heptech and ess innovation procurement workshop lund procurement at cern and innovative procurement:...

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 1000C

under hydrogen atmosphere;- brazing of the vacuum manifolds to the disk stack;- vacuum baking at 650C.

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Main Tolerances for Accelerating Structure Disc

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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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Power Extraction and Transfer Structures (PETS)

General View of a PETS Unit

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Procurement Strategy

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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.

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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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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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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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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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.

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 free-issue 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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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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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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Figure 2: Cross-section of the large aperture quadrupole magnet – 150-mm aperture

Figure 1: Cross-section of the 11-T dipole magnet – 60-mm aperture


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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Production phase (2016-2017):

- 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;

- 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;

- The scope of the invitation to tender will consist of 16 new 11-T Dipole magnets and 40 large aperture Nb3Sn quadrupole magnets.

Procurement Strategy - Prototyping and Industrialization Phase

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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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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.

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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