ENGINEERING CHALLENGES FOR BIG SCIENCE PROJECTS AT CEA-IRFU - 1st BRIGHTNESS WORKSHOP Florence ARDELLIER
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ENGINEERING CHALLENGES FOR BIG SCIENCE PROJECTS AT CEA-IRFU 1st BRIGHTNESS WORKSHOP Florence ARDELLIER CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016
CONTENTS 1. CHALLENGE FOR LARGE ENGINEERING SYSTEM 2. CEA IRFU ORGANISATION CUSTOMIZED FOR LARGE SCIENCE PROJECT CONTRIBUTIONS 3.CEA IN KIND CONTRIBUTION FOR ESS ACCELERATOR - CEA IKC for accelerator construction - managerial interfaces - interface control documents & drawings - deviation process control - risk register 4. CONCLUSION CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 2
CHALLENGES FOR LARGE SYSTEMS ENGINEERING Innovative, complex, integrated, compact and gigantic, more powerful and sensitive …… New technologies to use and to custom Environnement contraints: intense beams, magnetic field, accessibility, safety rules, … Reliability , « long » life cycle Limited Budget : prototypes and demonstrators have to be limited Internationale collaborations with several contact persons, different standards Very tight time schedule Splitted contributions with complex interfaces CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 4
CHALLENGES FOR LARGE SYSTEMS ENGINEERING Innovative, complex, integrated, compact and gigantic, more powerful and sensitive …… New technologies to use and to custom Adapted « technical » tools : Environnement contraints: intense beams, PLM, CAD, ERP… magnetic field, accessibility, safety rules, … Reliability , « long » life cycle Limited Budget : prototypes and demonstrators have to be limited Internationale collaborations with several contact persons, different standards Customized methodology Very tight time schedule and process Splitted contributions with complex interfaces CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 5
CHALLENGES FOR LARGE SYSTEM ENGINEERING : MULTIDISCIPLINARITY Environnement : Mechanical temperatures, radiations, structure vibrations instrumentation Material slow control Science Electro- Electronics Engineering magnetism for large systems Electro- Acquisition magnetic system compatibility Integration Vacuum, Process Interfaces and Cryogenics information Product life management Optics cycle CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 6
INTEGRATED MULTI DISCIPLINARITY SYSTEM assurance Prodcut Electro- Acquisition Engineering for magnetism system large systems Interfaces and information management Resources CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 7
IRFU ORGANISATION AND SOME HIGHLIGHT CONTRIBUTIONS TO LARGE SCIENCE PROJECT | PAGE 8 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016
IRFU : SCIENCE, TECHNOLOGY AND ENGINEERING 18% 20% 814 FTE ~800 FTE Missions 632/615 632/615CDI/CDI-CEA CDI/CDI-CEA 9% 814 Physicists 165 FTE Physics of the two infinites FTE Engineers 274 FTE 19% 34% Technicians 152 FTE Technology for Radiations Adm. Staff 72 FTE PhD & Post Docs 150 FTE Engineering Institute of Research into the Fundamental laws of Institute of Research into the Fundamental laws of Universe Universe 116 perm. Astrophysics Astrophysics SAp: Astrophysics Accelerators, Accelerators, SACM: Accelerators, 125 perm 94 temp. Space Space technologies technologies Supra. Supra. Magnets Magnets 25 temp 56 perm. Detectors, Detectors, electronic, electronic, SEDI: Detectors, 125 perm. Nuclear Nuclear SPhN: Physics Physics Nuclear Physics 29 temp. computing computing electronic, computing 11 temp. 72 perm. Particle Physics Systems engineering 97 perm. Particle SPP: Physics Particle Physics Systems SIS: engineering Systems engineering 45 temp. 15 temp CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 9
IRFU CONTRIBUTES TO WORLD LARGE INFRASTRUCTURES IN PHYSICS US-DOE CNRS/In2p3 GSI-FAIR GANIL DESY CERN KeK JAEA ESO CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 10
PARTICIPATION TO LARGE PROJECT ENGINEERING CHALLENGES Human ressources Technology Platforms Project oriented organization , HighTech ATLAS Toroïdal Magnet CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 11
SPIRAL2 : RFQ & CRYOMODULES 2014 2015 Results ALICE p+Pb Signature MOU ALICE-MFT Upgrades LHC Codes Parton Results CLAS-GPD CLAS12 tracking detector Delivery CLAS12 Start of Spiral2 Muon Tomography of "château Progresses of S3 d'eau centre de Saclay" Progresses of NFS S3 Triplets First publications MINOS RFQ CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 PAGE 12
XFEL : C RYOMODULES ASS DELIVERY OF INJECTORS: IPHI, IFMIF, SPIRAL2, FAIR PLAN D’INVESTSSEMENT IRFU 2 014 2 015 Dépenses Recettes Dépenses Recettes Ressources Ressources Investissements Subvention Investissements Subvention Externes Externes et marges sur et marges sur PL PL XFEL 3 000 1 960 4 500 1 595 IFMIF EVEDA 5142 0 4978 1691 FAIR 200 560 360 ESS Contract 2500 2500 1750 1750 ESS IN KIND 3860 3860 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 Sources et Injecteurs MOU CEA-FAIR? Livraison à GSI Injecteurs de protons LINAC4 FAIR p-Linac Décision SARAFer Décision post app. élargie 1 faisceau SPII Ganil Saraf fin des études 1er faisceau à Rokkasho Lancement des installations Saraf Sources deutons SPIRAL2 IFMIF-EVEDA SARAF ENS & Injecteurrs Réception RFQ ESS TDR Décision ESS Fin des tests IPHI Injecteurs haute intensité IPHI ESS RFQ LINACS supraconducteurs Décision SARAF Validation du concept SRF-Linac SRF-Linac intégration (déb.) Réception à Rokkasho (déb.) Livraison à Lund (déb.) Linacs SC Protons-Deutons IFMIF-Eveda SRF-Linac ESS / SARAF Cryomodule XFEL Convention signée Début de la production industrielle Fin de la production inductrielle Décision japonnaise Cryomodules à électrons E-XFEL ILC CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 PAGE 13
JT-60SA TEST STATION (TEST FACILITY MAGNETS FOR FUSION TOKAMAK) PLAN D’INVESTSSEMENT IRFU 2 014 2 015 Dépenses Recettes Dépenses Recettes Ressources Ressources Investissements Subvention Investissements Subvention Externes Externes et marges sur et marges sur PL PL ISEULT 1 400 1 400 1 600 1 600 R3B Dirac 411 411 100 100 JT60 CTF 1 985 1 111 1 500 237 JT60 TFC 2 427 4 140 4 598 2 751 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 Aimants supraconducteurs Déb. de réception à Neurospin Bobine réceptionnée à Grenoble ISEULT ISEULT LNCMI Hybride 43 T Gradiens Coils LNCMI 30+ T T MOU CEA-FAIR? Test dans le cryostat W7X Installation des aimants R3B à GSI Livraison des dipôles Super FRS à GSI GSI – Fair R3B Glad Super FRS dipoles LHC Upgrade FCC Stratégie européenne LHC Eucard 2 FP7 & CEF HL - LHC HE - LHC FCC Plateformes cryogéniques Fin construction CTF Fin des tests des bobines JT60 Plateformes de test des JT60 SA ITER - Activities bobines CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 PAGE 14
DOUBLE-CHOOZ : NEUTRINO PHYSICS 2014 2015 Higgs & EWSB Higgs, BSM Publications RUN1 LHC RUN2 Upgrades LHC upgrade LHC (ATLAS upgrade MOU, demonstrator NSW) Double-Chooz near det. Proposal phase 2 Cesox, Stereo: Double-Chooz, T2K Start of construction Publications R&D Neutrino: Cesox, Stereo: Work on proto TPC Preparation of data taking long baseline R&D Neutrino: Post-LHC MoU WA105 (proto TPC) FCC R&D HTc magnets with CERN CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 PAGE 15
EXTRA LARGE TELESCOPE UNDER CONSTRUCTION (LEADED BY ESO) 2014 2015 ELT – METIS start ELT Decision Caméra submm ArTéMiS APEX Camera submm ArTéMiS (ESO) 350 & 450 mm APEX (ESO) 350 mm SVOM review in China Restart of SVOM CTA Camera CTA Reviews Solar Orbiter (End of construction Calistes) Solar Orbiter (Calistes) Start phase A L2 Athena Selection ESA L2, M3 Launch Astro-H CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 PAGE 16
ELT UNDERCONSTRUCTION 2014 2015 ELT – METIS start ELT Decision Caméra submm ArTéMiS APEX Camera submm ArTéMiS (ESO) 350 & 450 mm APEX (ESO) 350 mm SVOM review in China Restart of SVOM CTA Camera CTA Reviews Solar Orbiter (End of construction Calistes) Solar Orbiter (Calistes) Start phase A L2 Athena Selection ESA L2, M3 Launch Astro-H CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 PAGE 17
IRFU ORGANISATION FOR BIG SCIENCE PROJECTS CHALLENGES Direction of the Institute Management Control Head of Head of Head of Head of Head of Head of External Partners Division Division Division Divisio n Devision Division SPP SAP SPhN SACM SEDI SIS Projet Double Chooz A-NEUTR-01-03 Collaboration RS CP Cnrs Projet Collaboration RS CP JWST-MIRI A-JWSTM-02 Cnes ESS RS CP Projet ESS-IK French Ministery A-ESSIK-01 RS Responsable scientifique CP Chef de projet Direction of the institute : Provide ressources, cover risks, realise arbitrations Head of Division : manage human resources and guaranty adequate skills Project direction : Project Manager & Scientist Responsible in charge to deliver instruments / components with the respect performances / cost / time schedule CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 18
IRFU ORGANISATION FOR BIG SCIENCE PROJECTS CHALLENGES Direction of the Institute Management Control Head of Head of Head of Chef de Chef de Chef de External Partners Division Division Division service service service SPP SAP SPhN SACM SEDI SIS Projet Double Chooz A-NEUTR-01-03 Collaboration RS CP Cnrs Projet Collaboration RS CP JWST-MIRI A-JWSTM-02 Cnes ESS RS CP Projet ESS-IK French Ministery A-ESSIK-01 RS Responsable scientifique CP Chef de projet Direction of the institute : Provide ressources, cover risks, realise arbitrations Head of Division : manage human resources and guaranty adequate skills Project direction : Project Manager & Scientist Responsible in charge to deliver instruments / components with the respect performances / cost / time schedule CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 19
IRFU « STANDARD » PROCESS OF THE PROJECTS MANAGEMENT Emergence Projet Management Physics: Bottom-up TGIR: Top-down Scientists Scientific Council EXPLORATORY Experience Validation by Recommandations PHASE proposal institute Strategic evaluation (Phase 0) directory Experts Kick Off review techniques EVALUATION Operational PHASE Référentiel Projet Evaluation (Phase A-B) Validation by Recommandations institute directory Realisation REALISATION PHASE Reporting Institute meeting (Phase C-D) EXPLOITATION Exploitation Publications PHASE Scientific Council Institute meeting (Phase E) CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 20
STANDARD PROCESS OF THE PROJECTS MANAGEMENT Emergence Projet Management Physics: Bottom-up TGIR: Top-down Scientists Scientific Council EXPLORATORY Experience Validation by Recommandations PHASE proposal institute Strategic evaluation (Phase 0) directory Experts Kick Off review techniques EVALUATION Consideration of Specific Large Operational PHASE Référentiel Evaluation Infrastructure Projet standards (licensing, data Validation by (Phase A-B) format required, CAD, …) Recommandations institute Contracts directory Preliminary strategy for procurement plan Signatures, CDR Realisation REALISATIONImplementation of standards : ESO, Cern, PHASE ESO, FAIR,Reporting XFEL…and ESS Institute meeting (Phase C-D) Choice of the subcontrators EXPLOITATION Exploitation Publications PHASE Scientific Council Institute meeting (Phase E) CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 21
IRFU « STANDARD » ORGANISATION CEA Partie (level 1) Organisms governance (CEA) strategy Institute Laboratories directory (Irfu) IRFU (level 2) Programmatic : steering committee, financial boards, risks, change SoW … Project Direction Scientist responsible Project manager Project Management system CEA ESSI Project Management Configuration & Project control management including PAQ, (Level 3) system engineer Officer configuration, risks register, conformity Quality, meeting, schedule,… documentation and Project assistant safety officer Technical & Engineering Level (Work- Packages leaders) technical design CEA ESSI Technical Leaders WP1 WP2 WP3 WP3 and developments, (level 4) realisation process Leader Leader Leader Leader choices and follow up, technical qualifications and acceptance, schedule… CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 22
FOR INKIND CONTRIBUTION PROJECTS, KEYS ENGINEERING PARAMETER TO SET UP : Contribution perimeters and deliverables : Reference Scope of Work to be approved during Kick Off meeting Interfaces definition Technical : limit of the components delivered and associated documentation Format of data exchanges Organisation and communication / decision scheme Process for changes / deviations management Implemented from reference configuration Risks management CEA Saclay/Irfu projet ESS | DATE | PAGE 23
CEA IN KIND CONTRIBUTION FOR ESS ACCELERATOR - CEA IKC OVERVIEW - MANAGERIAL INTERFACES - INTERFACE DRAWINGS - DEVIATION PROCESS CONTROL - RISK REGISTER | PAGE 24 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 24
CEA IN KIND PERIMETER FOR ESS ACCELERATOR CONSTRUCTION 1. CEA – IRFU contributes to 4 different ESS WPS For Elliptical Cryomodules WP - Collaboration with CNRS/ IPNO for Cryomodules CAD Design - ESS partners for cavities (INFN/LASA & STFC) in the assembly process Diagnostics Elliptical Cryomodules RFQ Demonstrators (M-ECCTD & H-ECCTD) Juin 2016 : Doppler Nov 2016 : EMU Mid 2018: delivery ar Lund 30 Elliptical Cryomodules Avril 2019 : nBLM - RFQ & support • Components supply (apart cavities) t et Juin 2019 : profileurs - Thermal system caractérisation des composants (sauf cavités) faisceau non invasifs - Tools for assembly in tunnel • Assemblage & part Integrated Control System of Cryomodules Mi-2016 : Proton Source LEBT tests 2017 : RFQ coupleursconditioning 2018-19 : 9 CM Med b 2019-22 : 21 CM High b Mi 2018 : RFQ vaccum & thermal contril CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 25
IRFU IKC for ACCELERATOR CONSTRUCTION : BILATERAL AGREEMENT between ESS-ERIC & CEA CEA ESS Parties (niveau 1) Administrateur général Directeur Général CEA – IRFU ESS Chef d’Institut Instituts (niveau 2) Directeur Technique Direction projet ESS Irfu Direction du projet ESS ESSI Responsables Divisions (niveau 3) Accélérateur & Control System ingénierie Système, Contrôle projet, analyse Equipe projet ESSI Qualité de risques (niveau 4) ESS Responsable du lot Responsable du lot Responsable des lots Responsable des lots Responsables des Work Cryomodules RFQ Diagnostics Système de Contrôle Packages Elliptiques • Niveau 1 : Strategy : meeting on demand, • Niveau 2 : Coordination Committee for IKC follow up : 2 / years, • Niveau 3 : Reporting & Technical Coordination : 2 / months • Niveau 4 : Monthly reports & weekly exchanges CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 26
INTERFACES CONTROL DOCUMENT Resources allocation Interface drawings : limit the technical perimeter of procurement and get compliant the integration from the preliminary design until the Factory Acceptance Checks / Tests Comité des engagements CEA | DRF | IKCA ESS | 14 Septembre 2016| 27
DEVIATION CONTROL SYSTEM The procedure CEA-ESS-PJT-AQ-0004 (Procédure de traitement des non- conformités et des demandes de modification du projet ESSI) covers non conformity and change request. It describes the process for the control of non conformities and for the configuration baseline changes. As designed configuration Product life cycle As built (baseline configuration configuration) Change and nonconformity control For the ESSI project, the reference configuration for an item is the configuration defined at the kick off meeting ( extract from ESSI Quality Plan). CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 28
CLASSIFICATION OF THE DEVIATIONS INTO 3 LEVELS MINOR INTERMEDIATE MAJOR MAJOR CEA WP CEA PMO/WP ESS responsibility responsibility responsibility N1 L2 N3 Safety of people and equipment X DEVIATION WITH Operational, fucntional and technical « USE AS IS », requirements X « REPAIR » AND « SCRAP » Interfaces with subsystems of the accelerator X DISPOSITIONS TRANSMITTED TO ESS Reliability, maintenability and availability X ------------------ ALL MAJOR NONCONFORMITIES Lifetime X RELATIVE TO Changes or nonconformance from approved CAVITIES qualification or established procedure X Internal interfaces X Deviations occurred during assembly and test X Minor deviation: Deviation which cannot be classified major. In case of several minor deviations on the same component, the classification shall be reevaluated (remain minor or reclassified major). Quality Assurance and Quality Control – Learning and Planning Workshop - 30 June 2016 | PAGE 29
PROCESS FLOWCHART SHARED WITH ESS Procédure de traitement des non-conformités et des demandes de modification du projet ESSI (Référence CEA-ESS-PJT-AQ-0004) Step 1: Detect and record the deviation Step 2: Analyse the root causes and the consequences Validate the corrective and preventive actions Step 3: Implement the actions Step 4: Check the actions and close the report CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 30 | PAGE 30 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016
RISKS MANAGEMENT Risks register is shared with ESS and updated every 6 months Initial : 18 risks in severe zone Currently : 9 risks in severe zone Currently : 9 risks in severe zone 01/2015 ESSI All WP risks portfolio - before mitigation ESSI All WP risks portfolio - under mitigation ESSI All WP risks portfolio - after mitigation Very Likely Very Likely Very Likely (16) - - 1 - - (16) - - - - - (16) - - - - - Likely (8) - 1 4 10 2 Likely (8) - 1 2 3 - Likely (8) - 1 - - - Not likely Not likely Not likely (4) - - 4 12 5 (4) - 1 6 14 6 (4) - - 3 1 - Unlikely (2) - 3 3 3 5 Unlikely (2) - 4 2 6 5 Unlikely (2) - 5 13 5 2 Not Not Not Credible (1) - - - 3 - Credible (1) - - 2 3 1 Credible (1) 1 6 8 4 7 Negligible VERY HIGH Negligible VERY HIGH Negligible VERY HIGH LOW (2) MEDIUM (4) HIGH (8) LOW (2) MEDIUM (4) HIGH (8) LOW (2) MEDIUM (4) HIGH (8) (1) (16) (1) (16) (1) (16) Most critical risks (9) - in severe zone - are currently : - Management & Engineering : Unclear definition of interfaces K64 - CM assembly : Assembly contractor not fully efficient (at the starting time mainly) K64 - CM components : Series components integrated not matching performances K64 - CM components / Couplers : Pre-serie will not reach the expected performance during conditioning K128 - RFQ : Couplers not reaching specifications (800 kW) K64 - RFQ : Difficulties to perform RFQ sections brazing K64 31 - RFQ : RFQ compromised during conditioning K64
CONCLUSIONS | PAGE 32 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 32
KEY ELEMENTS FOR EFFICIENT INFORMATION MANAGEMENT : 1. Perimeters (SoW) and Interfaces well identified and managed very accurately 2. Data to be registered have to be identified as « useful by users » (scientists and / or large infractructure organization) and could / will be provided by partners / contributors. 3. Standards baseline and methodology have to be fixed in the reference configuration and integrated in the Product Assurance Plan : Requirements for partners 4. Communication, exchanges and decisions at the right level 1. Keep a collaborative spirit 5. Engineering tools must integrate « system approach » 1. Multi physics platform for design 2. Virtual reality for communication, interferences, maintenance plan … 3. Collaborative Platform for data exchanges 4. ERP, … Engineering Soft Tools must be customised to the needs and not drive CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 33 the project
INKIND CONTRIBUTION FOR ESS IS AN EXISTING CHALLENGE COLLABORATIVE SPIRIT IS ONE KEY FOR SUCCESS CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 34
THANK YOU FOR YOUR ATTENTION | PAGE 35 CEA-F. Ardellier, Bilbao - 1st Brightness Workshop| 15th nov 2016 | PAGE 35
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