1. Functional Specification
H. Felice, D. Simon, J.M. Rifflet CEA/IRFU/SACM
A. Foussat CERN
for the QuaCo team
Bidder’s Conference, CERN, July 7th 2016

2. Technical Context of QuaCo
One of the insertion magnets of the high luminosity upgrade located before the interaction points
Belongs to the Matching Section magnets which match the optics function from the arc (regular cells) to the inner triplet
Double aperture magnet: 2 individual apertures powered independantly in a common yoke
MQYY
HL-LHC layout - Ezio Todesco IP
H. Felice - Functional Specification

3. Technical Context of QuaCo
Funding scheme aiming at supporting industries to develop and manufacture a First-of-a-kind magnet
Starting point:
a magnetic design as an example: which can be kept or modified
Coil geometry including end spacers
Contractor’s responsibility
Provide a complete magnet design
Tooling design and manufacturing
Magnet manufacturing
Contribution from the Buyer’s Group:
Magnet protection study
H. Felice - Functional Specification

4. Functional Specification
Document IT-4191/TE/HL-LHC
EDMS No:
Technical Scope of the PCP
PCP phases
Technical Deliverables
Functional requirements
Items provided by the Buyer’s Group
Example of magnetic design
Minimum set of electrical tests
H. Felice - Functional Specification

5. Some Definitions and important points
TOOLING definition.
Magnet tooling
Tooling dedicated to the magnet and including coil fabrication tooling (winding mandrel, curing mold…), structure assembly tooling, support fixture
Infrastructure tooling
Tooling usable for several types of magnets such as winding machine, curing press…
Development plan
Unlike other magnet contracts (built-to-print), the Contractor is expected to propose a magnet development and manufacturing plan including measurement and QA methods
The measurement accuracy and technique should be proposed by the Contractor and validated by the Buyer's Group
H. Felice - Functional Specification

6. Information transfer from the Buyer’s Group to the company
All the Contractors will have access to the same background from the Buyer’s Group.
This will cover the MQYY magnetic design and coil design as well as quench protection.
Tools development are part of the scope of the QuaCo PCP and will have to be developped by the Contractors along with a development plan.
Any Background from the contractor about previous magnets relevant to the Quaco PCP is welcome to the project and will be kept confidential
H. Felice - Functional Specification

7. Design starting Point Files provided by the Buyer’s Group
Magnetic Files
ROXIE: 3D and 2D, cadata, iron file
Opera CONDUCTOR file only
Coil model including end parts
STP and CATIA files
If the Contractor decides to modify the magnetic design, the magnetic design should be completed by the end of Phase I.
H. Felice - Functional Specification

8. Technical starting Point
Material, equipment and components provided by CERN
Material, equipment and components provided by CERN upon request
NbTi insulated Cable
Protection heaters
Low carbon steel for magnetic yoke (Hot rolled: 5.8 mm thickness, 650 x 3000 to 4000 mm)
Austenitic steel material
Rad hard Material for end parts
Calibrated warm magnetic measurements probe
No other material or components supplied unless a need is clearly expressed by the Contractor and is considered relevant by the Buyer's group
H. Felice - Functional Specification

9. Technical starting Point
Material, equipment and components provided by CERN
Some samples can be provided if the need is demonstrated by the development and manufacturing plan
NbTi insulated Cable
Protection heaters
Calibrated warm magnetic measurements probe
The protection of the magnet relies on protection heaters.
With protection heaters, the hot spot is expected to be below 200 K. Fault scenario are under study. For now there is no planned energy dump
The zero will depend on the magnetic measurement system accuracy.
H. Felice - Functional Specification

10. Miscellaneous technical questions
Radiation Hardness
If impregnation is foreseen by the Contractor as part of the fabrication, Epoxy CTD 101 K has been granted acceptable for this application without the need to go to cyanate ester. Any other resin should be qualified
LHC references : and 
Persistent current:
effect should be computed but not a driver for the design.
Capacitive gauges
This technology is not developed anymore at CERN.
The instrumentation lab is open to discuss with Contractors possible route for instrumentation to be developed by the Contractor.
Interface:
An initial set of interface specification will be available early in Phase 1 and shall be sufficient to execute the work of Phase 1.
Any modification from this initial spec is not expected to create any impact on price or schedule. The modification will typically be fine tuning of the yoke outer features (cut-outs for example).
H. Felice - Functional Specification

11. Licences Use of ROXIE Use of Castem
Will be available without licensed BEM FEM module
Use of Castem
License of approximately 4500 €.
No direct comparison with results from CEA as the development should be made only by the Contractors.
ANSYS is of course acceptable for mechanical computation
H. Felice - Functional Specification

12. Quaco 3 phases
Phase 3
First-of-a-kind manufacturing and testing
Phase1
Solution Design
Phase 2
Engineering Design
All tooling and components design completed and purchasing docs ready
Tooling and components procurement
H. Felice - Functional Specification

13. Scope of Phase 1
Conceptual designs of the tooling and of the magnet are expected including:
A preliminary magnetic design; If the Contractor chooses to develop a new magnetic design, the 2D and 3D magnetic designs shall be finalized by the end of Phase 1.
A conceptual design of the support structure consisting of finite element analysis and CAD models;
Conceptual designs of the coil fabrication tooling and of the magnet assembly and support tooling (preliminary 2D and 3D CAD models).
A preliminary manufacturing and inspection plan along with concept of assembly processes.
Project management documents including the detail of the work either carried out at the Contractor’s premises or subcontracted.
Reassessment of the work to be carried out in Phases 2 and 3.
H. Felice - Functional Specification

14. Deliverables of Phase 1 H. Felice - Functional Specification
Description
D1.1
Conceptual Design Report (CDR) of the magnet covering the results obtained in Phase 1 including:
Magnetic design study
Conceptual mechanical design study
List of requirements met by the design
D1.2
Preliminary 2D and 3D CAD models of the magnet
D1.3
Conceptual Design Report of the Tooling including:
Coil fabrication tooling conceptual design
Magnet assembly tooling conceptual design
D1.4
Development and Manufacturing plan including:
Detailed plan for Phase 2 detailed engineering design
Detailed plan for the mock-ups to be developed in Phase 2
Detailed plan for manufacturing, assembly and testing processes of the magnet
List of available tooling including required upgrade if necessary
List of tooling to be procured to complete the three Phases
Subcontrating plan
D1.5
Detailed schedule for the three Phases
D1.6
Preliminary Quality Assurance plan including risk assessment one month after the start of Phase 1 for Buyers Group approval.
D1.7
Final Phase 1 Technical Report including the reassessment report of R&D effort for Phases 2 and 3
H. Felice - Functional Specification

15. Scope of Phase 2: Detailed Engineering Design
Final coupled magnetic and mechanical design including integration features.
Final CAD models of the magnet and its components and of all the related tooling.
A final manufacturing and inspection plan including assembly and fabrication procedures.
Mock-ups and associated tooling if required.
Updated project management documents including the list of work carried out at the Contractor’s premises or subcontracted.
All the purchasing documents for the procurement of the magnet tooling and components
Reassessment of Phase 3 work
H. Felice - Functional Specification

16. Deliverables of Phase 2 Deliverable Description D2.1
Detailed Design Report (DDR) covering all the results obtained in Phase 1 and 2 including:
Detailed Magnetic design optimisation
Detailed Mechanical design optimisation
Sensitivity analysis toward fabrication
Magnet protection items provided by the Buyers Group
Updated list of requirements met by the design
D2.2
Detailed 2D and 3D CAD manufacturing drawings of the magnet and subcomponents including instrumentation schematics
D2.3
Detailed 2D and 3D CAD drawings of the manufacturing tooling
D2.4
Manufacturing and Inspection Plan (MIP)
D2.5
Mock-ups, if any, in agreement with development plan
D2.6
Updated schedule
D2.7
Final Quality Assurance plan
D2.8
Technical mid-phase report
D2.9
Final technical specification for tooling and components
D2.10
Final Phase 2 Technical report
D2.11
Technical specification of the MQYY First-of-a-kind and reassessment report of R&D effort for Phase 3
H. Felice - Functional Specification

17. Scope of Phase 3: First-of-a-kind manufacturing and testing
Procurement of all the components and tooling to proceed with magnet fabrication.
Coils fabrication
Assembly of the magnet
Final as-built CAD models and 2D drawings
Updated project documents.
Each stand-alone aperture and the First-of-a-kind magnet shall be validated by ambient temperature Factory Acceptance Tests
Minimum Tests proposed in FS
The First-of-a-kind magnet shall be packed and shipped to the Buyers Group (CERN or CEA/Saclay). The address will be communicated to the Contractor during Phase 2.
H. Felice - Functional Specification

18. Deliverables of Phase 3 Deliverable Description D3.1
Delivery certificates of tooling
D3.2
Delivery certificates of magnet components (excluding the components provided by CERN, indicated in § 2.4)
D3.3
One practice coil (trial full-scale coil built to validate the coil fabrication process), nine fully conforming cured coils including one spare coil
D3.4
Completed Manufacturing and inspection plan including updated list of subcontracted activities.
D3.5
Quality control and test reports in compliance with § 5.2 and § 5.3
D3.6
As-built 2D and 3D CAD manufacturing drawings of the magnet
D3.7
As-built 2D and 3D CAD manufacturing drawings of the tooling
D3.8
Delivery of MQYY quadrupole with complete MTF traveller and shipment file
D3.9
Updated detailed schedule
D3.10
Updated Quality Assurance plan
D3.11
Technical quarterly reports
D3.12
Pre-commissioning of the manufacturing tooling
D3.13
Commissioning report of the manufacturing tooling
D3.14
Final manufacturing report covering
All the results obtained in Phase 1, 2 and 3
Final list of requirements met by the magnet
D3.15
Preliminary technical specification of the MQYY series magnet
H. Felice - Functional Specification

19. Ownership of the infrastructure tooling
The Contractor owns the tooling before Quaco PCP or develops and buys the tooling during Quaco PCP with its own funds
The infrastructure tooling stays at the company at the end of Quaco. Only functional drawings (not detailed) will be requested by the Buyer’s Group at the end of Quaco to allow fabrication of the series.
The Contractor develops and buys the tooling during Quaco PCP with Quaco funds
If the Contractor uses the tooling either in the Buyer’s group series production or in any commercial exploitation, the tooling remains with the Contractor (clause #8 of the FA)
H. Felice - Functional Specification

20. Any additional questions?
H. Felice - Functional Specification