1 LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL 23-24 October 2002,...
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Transcript of 1 LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL 23-24 October 2002,...
1
LHC-DFBX
DFBX Production Readiness Review
Project Overview
Joseph Rasson
LBNL
23-24 October 2002, LBNL
Brookhaven - Fermilab - Berkeley
US LHC ACCELERATOR PROJECT
2
Outline
Functional Flow Diagrams Design Variants DFBX Components Engineering Activities Since May 02 Review Technical Design Reviews Design Change Summary Acceptance Specifications and Travelers Crating and Shipping Specifications Project Schedule Summary
3
DFBX Functional Flow Diagrams
IR Cryogenic and Electrical Distribution Box
IP1 & IP5 IP2 & IP8
LBNLDFBX
FNAL, KEK, CERNM QX (Q1 - Q3),
Correctors,Internal Absorbers
ELECT RICAL SIG NALS
VACUUMVACUUM
M AG NET & HEAT ER PO W ER
CERNCONTROL and
POW ER CONVERTERS
EL
EC
. SIG
'S.
CERNQRL
50 -
75
K, 1
8 B
AR
CRYO G ENIC
4.5
K,
1.3
BA
R
300
K,
1 B
AR
1.9
K,
16 m
BA
R
CERNROOM TEM P BEAM TUBE
AND PUM PING STATION
CERNINSULATION
PUM PING
CERNGHe RECOVERY
20 K
, 1.3
BA
R
LBNLDFBX
FNAL, KEK, CERNM QX (Q1 - Q3),
Correctors
ELECTRICAL SIGNALS
VACUUMVACUUM
M AGNET & HEATER POW ER
EL
EC
. S
IG'S
.
50 -
75
K,
18 B
AR
CRYOGENIC
4.5
K,
1.3
BA
R
300
K,
1 B
AR
1.9
K,
16 m
BA
R
BNLM BX (D1)
CRYOGENIC
M AGNET & HEATER POW ER
ELECTRICAL SIGNALS
CERNINSULATION
PUM PINGCERN
CONTROL and POW ERCONVERTERS
CERNQRL
CERNGHe RECOVERY
CERN
INSTALLATION
and
ALIGNMENT
20 K
, 1.
3 B
AR
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Design Variants
Eight cryogenic distribution boxes 6 Slightly different designs with many common components Major variation results from connection to either cold or warm
dipole
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DFBX Components
Major subsystems:Power leads: HTS & VC leadsVacuum vesselCryogenic pipingLHe vesselThermal shieldPower lead chimneysInstrumentation leadsSuper insulation
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DFBX Components (cont.)
Other subsystems:Jacketed beam tubeBus duct assembly:
BussesLambda plateBus duct
Interconnect hardwareAlignment toolsSupport jacks
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Engineering Activities Since May 02 Review
Enhanced the Engineering Team in the following areas: Mechanical design
Daryl Oshatz is leading the mechanical design effort Added more designers (2 FTEs}
Engineering analysis Steve Virostek is responsible for structural analysis
Lambda Plate R&D SUPERCON technician group headed by Roy Hannaford is
supporting Jon Zbasnik’s effort Vapor Cooled Lead
SUPERCON group supporting the mechanical design and layout Ron Scanlan prepared the lead design specification document
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Engineering Activities Since May 02 Review (cont.)
Fermilab Engineering Support: Cryogenic Engineering
Tom Peterson is providing cryogenic design oversight Don Brown (cryogenic consultant) provided reviewed the design
Interface Specification Phil Pfund is very active in supporting the interface specification
effort Kerry Ewald is generating mechanical interface drawings
High Temperature Superconducting (HTS) Lead Testing Sandor Feher will head the HTS testing effort at FNAL
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Engineering Activities Since May 02 Review (cont.)
Fermilab Engineering Support (cont.): Procurement Effort
Review procurement documents Participated in interaction with vendors Reviewed proposal evaluation effort
Acceptance Criteria Provided thorough review of acceptance plan Jim Strait is negotiating the acceptance criteria with CERN
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Recent Technical Design Reviews
Date Detail Technical Reviews November 2001 Fabrication study by Meyer Tool and PHPK. 25-26 February 2002 Review of design in parallel with DOE cost
review. 17-18 April 2002 Engineering review with PMO and DOE. 18-19 June 2002 Piping arrangements and safety reviews 6-8 August 2002 Review of drawings by Don Brown. 21-22 August 2002 Piping arrangements. 4-5 September 2002 Reviewers included R. van Weelderen & V.
Benda from CERN. 25-26 September 2002 Final details of DFBXG drawings and RFP
strategy.
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Design Change Summary
More Robust Mechanical Design: Thrust loads and Pipe support
Most of pipe thrust loads were eliminated by use of flex hoses Bus duct and overflow tank support were modeled and redesigned Magnet G-10 spiders are no longer load path components QRL G-10 spiders were simplified and stiffened up
Pipe thermal contraction Thermal contraction up to 1 inch is possible with flexhoses
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Design Change Summary (cont.)
More Robust Mechanical Design (cont.): Helium tank support
Added invar rods for vertical support Redesigned lateral and longitudinal supports Modified access panel and rib thickness Modified weld preps to conform to ASME Pressure Vessel Code Completed a detailed FEA model Pressure Vessel Safety Note written and approved by LBNL
Safety Committee
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Design Change Summary (cont.)
More Robust Mechanical Design (cont.): Optimized thermal shield design and cooling
Added trace cooling channels Reduces wall thickness of all panels except top panel Simplified the design by eliminating complex forming Reduced number of vertical supports Give vendor more flexibility in forming and attaching panels
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Design Change Summary (cont.)
Enhance Design for Manufacturability: More relaxed tolerances
Design intent is conveyed and moved tight toleranced to top level assemblies
Maintained tolerances that are tied to interface specifications Give vendor more flexibility to manufacture pipe assemblies
Vendor can select construction and fabrication method Vendor can substitute for elbows, T’s and rearrange routing
Simplify welding and assembly process Added weld rings to address warping during welding which allows
vendor to meet the design intent
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Design Change Summary (cont.)
Bus Duct and Lambda Plate R&D: Completed R&D effort
LBNL fabrication and test plan has been developed
Bus duct assemblies will available at the cryogenic system 2 months before the first pair is needed
16
Design Change Summary (cont.)
Beam Tube: Beam tube cooling jacket design complete Cold to warm transition layout is underway (to be completed
Nov 02) Bore tubes to be shipped to LBNL (Jan 03) LBNL to fabricate and test beam tube assemblies then ship
them to cryogenic system fabricator Beam tubes are scheduled to be delivered 3 months before the
first beam tube is needed for installation
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Design Change Summary (cont.)
Current Lead Splice Procedures: Current lead splice process developed and prototyped Used the DFBX mock-up to demonstrate the process Issued purchase orders to the vendors to:
1. Transfer the technology by training the vendors before the RFP is released
2. Assess vendors’ capabilities3. By making the vendors comfortable with the process, we remove
uncertainties that could lead to bids Roy Hannaford visited the vendors with tools and fixtures to
train them Both vendors showed good capabilities as demonstrated by the
samples they produced on their own
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Status ofMechanical Interface Specifications
Fermilab is supporting the magnet mechanical interconnect hardware design effort
Not all interconnect hardware proposals have been accepted by CERN yet
Reviewing dipole as-built pipe positions (some are out of tolerance)
Pipe ends will be capped since pressure and vacuum leak tests will be repeated at CERN
Therefore pipes will be fabricated with capped long stubs
Pipe ends will be measured and cut during installation at CERN
19
20
Status of the fabrication drawing package
Detailed fabrication drawing package for DFBX-G and C are released
Top level configuration drawings for the other 5 variations are complete
Bill of Materials is complete All remaining unique pipe drawings ready for release by end of
November
21
High Temperature Super Conducting Leads(HTS)
A total of 40 lead assemblies (20 lead pairs) are required Full current tests of the prototype pair were performed at CERN
in Nov 2001 Authorized Pirelli to start production in May 2002 Cold test facility is under construction at Fermilab
22
High Temperature Super Conducting Leads (HTS) (cont.)
HTS Production Schedule: Pirelli’s initial production schedule slipped 1.5 months Latest Pirelli schedule as of 21 Oct:
1st 5 pairs @ FNAL Dec. 2002
2nd 5 pairs @ FNAL Jan. 2003
3rd 5 pairs @ FNAL Feb 2003
4th 5 pairs @ FNAL Mar. 2003
Leads for first box will be delivered to the vendor at least 4 months before they are needed
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Vapor Cooled Leads
VC Leads required
16 sets of 600A-3pair
8 sets of 600A-1pair
8 sets of 120A-5pair Lead design layout was revised to provide more installation
clearance Eliminated Fisher connectors (high cost and long lead time) Ron Scanlan prepared the performance/design Specification Specification was reviewed by CERN and FNAL Design reviewed by vendors in August
24
Vapor Cooled Leads (cont.)
Procurement Schedule:
Issue RFQ 7 Oct. 2002
Bidder responses 8 Nov. 2002
Place order 10 Dec 2002
Deliver leads for DFBX-G Apr 2003
2nd shipment@ LBNL May 2003
3rd shipment @LBNL Jun 2003
Leads for DFBX-G will be delivered to the vendor 3 months before they are needed for installation
25
Acceptance Specification and Travelerstatus
LBNL acceptance from vendor: Defines the tests and measurements required to meet functional
and interface specifications Defines in process inspection points that give the vendor
flexibility in selecting the manufacturing process and assembly sequence
Defines the set of travelers to be completed by the vendor LBNL final acceptance takes place after pressure and vacuum
leak tests are completed at CERN
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Acceptance Specifications and Travelers (cont.)
CERN acceptance from US-LHC is based on: Approval of LBNL-vendor Acceptance Specification,mainly:
o In-process tests and inspection
o Final test/inspection prior to shipping
o Inspection and tests at CERN after shipping
Approval of power lead Acceptance Specifications Approval of LBNL-manufactured components Inspection
Specifications Completing a series of electrical tests at CERN:
Hi pot and continuity tests of leads, bus duct and instrumentation conduits
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Crating and Shipping Specification
Requirements based on FEA of shipping package with appropriate safety factors: Maximum vertical shock acceleration transmitted to DFBX +/- 5.0 g Maximum horizontal shock acceleration transmitted to DFBX +/- 2.0 g Free drop from a height of 6 inches without transmitting more than the
vertical shock limit of 5.0 g
Crating and shipping specification document has been distributed to the vendors for review by their shipping subcontractors
Vendors feel comfortable with taking on the crating shipping responsibility
28
Project Schedule
Requested Fab Float
IP CERN DOE Deliv. Date No. of Days
8L - G Aug-04 Aug-04 19-Mar-04 147 days
2R - D Oct-04 Oct-04 28-May-04 126 days
1L - A Feb-05 Feb-05 23-Jul-04 217 days
8R - H Feb-05 Feb-05 1-Oct-04 147 days
1R - B Aug-05 Aug-05 10-Dec-04 245 days
2L - C Aug-05 Aug-05 25-Feb-05 168 days
5R - F Mar-06 Sep-05 30-Apr-05 124 days
5L - E Mar-06 Sep-05 30-Jun-05 63 days
Milestones
Additional schedule constraints: US-LHC Accelerator Project Ends September 2005
29
Project Schedule (cont.)
Schedule forecast Based on the LOI production schedule provided by the
manufacturers: First DFBX Delivered 13 month ARO
o Meets CERN requirement Last (8th) DFBX Delivered 27-29 months ARO
o Meets DOE-LHC requirement
However, production schedule is aggressive To meet schedule extensive oversight is required Highlights the urgency to get process started
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Summary
Design team was enhanced Fermilab is playing an active role in supporting the design
effort Mechanical design is more robust and simpler to fabricate and
assemble Detailed fabrication drawing package being readied for the RFP LBNL components will be ready 2-3 months before need dates HTS production has started VC leads RFQ is released and order will placed in Dec 02 Project is ready to start the RFP process Meeting production schedule is a major challenge