ALSYOM: Key Player in High-Tech Industries
X-FEL linear accelerator
cryomodule integration
LCWS, Strasbourg, the 26
th
October 2017
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X-FEL accelerator
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Cryomodule description
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ALSYOM Industrial mission
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ALCEN Group
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An Intermediate Size Company created in 1988 : Industry and Innovation
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High Technology activities dedicated to following domains:
Defence and Security
Energies
Aeronautic
Medical Equipment
Large Research Infrastructure
Main figures:
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About 31 subsidiaries in France and North Africa
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2016 turnover ≈ 215 M€
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2016 employees ≈ 1 900
350 in Design Office
1 300 in Production
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Assembly, Integration and test
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Installation on Customer site, including cleanliness, welding and tests
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Optical Surface Treatment « sol-gel »
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Cryomodule description
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ALSYOM Industrial mission
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Cryomodule description
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Industrialization and process definition
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Assembly, Integration and test activities : production team management
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Deliver 100 cryomodules
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Meet deadlines
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Manage the documentation
(Quality, Traceability…)
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Process Improvement
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Customer Satisfaction
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Coupler Cold Part assembly + 1 Gate valve
Leak tests / RGA tests (RGA : Residual Gas Analysis)
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String Assembly Area – (ISO4-SA-WS1, ISO4-SA-WS2 )
Connection of the 8 cavities + 1 Quadrupole
Leak tests / RGA tests
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Roll Out Area – (RO-WS1, RO-WS2)
2 Phase Pipe welding + tests (VT, LT, PT, RT)
Temperature sensors, magnetic shields, 4K & 70K assembly
Tuner systems assembly + RF controls
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Alignment Area – (AL-WS1, AL-WS2)
Alignment of the cavities/Qpole with the cold mass (~ 100µm)
8mm pipe welding + tests (VT, LT, PT)
Electrical tests (Tuners & piezo systems)
Current leads welding
Thermalization
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Cavity string pumping + final Leak test & RGA
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Shipment Area – (SH-WS1, SH-WS2)
End caps positioning on the vacuum vessel
Pumping and Nitrogen flushing
RF controls, Motors controls
Connection of the vacuum recording box for transportation
Loading on truck
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Welder and coordinator
RF, laser tracker, vacuum test technician
Logistician
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4 years divided in 3 Phases
Training and Process definition (3 prototypes)
Ramp Up to reach the rate of 5 days
Series Production (100 cryomodules) with rate acceleration up to 4 days
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Complete production cycle for ONE Cryomodule : 7 weeks
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Up to ONE Cryomodule every for 4 days, ready for delivery
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Thierry HOVSEPIAN
Managing Director
Eric GIGUET
Commercial and Development Director
ALSYOM
17 Bis Avenue des Forges
CS 20125
65 001 Tarbes Cedex - France
Tel.:
+33 (0)562 446 700
Fax:
+33 (0)562 446 701
www.alsyom-alcen.com
Thank you for your attention
Welcome in the South West of France
ALSYOM, a subsidiary of ALCEN Group, is a leading company specializing in high-technology activities across various domains including defense, security, energies, aeronautics, and more. With a strong focus on innovation and expertise in development and industrialization, ALSYOM stands out as a unique industrial entity offering a wide range of services in mechanical, opto-mechanical, electronic, and control systems. The company's contributions span from accelerator technologies and nuclear fusion reactors to astrophysics, high-power lasers, and aeronautics. Operating with over 1,900 employees and a turnover of 215 million in 2016, ALSYOM continues to excel in program management, design, engineering, and manufacturing of complex systems and equipment.
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X-FEL linear accelerator cryomodule integration LCWS, Strasbourg, the 26thOctober 2017
ALSYOM a subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL accelerator Cryomodule description ALSYOM Industrial mission
ALSYOM : a subsidiary of ALCEN Group ALCEN Group An Intermediate Size Company created in 1988 : Industry and Innovation High Technology activities dedicated to following domains: Defence and Security Energies Aeronautic Medical Equipment Large Research Infrastructure Main figures: About 31 subsidiaries in France and North Africa 2016 turnover 215 M 2016 employees 1 900 ALCEN has a permanent innovation policy applied to its product and services 350 in Design Office 1 300 in Production CONFIDENTIEL 3
ALSYOM : domains of activities Accelerator Experimental Nuclear Fusion Reactors X-FEL ITER, RJH Astrophysics High Power Lasers Astronomy (CTA) Laser Megajoule, PETAL Aeronautic, Defense and security ELI (Extreme Light Infrastructure) Turret, satellite antenna and aero structure tools Program Management, Design, Engineering and Manufacturing for the production of mechanical and opto-mechanical equipment CONFIDENTIEL 4
ALSYOM : main expertise Development and industrialisation Mechanical, Opto-mechanical, Optic, electronic, command control Design, in collaboration with SEIV design office Product and Process Industrialisation System and Equipment manufacturing Series equipment and complex system production, including: High accuracy mechanism, control command electronic, Optic and cabling Opto-mechanical system in cleanliness and vacuum environment Integration and cleaning Geometrical characterisation Cleaning and integration in ISO 5 and ISO 8 condition Assembly, Integration and test Services Installation on Customer site, including cleanliness, welding and tests Optical Surface Treatment sol-gel Maintenance: mechanism, opto-mechanism, vacuum Unique Industrial entity in France grouping these expertise and combined performances High accuracy, large Dimension, Cleanliness and Vacuum CONFIDENTIEL 5
ALSYOM : location in France Paris VERSAILLES ALSYOM Headquarter TARBES Bordeaux Le Barp LASERIS Tarbes Cadarache Bordeaux LASERIS & LMJ CONFIDENTIEL 6
ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL linear accelerator Cryomodule description ALSYOM industrial mission
X-FEL linear accelerator Construction and installation of the European X-ray Free Electron Laser (E-XFEL). Location : DESY (Deutsch-Elektronen-Synchrotron) in Hamburg (Germany) Tunnel : ~ 1,6 km length 5 X-ray beams 10 experiment stations (research in biology, chemistry, nanotechnology, ) CONFIDENTIEL 8
X-FEL linear accelerator Description of the X-FEL Accelerator Linac (Energy : 17,5 GeV) CONFIDENTIEL 9
X-FEL linear accelerator Institutes involved in the construction of the E-XFEL accelerator CONFIDENTIEL 10
ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL linear accelerator Cryomodule description ALSYOM Industrial mission
X-FEL Cryomodules E-XFEL accelerator main components CONFIDENTIEL 12
X-FEL Cryomodules E-XFEL Cryomodule - Main Components 496 types of parts CONFIDENTIEL 13
ALSYOM, subsidiary of ALCEN Group X-FEL cryomodule integration X-FEL linear accelerator Cryomodule description ALSYOM Industrial mission
ALSYOM mission Domain of expertise and responsibilities : Industrialization and process definition Assembly, Integration and test activities : production team management ALSYOM Responsabilities Industrialization Methods Environment Machines Deliver 100 cryomodules Meet deadlines Manage the documentation (Quality, Traceability ) Process Improvement Customer Satisfaction INTEGRATION PROCESS Materials People CONFIDENTIEL 15
ALSYOM mission Integration process organized in 7 workstations Cold Coupler Area (ISO4-CC-WS) Coupler Cold Part assembly + 1 Gate valve Leak tests / RGA tests (RGA : Residual Gas Analysis) String Assembly Area (ISO4-SA-WS1, ISO4-SA-WS2 ) Connection of the 8 cavities + 1 Quadrupole Leak tests / RGA tests Roll Out Area (RO-WS1, RO-WS2) 2 Phase Pipe welding + tests (VT, LT, PT, RT) Temperature sensors, magnetic shields, 4K & 70K assembly Tuner systems assembly + RF controls Cold Mass positioning and hooking Alignment Area (AL-WS1, AL-WS2) Alignment of the cavities/Qpole with the cold mass (~ 100 m) 8mm pipe welding + tests (VT, LT, PT) Electrical tests (Tuners & piezo systems) Current leads welding Thermalization CONFIDENTIEL 16
ALSYOM mission Integration process organized in 7 workstations Cantilever Area (CA-WS) 4K & 70K shells welding Cables positioning and thermalisation Introduction inside the vacuum vessel ; fixing Alignment Cold Mass / vacuum vessel Coupler Area (C0-WS1, CO-WS2) Coupler warm part assembly + Leak test Coupler Pumping Line assembly + Leak test T sensors and Motors cabling Current lead connection + Electrical tests Current lead welding on the vacuum vessel + Leak Tests Cavity string pumping + final Leak test & RGA Shipment Area (SH-WS1, SH-WS2) End caps positioning on the vacuum vessel Pumping and Nitrogen flushing RF controls, Motors controls Connection of the vacuum recording box for transportation Loading on truck CONFIDENTIEL 17
ALSYOM mission Integration process organized in 7 workstations CONFIDENTIEL 18
ALSYOM mission ALSYOM industrial team Up to 33 people Management and Quality Integrator in clean room Welder and coordinator RF, laser tracker, vacuum test technician Logistician Production activities Supply Chain Production Flow management Technical event management : from the problem to the solution Transverse activities Quality management Documentation management Configuration management CONFIDENTIEL 19
RESULTS Schedule and production rate 4 years divided in 3 Phases Training and Process definition (3 prototypes) Ramp Up to reach the rate of 5 days Series Production (100 cryomodules) with rate acceleration up to 4 days 2013 2014 2015 2016 S1 S2 S1 S2 S1 S2 S1 S2 Contract Signature Phase 1 : Industrialisation and Traning XM -1 to XM -3 Phase 2 : Ramp Up XM 1 to XM 13 Phase 3 : Series production XM 14 to XM 100 5 days / XM 4 days / XM Complete production cycle for ONE Cryomodule : 7 weeks Up to ONE Cryomodule every for 4 days, ready for delivery CONFIDENTIEL 20
RESULTS Schedule and production rate achieved Performance achieved for the 100 Cryomodules CONFIDENTIEL 21
X-FEL inauguration in Hamburg CONFIDENTIEL 22
Thank you for your attention Thierry HOVSEPIAN Managing Director Eric GIGUET Commercial and Development Director ALSYOM 17 Bis Avenue des Forges CS 20125 65 001 Tarbes Cedex - France Tel.: +33 (0)562 446 700 Fax: +33 (0)562 446 701 www.alsyom-alcen.com Welcome in the South West of France
