of 5.5 m and an approximate
weight of 12 t;
- New large aperture Nb3Sn quadrupole magnets with an aperture
of 150 mm, a coil length of 4 m and an approximate weight of 8 t.
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Nb3Sn Magnets for HL-LHC
 To this end, an R&D project needs to be launched in order to prepare
industry for the future series production of the new types of
superconducting magnets;
 In this way, technology transfer can occur at an early stage of the
development;
 Contractors will benefit from the technical solutions jointly developed
with CERN and those jointly developed by CERN with other
contractors.
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Nb3Sn Magnets for HL-LHC
Figure 1: Cross-section of the 11-T dipole
magnet – 60-mm aperture
Figure 2: Cross-section of the large aperture
quadrupole magnet – 150-mm aperture
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Procurement Strategy
The overall procurement will be divided into two phases:
 A prototyping and industrialization phase (2013-2015):
- The required services consist of providing a total of approximately
10’800 hours of technology development support at CERN for the
construction of Nb3Sn magnets;
- The services are structured into nine work-packages;
- Each contractor shall assign at least four members of its
personnel (an academic engineer, a technical engineer, a
draftsman and an experienced practitioner) in the relevant fields
of competency;
- It is foreseen to place contracts with several contractors for a
period of two years in order to ensure adequate distribution of the
technology in preparation for the series-production;
- Each contractor may be given several work-packages, depending
on its strengths and the relevance of its fields of expertise.
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Procurement Strategy
 Production phase (2016-2017):
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The results of the prototyping and industrialization phase will be
used to finalise the technical specifications for the series
production of the new types of superconducting magnets;
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Since the firms involved in the prototyping and industrialization
phase will only be involved in certain steps of the entire
process, the invitation to tender(s) for the series production
shall not be restricted to only these firms;
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The scope of the invitation to tender will consist of 16 new 11-T
Dipole magnets and 40 large aperture Nb3Sn quadrupole
magnets.
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Procurement Strategy - Prototyping and Industrialization Phase
Prototyping and Industrialization phase
 A market survey to be issued, based on a typical set of qualification
criteria. Only those firms which have been qualified as a result of the
market survey will be contacted for the invitation to tender for this
phase;
 Bidders will be requested to quote prices (hourly rates) based on a
total volume of services (technology development support) estimated
by CERN for the different categories of personnel required;
 The contracts will be awarded to several bidders and will be
adjudicated on a “best-value-for-money” basis.
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Procurement Strategy – Production Phase
Production phase
 The results of the prototyping and industrialization phase will be used
to finalise the technical specifications for the series production and the
invitation to tender(s) for the series production shall not be restricted to
only those firms having taken part in this phase;
 The invitation to tender shall be adjudicated on the basis of the lowest
compliant bid.
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Intellectual Property Scheme
 General Conditions of CERN Contracts shall apply; i.e. all
intellectual property generated during the execution of the contract
will belong to CERN;
 CERN to give free access to the results generated during the
execution of the contract to third parties. Contractors acknowledge
that the results of work related to the prototyping and
industrialization of Nb3Sn magnets will be made available to the
successful bidder for the series production;
 Secure licence on Background and Foreground of contractors for
prototyping and industrialization phase, with right to sub-license the
results to third parties within the scope of CERN’s activities;
 CERN to offer a licence on Foreground for other applications,
beyond HL-LHC procurement, at preferential rates.
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