Collaborating with industry:Collaborating with industry:lessons from the LHC projectlessons from the LHC project

Philippe LebrunAccelerator Technology department, CERN

Eleventh European Particle Accelerator ConferenceGenoa, Italy

23-27 June 2008

ContentsContents

• Industrial features of the LHC• Specification & procurement strategy• Case-illustrated issues

– Qualitative and quantitative jumps in technology– Managing industrialization and series production ramp-up– Partnership in commercial contracts– Performance through shared incentives– From emulation in R&D to competition in market– State-of-the-art technology for affordable hi-tech– Developing emerging industrial products– Industrial production in the lab– Recovering from industrial difficulties

• Conclusion

A large scientific instrumentA large scientific instrumentand a superlative technological projectand a superlative technological project

A A particleparticle collidercollider wellwell beyondbeyondthethe prepre--existingexisting statestate--ofof--thethe--artart

SppS

LEP1

HERA TeVatronLEP2ISR

LHC

1.E+30

1.E+31

1.E+32

1.E+33

1.E+34

1.E+35

10 100 1000 10000 100000

Center-of-mass energy [GeV]

Lum

inos

ity [c

m-2.s

-1]

x 100

x 7

Cost structure of the LHC acceleratorCost structure of the LHC accelerator

Total ~ 2.2 BEuro

54%

12%

1%

1%

3%

2%

2%

15%

3%

2% 3% 2%

MagnetsCryogenicsBeam dumpRadio-frequencyVacuumPower convertersBeam instrumentationCivil EngineeringCooling & ventilationPower distributionInfrastructure & servicesInstallation & coordination

90 hi90 hi--tech industrial contracts in the worldtech industrial contracts in the world

A global A global projectproject spanningspanning spacespace……

……andand timetime

• Preliminary conceptual studies 1984• First magnet models 1988• Start structured R&D program 1990• Approval by CERN Council 1994• Industrialization of series production 1996-1999• DUP & start civil works 1998• Adjudication of main procurement contracts 1998-2001• Start installation in tunnel 2003• Cryomagnet installation in tunnel 2005-2007• Functional test of first sector 2007• Operation for physics 2008-2030

Engineering data management Engineering data management systemsystemSingle data Single data repositoryrepository, , accessaccess to documentation via WWWto documentation via WWW

SpecificationSpecification & & procurementprocurement strategystrategy

• Legal/regulatory framework– CERN purchasing rules– Seeking « fair return » among CERN Member States– Handling special « in-kind» contributions

• Call for tenders– Selecting the right companies– Building know-how & maintaining interest through prototyping,

preseries and series– Technical specification: functional & interface vs. build-to-print

• Contract– Split: security of supply & balanced return vs. additional follow-up– Intermediate supply & logistics– MTF and inspection– JIT vs. production buffer & sorting

• Cost risk estimate from tender statistics

ManagingManaging an an integratedintegrated supplysupply chainchain

BenefitsBenefits

• Technical homogeneity• Quality assurance• Economy of scale• Safety of supply• Balanced industrial return

RisksRisks & drawbacks& drawbacks

• Responsibility interface• Additional workload• JIT breakdown• Transport, storage, logistics

ProcurementProcurement logisticslogisticsQualityQuality & & quantityquantity atat thethe rightright timetime in in thethe rightright placeplace

Installed in LHC tunnel: 50 000 t

Transported throughout Europe: ~150 000 t

TheThe ManufacturingManufacturing & Test & Test FolderFolder (MTF),(MTF),keykey to to qualityquality assurance in productionassurance in production

Production Production bufferbuffer enablesenables sortingsorting ofof magnetsmagnetsfor for optimizedoptimized installation in installation in acceleratoraccelerator

Standard deviation of sextupolecomponent in LHC dipoles

Outdoor storage of cold masses and cryomagnets

ProbabilisticProbabilistic costcost assessmentassessmentfromfrom analysisanalysis ofof quotedquoted tender tender pricesprices

• Number of LHC industrial contracts allowsstatistical analysis of tender prices, grouped by type of technology

• Distribution of quoted prices is taken as measure of the industrial cost variability ofwork packages in the project

• Observed distributions are clearly skew, and better fitted by exponential thannormal probability density function

• Probabilistic assessment of future projectcosts should be based on skew, e.g.exponential rather than normal probabilitydensity functions for individual workpackages

Cryogenics & vacuum

0

5

10

15

20

251.2

51.7

52.2

52.7

53.2

53.7

54.2

54.7

55.2

55.7

56.2

56.7

57.2

57.7

58.2

5More

Tender price relative to lowest bid

Num

ber

Observed frequencyExponential fit

Mechanical components for magnets

05

101520253035404550

1.25

1.75

2.25

2.75

3.25

3.75

4.25

4.75

5.25

5.75

6.25

6.75

7.25

7.75

8.25

More

Tender price relative to lowest bid

Num

ber

Observed frequencyExponential fit

Electronics

0

5

10

15

20

1.251.752.252.753.253.754.254.755.255.756.256.757.257.758.25More

Tender price relative to lowest bid

Num

ber

Observed frequency

Exponential fit

Qualitative Qualitative jumpsjumps in in technologytechnology7000 km 7000 km superconductingsuperconducting cablecable withwith controlledcontrolled propertiesproperties

InnerCable

OuterCable

Number of strands 28 36

Strand diameter 1.065 mm 0.825 mm

Filament diameter 7 µm 6 µm

Number of filaments ~ 8900 ~ 6520

Cable width 15.1 mm 15.1 mm

Mid-thickness 1.900 mm 1.480 mm

Keystone angle 1.25 ° 0.90 °

Transposition length 115 mm 100 mm

Ratio Cu/Sc ≥ 1.6 ≥ 1.9

Superconducting wire & cable productionSuperconducting wire & cable productionALSTOM, EAS, FURUKAWA, LUVATA (LMI, OUTOKUMPU, IGC)

Superconducting cable production statisticsSuperconducting cable production statistics

• Critical current ~10% above specified value• Magnetization and inter-strand resistance under control• Cables within tight dimensional tolerances• Rejection/declassification rate < 1%

Specified 14140 A at 4.2 K, 7 T Specified 13236 A at 4.2 K, 6 T

Quantitative jumps in technologyQuantitative jumps in technology

23 km of superconducting magnets23 km of superconducting magnets1232 dipoles, 474 quadrupoles, 7612 correctors1232 dipoles, 474 quadrupoles, 7612 correctors

Series production of LHC componentsSeries production of LHC components

1.E+00

1.E+01

1.E+02

1.E+03

1.E+04

1.E+05

1.E+06

1.E+07

1 10 100 1000

Number of variants

Max

imum

num

ber o

f uni

ts p

er v

aria

nt SuperconductorsMagnet componentsMagnetsPower convertersCryolinesVacuum

Flexible cells, manual work

Flexible workshops

Automatic chains

Manufacturing of superconducting coilsManufacturing of superconducting coils

JEUMONT, NOELL, ANSALDO

Assembly of superconducting magnetsAssembly of superconducting magnets

ALSTOM, NOELL, ANSALDO

Quantitative jumps in technologyQuantitative jumps in technologySuperfluidSuperfluid heliumhelium as technical coolantas technical coolant

1 liter in the laboratory

500’000 liter in the LHC

Tore Supra

CEBAF

Quantitative jumps in technologyQuantitative jumps in technologyLargeLarge--scale superfluid helium systemsscale superfluid helium systems

0

10

20

30

40

50

60

70

80

90

Tore Supra CEBAF LHC

He

II in

vent

ory

[t

He II inventory

0

5

10

15

20

25

Tore Supra CEBAF LHC

Ref

riger

atio

n <

2 K

[kW

]

Refrigeration power < 2 K

Industrialization & production rampIndustrialization & production ramp--upupSuperconducting cableSuperconducting cable

Development

Industrialization

Industrialization & production rampIndustrialization & production ramp--upupSuperconducting dipolesSuperconducting dipoles

Development

Industrialization

Industrialization & production rampIndustrialization & production ramp--up up Learning curve for superconducting dipolesLearning curve for superconducting dipoles

Beam dynamics requirements

Field quality specifications

Magnet design Component specification

Industrial production

QA & SPCHomogeneization & mixing

Warm mag. measurements

Cold mag. measurementsSampling Cold/warm correlations

Allocation to position in ringInstallation strategy

CERN

Industry

Partnership in commercial contractsPartnership in commercial contractsSteering magnet production for quality and homogeneitySteering magnet production for quality and homogeneity

Statistical production control of componentsStatistical production control of components

Radius 275±0.05

274.90

274.95

275.00

275.05

275.10

ELA 00

1-1ELA

008-

1GELA

015-

1EYA

0002

2-1

EYA00

029-

1

EYA00

046-

2500

EYA00

066-

2500

EYA00

086-

2500

EYA00

105-

2500

EYA00

126-

2500

EYA00

145-

2500

EYA00

165-

2500

EYA00

186-

2500

EYA00

207-

2500

EYA00

227-

2500

EYA00

248-

2500

EYA00

267-

2500

EYA00

287-

2500

Batch number acceptance piece

Ave

rage

radi

us (m

m)

274.90

274.95

275.00

275.05

275.10

Radius averageGrinding Operation

Field quality achieved in series magnetsField quality achieved in series magnets

10.07

10.09

10.11

10.13

10.15

0 100 200 300 400 500 600 700 800 900 1000 1100 1200

Magnet progressive number

Int t

rans

f fun

c (T

m/k

A)

-40

-20

0

20

40

Uni

ts

Firm 1Firm 2Firm 3

AT-MAS

Cold mass

upper limit for single magnet (3 sigma)

lower limit for single magnet (3 sigma)-10

-5

0

5

10

0 100 200 300 400 500 600 700 800 900 1000 1100 1200

Magnet progressive number

b3 in

tegr

al (u

nits

)

Firm 1Firm 2Firm 3

Cold mass

upper limit for systematic

lower limit for systematic

AT-MAS & MTM

Cro

ss-s

ectio

n 2

Cross-section 3

-5

-4

-3

-2

-1

0

1

2

3

4

5

0

Targets

Measured

Cold mass - systematic vs targets

a3 a4b2

ape

rture

1

b2 ape

rture

2

b2 both ap

erture

s

b4 ape

rture

1

b4 ape

rture

2

b4 both ap

erture

s

a2 a5

AT-MAS-6

-4

-2

0

2

4

6

9

Targets

Measured

b3b5 b7

AT-MAS

33 kW @ 50 K to 75 K 23 kW @ 4.6 K to 20 K 41 g/s liquefaction

AIR LIQUIDE

LINDE

Eight 18 kW @ 4.5 K helium refrigerators

Performance through shared incentivesPerformance through shared incentivesEfficiency of cryogenic plantsEfficiency of cryogenic plants

Performance through shared incentivesPerformance through shared incentivesSpecifying cryogenic plants for efficiencySpecifying cryogenic plants for efficiency

• Include capital & operating costs over amortization period (10 years)in adjudication formula

• Operating costs dominated by electricity• Include externalities in electricity costs

– distribution & transformation on CERN site– heat rejection in aerorefrigerants

• Shared incentive in the form of bonus/malus on measured vs. quoted electrical consumption

⇒ breach of “high efficiency = high investment” legend: for given (specified) output, a more efficient plant is not onlycheaper to operate, but also smaller, resulting in lower investment (direct & indirect)

C.O.P. of cryogenic helium refrigeratorsC.O.P. of cryogenic helium refrigerators

0

100

200

300

400

500

TORESUPRA

RHIC TRISTAN CEBAF HERA LEP LHC

C.O

.P. [

W/W

@ 4

.5K

]

Carnot

4 cold compressor stagesCartridge 1st stage

From emulation in R&D to competition in marketFrom emulation in R&D to competition in marketCold compressors for refrigeration at 1.8 KCold compressors for refrigeration at 1.8 K

Air Liquide & IHI-Linde

Axial-centrifugal impeller

Specific features of LHC cold compressorsSpecific features of LHC cold compressors

Axial-centrifugalImpeller (3D)

Fixed-vanediffuser

3-phase inductionElectrical motor(rotational speed: 200 to 700 Hz)

Activemagneticbearings

300

K un

der

atm

osph

ere

Cold

und

erva

cuum

Inlet

Outlet

Pressure ratio2 to 3.5

Spiral volute

Development of LHC cold compressors Development of LHC cold compressors

• Preexisting state-of-the-art

• Preliminary studies

• Prototypes

• Preseries/series

Air Liquide

Air Liquide

Air Liquide (PBS)

Ateko/PBS/LindeAir Liquide

IHI/Linde

IHI

IHI

SEPAteko/PBS

Air LiquideCold Compressor box

IHI-LindeCold Compressor box IHI-LINDE

AIR LIQUIDE

Eight 2400 W@1.8 K refrigeration unitsEight 2400 W@1.8 K refrigeration unitsintegrating 28 cold compressors integrating 28 cold compressors

StateState--ofof--thethe--art technology for affordable hiart technology for affordable hi--techtechCryostat assembly by industry on CERN siteCryostat assembly by industry on CERN site

ICS Consortium

StateState--ofof--thethe--art technology for affordable hiart technology for affordable hi--techtechIndustrial solutions for magnet cryostatsIndustrial solutions for magnet cryostats

Low heat inleak GFRE support post

Aluminium extrusion for thermal shield

CASA ESPACIO

EWK

StateState--ofof--thethe--art technology for affordable hiart technology for affordable hi--techtechInterconnections in the LHC tunnelInterconnections in the LHC tunnel

65’000 electrical joints

Induction-heated soldering

Ultrasonic welding

Very low residual resistance

HV electrical insulation

40’000 cryogenic junctions

Orbital TIG welding

Weld quality

Helium leaktightness

INEO-ENDEL

Developing emerging technologiesDeveloping emerging technologiesModular switchedModular switched--mode power convertersmode power converters

[2kA,8V] converters

KEMPOWER, TRANSTECHNIK

Curre

nt in

Am

ps

500.0

500.1

500.2

0 1 2 3 4 5 6

0

5

10

Curre

nt o

ffset

in p

pm o

f 20 k

A

Time in Seconds

1ppm

ReferenceMeasured

High-precision DCCT

HITEC

Developing emerging technologiesDeveloping emerging technologiesHIP powder metallurgy for HeHIP powder metallurgy for He--tight stainless steel coverstight stainless steel covers

METSO POWDERMET

Developing emerging technologiesDeveloping emerging technologies1200 current feedthroughs (0.6 to 12 kA)1200 current feedthroughs (0.6 to 12 kA)

based on highbased on high--Tc superconductorsTc superconductors

EAS, ASC

Industrial production in the labIndustrial production in the labCryogenic magnet test station at CERNCryogenic magnet test station at CERN

Cryostating 425 FTE.years

Cold tests 640 FTE.years

Recovering from industrial difficultiesRecovering from industrial difficultiesInternalization of SSS assembly after insolvency of contractorInternalization of SSS assembly after insolvency of contractor

Recovering from industrial difficultiesRecovering from industrial difficultiesRepair & reinstallation by CERN of cryogenic ring line sectorsRepair & reinstallation by CERN of cryogenic ring line sectors

following technical/managerial production errorsfollowing technical/managerial production errors

One sector

Two sectors

Three sectors

Four sectors

Five sectors

Six sectors

Seven sectors

Eight sectors

020406080

100120140160180200220240260280300320

01-Jan-01 01-Jan-02 01-Jan-03 01-Jan-04 01-Jan-05 01-Jan-06 01-Jan-07

Equ

ival

ent c

ells

Pipe elements delivered Service modules delivered InstalledInterconnected Interconnected (Contract)

Total installed by Air Liquide

Total fabricated by Air Liquide

ConclusionsConclusions

...however, large scientific instruments such as the LHC require massive investment of human and material resources and unprecedented level of organization, making them industrial-size global projects in advanced technology

• Cooperation with industry is essential from early stages of the project in order to achieve success within business constraints– Develop and maintain interest in a one-off, technically risky supply– Series production of innovative items at market prices– Competition with other products/markets

• Industrial competencies and production capacities developed for the LHC constitute a comparative advantage: they can now be applied to other projects sharing similar technologies

The sole end of science is the honor of the human mind…Carl Gustav Jacobi

Projects sharing LHC technologyProjects sharing LHC technology