lhc-dfbx dfbx production readiness review project overview joseph rasson lbnl

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1 LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL 23-24 October 2002, LBNL Brookhaven - Fermilab - Berkeley US LHC ACCELERATOR PROJECT

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US LHC ACCELERATOR PROJECT. Brookhaven - Fermilab - Berkeley. LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL 23-24 October 2002, LBNL. Outline. Functional Flow Diagrams Design Variants DFBX Components Engineering Activities Since May 02 Review - PowerPoint PPT Presentation

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Page 1: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

1

LHC-DFBX

DFBX Production Readiness Review

Project Overview

Joseph Rasson

LBNL

23-24 October 2002, LBNL

Brookhaven - Fermilab - Berkeley

US LHC ACCELERATOR PROJECT

Page 2: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 3: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 4: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 5: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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DFBX Components

Major subsystems:Power leads: HTS & VC leadsVacuum vesselCryogenic pipingLHe vesselThermal shieldPower lead chimneysInstrumentation leadsSuper insulation

Page 6: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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DFBX Components (cont.)

Other subsystems:Jacketed beam tubeBus duct assembly:

BussesLambda plateBus duct

Interconnect hardwareAlignment toolsSupport jacks

Page 7: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 8: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 9: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 10: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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.

Page 11: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 12: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 13: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 14: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 15: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 16: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 17: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 18: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 19: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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Page 20: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 21: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 22: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 23: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 24: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 25: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 26: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 27: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 28: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 29: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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

Page 30: LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL

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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