Procurement of Nb 3 Sn strand, cable fabrication, and quality control for the U.S. Hi-Lumi LHC Accelerator Upgrade Project Lance Cooley, Fermilab L3 manager for strand and cable MQXF International Review – CERN, June 7 th – 10 th, 2016

logo area Overview - strand  The U.S. team is moving forward with an acquisition plan for 10 tons of conductor  The present LARP procurement of 208 km = ~1 ton, to conclude early 2017, has exhibited properties well above specification  Pre-production issues have emerged as well  The AUP profile requires a LARP procurement of 1.5 ton = 300 km at FY17 start with option for 1700 km = 8.5 additional tons after CD-1 / CD-3a  Magnets are critical path; procurement start is important for schedule margin  The acquisition plan assumes a phased procurement  The schedule addresses risks for raw material delay by adding 20% of (year+1) needs to yearly procurement Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 20162

logo area Overview - cable  The AUP plan assumes fabrication of 100 cables will be needed for 90 coils  Risk for cable failure is incorporated into the project baseline procurement  Mitigation requires procurement of more unit lengths …  … However, the UL will reduce, so net procurement is same  6 long cables have been fabricated with no issues; the 7 th long cable was started and then halted due to a strand break 15 m after start of run  Resolution and corrective actions will be discussed  LARP will have produced 17 long cables by close of program Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 20163

logo area Overview – QA / QC  Quality Assurance  International standards, written procedures, personnel and facility qualification, and benchmarking are integrated into the project  Quality Control  Primary strand QC responsibility is the supplier  Testing at each end of billet mandatory  Interior piece testing shall be triggered by breakage  QC test is a ~3% cost penalty, encourages long pieces  Labs will verify supplier tests with graded testing approach  50% at start; lower as production continues  Benchmarking has been completed  Cables qualified by RRR and microscopic analyses  Addition of cable scanning and strain sensors on Turk’s head Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 20164

logo area Specification table for LARP and HL-LHC AUP strand Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 2016 Magnet length and field gradient Field quality Magnet protection 5 Field quality

logo area Specification table, p.2 Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 2016 < 5% reduction of properties upon cabling Cooling 6 Magnet length Cooling

logo area Conductor acquisition plan for HL-LHC AUP  100 cable ULs x 40 strands = 4000 unit lengths = 2000 km = 10,000 kg  1 cable UL = 500 m  1 cable UL = 20 km strand = 100 kg = $175k (per basis of estimate) or $155k (present LARP cost)  About 250 billets  8 potential suppliers (next slide)  Only OST was qualified under LARP  Best value procurement  Technical review panel identified  Cost-performance balance defined Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 20167

logo area Suppliers and qualification A source evaluation board will not be used for HL-LHC AUP Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th Only vendor to meet LARP qualification = Vendors with significant potential to respond to Project RFP

logo area RRR vs Ic for present LARP procurement Statistical process control at 3-sigma (99.1%) level  Statistics (11 billets, 22 spools) for 665 °C / 75 h HT  Shipment B received 31 March 2016, Lab measurements not yet available  Hotter, longer HT promotes higher 15 T Jc  RRR difference was found to be arise from different sample preparation by benchmarking, and possible actions are being considered at this time Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th  = 48 A 3  = 59 A 2738 A/mm A/mm 2 3  = 90 9

logo area N-values and copper to non-copper ratio Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th  =  = 4.8 Cu:NC = 1.2 ± 0.1 Average Dia. Spec ± mm

logo area Delivered piece length distribution (162 of 308 km) Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th m 1100 m 2200 m3300 m4400 m5500 m6600 m7700 m8800 m9900 m Max length for 45 kg billet = 9250 m  LARP = 141 UL (i.e. 3.5 cables)  CERN = 123 UL

logo area Diameter measurements along axes – example of QC A discrepancy at supplier was corrected after shipment A Average diameter = (dx + dy) / 2 12 Verification at labs identified a faulty laser micrometer, a die out of calibration, and vertical axis vibration on supplier’s line  non-conformity, corrective actions completed Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th 2016

logo area Deviations and Non-conformance  While the QC plan outlines procedures for handling discrepancies, established procurement policies at the supplier and the labs work very well  Supplier is required to receive authorization to deliver, and must provide a certificate of compliance  Request for authorization to deliver must include all QC data, billet pedigree report, and piece report  Verification samples are sent to lab when request is made; lab can hold shipment until QC data are verified  NC, DR, and discrepancy processes have all been exercised during the present LARP procurement  Non-conforming: diameter at specification limit, corrective actions  Deviation request for piece shorter than minimum length  RRR test discrepancy revealed difference in sample preparation Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th

logo area QA as a continuous process  Diameter non-conformity: fault at 2 levels  A round-robin test (OST, LBNL, BNL) revealed the discrepancy  Laser micrometer out of calibration and was replaced; drawing die was retired; new equipment and dies were installed  Raw material: boron impurity caused hard NbB precipitates to occur  Boron was not included in material specifications (e.g. ASTM)  Documentation allowed OST and sub-contractor to trace defect to ore source at sub-contractor  New spec, QC and testing have been added  Cable: fault at 2 levels and production learning  A clean room defect was present within “manually scan” length  QC procedure was not followed by 2 nd shift tech in production Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th

logo area Conclusions  A comprehensive acquisition plan, QC plan, and strand specification have been completed  These were exercised in a pre-production LARP procurement  LARP will request proposals for 1.5 tons, with option for additional 8.5 tons (AUP), this summer, for contract award Oct-Dec 2016  Start of procurement at beginning of FY17 is required to provide adequate schedule margin for magnet production  The 0.85 mm RRP ® 108/127 strand meets or exceeds specifications, with significant margin for I c and RRR  Delivered piece lengths are consistent with past performance and cost model, no surprises Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th

logo area Conclusions - 2  Risks were uncovered during the pre-procurement run  Strand production has been delayed by 9 months due to raw material issue  Phased procurement will add 20% of (year+1) strand needs to mitigate risk of raw material gap  A strand break occurred during the 7 th long cable run  Location was in startup length, cause appears to be an inclusion that escaped supplier QC at a “manually scan” region  At OST: R&D teams are handing off responsibility for conductor to production teams  If this had occurred in the middle of the run, the cable would have been lost  Total acquisition will support 100 cable unit lengths to address a 10% cable failure rate Cooley – US Strand, Cable, and QC - MQXF International Review, June 7th-10th