progress report on the test facility project, design and construction

Progress report on the test facility project, design and construction

L. Serio on behalf of bldg. 180 test facility project team members(TE and EN departments)

L. Serio 3

Outline• Introduction• Project Plan

– Scope of work and implementation strategy– Organization– Action plan and schedule– Resources and cost– Financing

• Progress report– Test program and acceptance tests– Test benches scenarios– Design and construction activities

• ConclusionsCERN – GSI c.tte meeting 20140625

Introduction

According to the last collaboration meeting we have proceeded with the review and optimisation of the test program and the internal / external interfaces in order to fix the requirements and develop a detailed project plan and resource loaded schedule.

Several meetings have taken place between CERN and FAIR personnel leading to the requirements, plans, resources and preliminary design reported hereafter.

Design and construction activities have started.

CERN – GSI c.tte meeting 20140625 L. Serio 4




• ConclusionsCERN – GSI c.tte meeting 20140625 L. Serio 5

Implementation status• Scope of work – done; review of scope/financing required

• Fix the preliminary requirements with FAIR• Review the existing implementation constraints• Establish a preliminary test program and WBS

• Schedule- done; review required• Establish the test phases, sequence and overall testing rate• Establish the overall schedule and action plan

• Cost- done; review of scope/financing required• Establish the PBS and corresponding material and personnel budget

• Issue the Project Plan- done

• Implement the Project Plan – started; review of scope/financing required


Project Plan: Scope of Work 1/2• Addendum n.2 to the 2010 Agreement K1727/DG between CERN

and GSI

• Testing of 3 prototypes and 52 series magnets: MULTIPLETS:

SHORT: 1 prototype and 7 series magnets LONG: 1 prototype and 22 series are magnets

DIPOLES: 1 prototype and 23 series magnets Schedule:

‒ prototypes 1.2016 – 6.2016‒ series testing 7.2016 – 1.2019

• Refurbishing and upgrade of the existing cryogenic test facility located in the test hall n. 180 at CERN - Meyrin


Project Plan: Scope of Work 2/2• Design a facility adequate for the testing of SFRS magnets

• Make extensive use of the existing CERN infrastructure– Refurbish the available equipment, within the existing limitations and space constraints

• Testing according to the magnet production schedule and optimised test program

• Design the facility according to the following magnets test phases:– Acceptance, preparation, installation and connection– Check electrical integrity of the magnet and its instrumentation at warm– Cool-down– Cold powering, magnetic field and heat-load measurements– Warm-up– Check electrical integrity of the magnet and its instrumentation at warm– De-mounting of magnet from test-bench– Storage of raw data, data analysis and report on magnet performance


Implementation strategy: WBSFAIR MAGNETS TEST FACILITY

1 PROJECT MANAGEMENT

2 CRYOGENIC SYSTEM

2.1 CRYOPLANT

2.2 CRYODISTRIBUTION

2.3 CONTROLS AND ELECTRICAL

3 MAGNETS TEST STAND

4 POWERING SYSTEM

5 ENERGY EXTRACTION SYSTEM

6 QUENCH PROTECTION SYSTEM

7 UTILITIES

7.1 CIVIL ENGINEERING

7.2 CONTROLS AND NETWORK

7.3 COOLING WATER AND VENTILATION

7.4 ELECTRICAL POWERING AND DISTRIBUTION

7.5 SURVEY SYSTEM

7.6 TRANSPORT AND HANDLING


Organization Chart

Nota: The construction of this facility has been grouped together with the upgrade of the SM18 test facility in a new project with Volker Mertens as Project Leader


CERN – GSICollaboration Committee

F. Bordry, M. JimenezO. Kester, E. Fischer

CERNTechnical Coordinator

Luigi Serio

FAIR Technical Coordinator

Pierre Schnizer

Magnetic Measurements

Stephan Russenschuck

Test FacilityMarta Bajko

Electrical Power Rene Necca

Power ConvertersHugues Thiesen

CryogenicsAntonio Perin

Quench ProtectionReiner Denz

Cooling and Ventilation

Michele Battistin

SurveyDominique Missiaen

Cryogenic Testing at CERN of SUPER -FRS Magnets for FAIROrganization Chart

EN Dept.

TE Dept.

HSEAndre Henriques

FAIR Mirror Organization

ICEPhilippe Gayet

IntegrationY Muttoni

Energy ExtractionKnud Dahlerup-

Petersen

Handling and transport

Ingo Ruehl

Platforms and structures

M Willhelmson

Project Mgt. support

David Hay

Baseline test sequencing installation & preparationcooling4 K testswarm upwarm tests and disconnect

closureshutdowninstallation & preparation 1 1 1 1 1 1 1cooling4 K tests . . . . . . .warm upwarm tests and disconnect 1 1 1 1 1 1 1 1 1

closureshutdowninstallation & preparation 1 1 1 1 1 1 1 1cooling4 K tests 3 3 3 3 3 3 . . . . . . . . . . . . . . 3 3warm upwarm tests and disconnect 1 1 1 1 1 1 1 1number of benches 0 0 0 1 1 2 2 3 3 4 4 5 4 5 4 5 4 5 4 . . . . . . . . . . . . . 5 4 4 4 3 2 2 1 1 0 0 0cooling power 4 K 0 0 0 0 0 4 2 6 4 6 4 6 4 6 4 6 4 . . . . . . . . . . . . . . . . 4 6 4 2 2 0 0 0 0 0 0cooling power 300 - 80 K 0 0 0 0 1 1 1 1 1 2 2 2 2 2 2 2 2 . . . . . . . . . . . . . . . . 2 2 1 1 1 1 1 0 0 0 0power supply 0 0 0 0 0 0 1 1 2 1 2 1 2 1 2 1 2 1 2 . . . . . . . . . . . . . . 2 1 2 1 1 0 0 0 0 0 0

available cooling 4 Kavailable cooling 300-80 Kavailable power supply 1

2 2 2 2 2

6 g/s2*10 kW

22 2

21

1015

14

number of magnets tested

number of magnets tested

2 2 2 2 2

2

23

2 2 23 3

52 weeks46 weeks (44 weeks cold)

3 3

2 2 2

2 22

3

23 3

3


10

53 days (44 working days - cryo also during non working days)

4

5

2 2

2 2 2 2 23 3 3


Baseline Action Plan and ScheduleCONSTRUCTION andOPERATIONSchedule

J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N DConceptual DesignPreliminary DesignFinal DesignProcurementManufacturingInstallationCommissioningMultiplet prototypeDipole prototypeSeries Magnets TestingPANDA testing

20192014 2015 2016 2017 2018

* If approved by CERN management

DIPOLES: 1 prototype, 23 series magnets, 2 spares cryostatMULTIPLETS: 2 prototypes (L and S), 22 (L) and 7 (S) series, 2 spares (L and S) 3 prototypes, 52 series magnets in total (plus 2 spares)

7.2016 7.2017 7.2018 7.2019 #24 24 4

15 days cold tests 14 14 14 10 52 3.75 years13 days cold tests 17 17 17 1 52 3 years

*


M+P estimate


2013 2014 2015 2016 2017 2018 2019

BUDGET kCHF 348 1,011 8,238 1,070 1,120 1,120 1,120

0.1 5.9 7.3 3.1 3.1 3.1 3.1

0.0 2.3 7.6 3.5 3.5 3.5 3.5 9.9

2016-2019

4,430

12.2

13.8

2013-2015

9,596

13.3TOTAL

Cat 3+4 FTE-y

CONSTRUCTION OPERATION

Cat 2 FTE-y

TOT.CONSTRUCTION TOT.OPERATION

Financing(Construction)


CHF 6,000,000FAIR accepted extra contr CHF 1,200,000 pre-cooler

CHF 410,000 survey and EECHF 4,179,000

CHF 11,789,000CHF 12,171,771

CHF 959,577-CHF 1,342,348-CHF 2,952,348

Total FUNDINGBudget total M+P

Missing budgetMissing agreed budget FAIR

GSI contribution

FAIR extra activitiesFunding CERN

Contingency

Options according to financing availabilities


9596960800

177760004179

13132 10179 -2953

7090709800

158060004179

10179 10179 0

GSI contributionCERN contribution

ContingencyMaterial

staff (16 FTE-y but 1/3 for constr)non staff (15.8 FTE-y)

Costing 2 test benches & 1 precooler - Construction

Costing 3 test benches & 2 precooler - ConstructionMaterial

staff (16 FTE-y but 1/3 for constr)non staff (17.8 FTE-y)GSI contributionCERN contribution

Contingency

2 versus 3 test facilities• Presently agreed budget allows only for two TBs• Implications of 2 versus 3 test benches analyzed• Main WPs affected:

– Cryo, Platforms&Supports, Test Stand


cost breakdown 3rd bench (option)kCHF1200

EE and survey 410200200100100290200253

1343

resourcescontingencyTOTAL

utilities

precooler

cryolinessatellite valve boxesone test benchelectrical, instrumentation & control

Project PlanTable of Contents https://edms.cern.ch/document/1370663/2

status

a. Note

b. Scope of Work

c. Project Requirements

d. Organization Chart

e. PBS

f. WBS

g. RASCI

h. Schedule and Action Plan

i. Summary M+P

j. Graphs

k. Resources Operation

l. Resources Construction

m. Risk Matrix

n. Financing

o. Documentation Management

p. Annexes

Individual groups resource estimates and WBS/PBS


https://edms.cern.ch/document/1370663/2

Reviewed test program and time


Reception at CERN 0.75 days 0.75 daysUnloading 1 day 1 dayReception test 1.25 days 1.25 daysInstallation from temporary storage to Test Bench 1.75 days 1.5 daysConnection to the test bench 3 days 2.5 daysTest at Room Temperature 2.38 days 2 days in //DAQ system preparation 2 days 2 days in //Leak test 1.5 days 1.5 days in //Purging 2 days 2 days in //Cooling 300 - 80 K 12 days 8 days 8Cooling 80 - 4 K 2 days 1 days 1Filling Lhe 2 days 1 days 1Leak test if cooling indicates a problem 2 days not considered 0Preparation Work at 4 K 2 days 2 days inDAQ system at 4 K 2 days 2 days in //Protection system set up 1 day 1 day inPowering the magnet at 4 K 3.25 days 3 days 1.5Magnetic measurements at 4 K 11 days 10 days 10

Stationary loss measurements 3 days3 days overnight for static losses and no AC losses

0

Warm up 12 days 10 days 10Test at Room Temperature 1.88 days 1.88 days 2Disconnection from test bench 2 days 2 days Electrical disconnection 1 day 1 day Hydraulic disconnection 1 day 1 dayInstallation from test bench to temporary storage 1.25 days 1.25 daysLoading 4 hrs 4 hrs

67 41

rece

ption

ar

ea

3 3

occu

patio

n of

the

test

ben

ches

67

4

1.5

2

rece

ption

are

a

1.5 1.5

Reviewed overall duration(3 test benches and 2 precoolers)

installation & preparationcooling4 K testswarm upwarm tests and disconnect


1013

446 days (41 working days - cryo also during non working days)

410

number of magnets tested per year

or 1.35 magnets per month16with 3 test benches and 13 days cold magnetic


Optimal overall duration(3 test benches and 2 precoolers)


closureshutdown 2 2 number of magnets tested per yearinstallation & preparation 1 1 1 1 1 1 1 1 1cooling or 2 magnets per month testing rate4 K tests . . . . . . . . . . . . .warm upwarm tests and disconnect 1 1 1 1 1 1 1 1number of benches 0 0 0 1 1 2 2 3 3 3 3 3 3 3 3 3 3 3 3 . . . . . . . . . . . . . 3 3 3 3 3 2 2 1 1 0 0 0cooling power 4 K 0 0 0 2 2 4 4 4 4 4 4 4 4 4 4 4 4 . . . . . . . . . . . . . . . . 4 4 4 4 4 2 2 0 0 0 0cooling power 300 - 80 K 0 0 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 . . . . . . . . . . . . . . . . 2 2 2 2 2 1 1 1 1 0 0power supply 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 . . . . . . . . . . . . . . 1 1 1 1 1 0 0 0 0 0 0

available cooling 4 Kavailable cooling 300-80 Kavailable power supply

42 days (37 working days - cryo also during non working days)4

22 2 2 2 2

21


2 2

with 3 test benches and 2 weeks cold magnetic measurements

1010

103

2 2 2 2 2 222 22 22 2 2 2 2 2

2

6 g/s2*10 kW

1


Series tests duration comparison


Test duration15 days cold tests - 3TB2PC optimised13 days cold tests - 3TB2PC no margin10 days cold tests - 3TB2PC unfeasible 5 days cold tests - 2TB2PC no MM13 days cold tests - 2TB2PC no margin13 days cold tests - 2TB1PC no redund

year 1 year 2 year 3 year 4 year 5 year 6 note

Schedule updateUPDATE Planning 6.2014

3 test benches, 2 CWUs12 days cold testing J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N DConceptual DesignPreliminary DesignFinal DesignProcurementManufacturingInstallationCommissioningProto magnets testingSeries Magnets TestingShort Multiplets Proto . . . . .Long Multiplet Proto . . . . .Dipole Proto . . . . .First Series Short MultipletFirst Series Long MultipletFirst Series DipoleFirst Energy Buncher ?Last Energy Buncher ?PANDA testing ?

3 test benches, 2 precooler, 13 days cold testingmagnet testing rate1.35 magnets modules/month

0.8 multiplets/months0.55 dipoles/month

2019 20202014 2015 2016 2017 2018

Fix layout interfaces

LLI launch procur. commissioning


LS2

Alternative scenarios (2TB-2PC with a later upgrade to 3TB-2PC)

2/3 test benches, 2 CWUs12 days cold testing J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F A J J A S O N DConceptual DesignPreliminary DesignFinal DesignProcurementManufacturingInstallationCommissioningUPGRADEProto magnets testingSeries Magnets TestingShort Multiplets Proto . . .Long Multiplet Proto . . . .Dipole Proto . . . . .First Series Short MultipletFirst Series Long MultipletFirst Series DipoleFirst Energy BuncherLast Energy BuncherPANDA testing ?

3 test benches, 2 precooler, 13 days cold testingmagnet testing rate1.35 magnets modules/month

0.8 multiplets/months0.55 dipoles/month

2014 2015 2016 2017 2018 2019 2020 2021

Nota: a. Delayed decision / financingb. Increased overall costc. Reduced testing capabilities and time for prototypes


WP: all

DONE• Overall scope, WBS, resources, budget and schedule

reviewed and agreed

IN WORK• Detailed PBS, WBS and resource loaded schedule• RASCI

DELAYED• Interface documents (ext and int) – September 2014• EVM based project reporting – October 2014CERN – GSI c.tte meeting 20140625 L. Serio 26

WP: CryogenicsDONE• CERN-GSI agreed design and main specifications parameters for the cryogenic

components (pre-cooler) - https://edms.cern.ch/document/1355497/1• Preparation of bldg 279 and galleries sites (cleaning)• Updated naming, database, PFDs, P&IDs, controls specifications of the helium

refrigerators

IN WORK• Writing of the pre-cooler technical specification• Review and approval of final PFDs and P&IDs

DELAYED• Finalised interface documents (requirements) – September 2014• Market survey LLI– October 2014• Procurement documents – December 2014




WP: Magnetic MeasurementsDONE• Magnet tests database definition• Review of magnet test program, time and tools requirements

IN WORK• Development on the fluxmeter and rotating coils (challenging precision

measurements, high cost of industrially available instruments)• Measurement strategy within the boundary constrains being reviewed

in order to streamline tests, analysis, time

DELAYED• Review of finalised magnet database and required test data –

September 2014 in order to launch the required development and procurements


WP: TF and ICE

DONE• Facility test program and optimised activities

duration in collaboration with FAIR

IN WORK• Specifications for DAQ and signals exchange

being prepared


WP: Power Converters

DONE• Procurement of Power Converters launched

(PCs expected at CERN mid-2015)

IN WORK• Definition of detailed requirements and

interface specifications (in particular Energy Extraction system)


WP: Cooling and VentilationDONE• Conceptual Design and preliminary interface data

IN WORK• Layout and implementation• Measurement strategy within the boundary constrains being

reviewed in order to streamline tests, analysis, time

DELAYED• Finalised interface documents (requirements) – September 2014• Market survey LLI– October 2014• Procurement documents – December 2014


WP: Cooling and VentilationDONE• Conceptual Design and preliminary interface data

IN WORK• Equipment layout and general integration

DELAYED• Finalised interface documents (requirements) – September

2014• Market survey LLI– October 2014• Procurement documents – December 2014CERN – GSI c.tte meeting 20140625 L. Serio 32

WP: Platforms and Structure

DONE• General layout and concept• Interfaces with magnets

IN WORK• Freezing of magnets interfaces• Detailed design and cost optimisation


Platform review and optimization


WP: Integration

DONE• General layout and concept• PANDA space sharing agreement

IN WORK• Review and freezing of individual system

routings and layout


FAIR and PANDA layoutPanda assembly and testing area


WP: Handling and Transport

DONE• Modifications for coupling of two existing

cranes

IN WORK• Industrial survey for the procurement of

interface lifting spreader (coupling) and dedicated magnets lifting spreaders (to be decided if procured directly by FAIR or via CERN)


Conclusions 1/2• Conceptual design, project plan, financing and

resources (limited to two test benches) agreed upon • Financing issues (choice of 2 or 3 test benches) and

possible staging option analysed• Test program optimised and finalised• Launch Safety Agreement prepared and issued

– GSI to review and accept safety requirements• Cryogenic layout and precooler requirements agreed

to proceed with Specification and Tendering phase• PANDA issues solved but no synergy implemented yet


Conclusions 2/2

• September 2014 freezing of interface requirements (internal &external) to launch final design phase and procurement

• Formal agreement (technical reached) on cryogenic layout and components (with financing for second pre-cooler) required asap in order not to delay the project (LLI)


References

• Project Plan (contains all up to date information): – EDMS: https://

edms.cern.ch/document/1370663/3

• Technical coordination meetings and reviewed interface parameters:– EDMS:

https://edms.cern.ch/nav/P:FAIR-000001263:V0/P:FAIR-000002500:V0/TAB3






progress report on the test facility project, design and construction

Documents

preliminary test program

test hall

gsi testing

optimised test program

detailed project plan

following magnets test

serio6project plan

serio7project plan