1. Manufacturing contracts for RFQ
CDR2 RFQ| Vincent Hennion
System engineering activities

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Table of contents
Chapter 01 Rules and purchasing P.04 List of RFQ Contracts P.05 Tendering documents file P.06 Contracts follow-up strategy P.07 Chapter 02 Focus on the 5 main contracts P.09 Questions P.15
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

3. Chapter 1
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

4. Rules and purchasing procedures
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 simplified procedure (not formalized) for purchases < € 207,000
The formalized procedure 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

5. 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, …
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

6. 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 Purchasing Department
IRFU Engineering team and DO
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

7. Contract follow-up strategy
Regular progress meeting (face to face or by teleconference)
Sensitization of the 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 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

8. Chapter 2
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

9. 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 coupling loops
Machining and brazing of the ceramic window
Manufacturing of the water cooling loop
TiN coating characterization
Contract 5: RF tuners
Cu/bellows assembly
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15

10. Contract 1: copper raw material
Forging process
Isotropic and homogeneous pure copper, with grain size <500µm
3D hot forged copper, at °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 sampled from 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

11. 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

12. 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 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

13. Contract 4: RF coupling loop
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

14. 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

15. Thank you for your attention!
QUESTIONS?
Commissariat à l’énergie atomique et aux énergies alternatives
Centre de Saclay | Gif-sur-Yvette Cedex
T. +33 (0) xx xx | F. +33 (0)
Etablissement public à caractère industriel et commercial | RCS Paris B
DSM Irfu
CEA Saclay/Irfu ESS RFQ CDR2| 8-9 Dec15