at FNAL Michael Tartaglia LARP/HiLumi Program Management Group 02 - - PowerPoint PPT Presentation

Upgrade of the Horizontal Test Facility at FNAL

Michael Tartaglia LARP/HiLumi Program Management Group 02 August 2017

Stand 4 Refurbishment Plan Overview

• April 2016 Conceptual Design Options & Cost Estimates

– Refinement of previous work dating to 2014 and before

• July 2016 DOE CD-0, emphasis on tunnel ready deliverables

– 1.9K, 18kA, magnetic measurements & alignment

• Working Group Meetings (Nov ‘16, Feb & June ‘17)

– Refinement, discussion of details, cost estimates, schedules – Still developing integrated schedule w/high level milestones

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Overview

• Follow up on Meeting #2 (2/16/17) [update since 6/8]

– Acceptance Requirements, Interfaces from CERN expected January 2018

• Cold Hipot Voltage requirement is expected to be increased to 1800 V.

– Revision of “on” and “off” project scope completed (cryo, mechanical) – SWF and M&S estimates revised accordingly – QPM SWF and M&S estimates (FY18 “off project”) evaluated – Labor and Cost Summary Overview Completed

• Integration of Tom Page “interconnect” estimates in progress [in BOEs]

– Review & Refinement of schedules started, in progress

• Tool for assessing resources and tracking progress
• High Level Milestones still to be added [good progress]
• Test Stand Refurbishment Status

– Feedbox Top Plate Insert Removed – Refurbishment of “15kA” Current Leads well under way[3 leads done]

• [SC lead assembly still to do]

– Procurement of Flexible Leads in progress [Ordered] – Cryogenic Upgrades will start soon [Quench and K.Pump Started in July]

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• M. Tartaglia | Stand 4 Refurbishment Status Update

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Upgrades Overview

• Cryogenic and Control/Monitoring Systems
• Mechanical Systems
• Power and Protection Systems
• Magnetic Measurement Systems

Designs led by veterans of the IR Quad test program, joined by new generation of engineers and scientists to develop upgrades (but with a different department structure than in the past) Plans represent understanding of cryo-assembly deliverables and test acceptance requirements discussed in July 2016 Final acceptance requirements, interface definitions in Jan 2018

Ongoing discussion with CERN to establish ASAP

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T&I FTE Summary

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• M. Tartaglia | Stand 4 Refurbishment Status Update

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Task Labor Type FY17 OFF FY17 ON FY17 TOT FY18 OFF FY18 ON FY18 TOT Cryo M-ENG 0.08 0.17 0.25 0.33 0.26 0.59 M-TECH 0.14 0.1 0.24 0.36 0.18 0.54 DESIGNER 0.14 0.14 0.08 0.05 0.13 Mechanical M-ENG 0.16 0.16 0.03 0.12 0.15 M-TECH 0.43 0.43 0.3 0.19 0.49 DESIGNER 0.13 0.13 0.22 0.22 Quench Protection E-ENG 0.8 0.8 E-TECH 0.57 0.57 S-DEV 0.14 0.14 TOTALS BY FY FY17 FY18 TOTAL OFF TOTAL ON DOES NOT INCLUDE INTERCONNECTS, COMMISSIONING M-ENG 0.41 0.74 0.44 0.71 M-TECH 0.67 1.03 0.80 0.88 DESIGNER 0.27 0.35 0.08 0.53 E-ENG 0.8 0.80

• E-TECH

0.57 0.57

• S-DEV

0.14 0.14

BOE Summary

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• M. Tartaglia | Stand 4 Refurbishment Status Update

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Resource Role Year 1* Notes Estimate Source Mechanical Technician 2,635

Various assembly and fabrication work Past experience with the old LHC quadrupole magnets

Mechanical Technician Sr 2,634

Various assembly and fabrication work

QC Technician 160

Inspection and QC of test stand components and equipment

Procurement Specialist 160

Procurement and communication with outside vendors Past experience with the old LHC quadrupole magnets

Mechanical Engineer 1,568

Design of components Past experience with the old LHC quadrupole magnets

Mechanical Engineer Sr 1,704

Design of components

Cryogenics Engineer 480

Design of cryogenics system components Past experience with the old LHC and mu2e cryo systems

Cryogenics Engineer Sr 520

Design of cryogenics system, components Past experience with the old LHC and mu2e cryo systems

Electrical Engineer 300

Electrical wiring and checkouts

Electrical Engineer Sr 300

Electrical wiring and checkouts

Designer 3,248

Design and drafting of test stand components Past experience with the old LHC quadrupole magnets

Welder 112

Welding cryogenics system components Past experience with the old LHC quadrupole magnets

T&I ON Project plus interconnect & commissioning estimates (TPage) *This work is likely to extend into FY19

Test Stand 4 Upgrade – Cryogenics

• The Midway Kinney Pump Room will be used for 1.9 K testing.

– Includes redundant pumping capacity (4 pump skids installed) – Eliminates costly refurbishment of IB1 Kinney Pump skids – Only final connections are required to complete the pumping line

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[ In Progress ~40%]

Test Stand 4 Upgrade – Cryogenics

• Buffer Tank 1 will capture quench gas.

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New piping required

Stand 4

[ In Progress ~40%]

Test Stand 4 Upgrade – Cryogenics

• New piping/transfer lines required (controlled DT cool down)

– LN2 supply to bath, GN2 from bath (Vacuum-Jacketed) – GHe supply lines to bath HX and bath bypass – Mixed GHe flow to test stand (V-J)

• Modify existing piping

– LHe supply from Storage Dewar – LHe supply to test stand

• Mass flow control required on 2 GHe supply lines
• Valve and instrument upgrades

[started purchases]

• Test stand ‘hardening’ to reduce He losses
• Update insulating vacuum system

[purchasing pumps]

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4.5 K LHe Operations – Test Stand Upgrades/Modifications

• Test Stand Cryogenic Controls

[Reqs in process FY17]

– Plan to upgrade to new PLC – All monitoring (T, P, Flow, LL) through PLC modules

• iFix/iHistorian archive, plus gateway to DAQ system archive

– Hipot requirement

• Cryo Assembly Sensor Monitoring

– Automated precision splice measurements

• New Labview/Keithley nV-meter system development [just deployed]

– Will replace old VME/Unix system for T, SG sensors

• Labview-based solutions now under consideration
• Requesting additional resources for this development (MSD)

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Test Stand 4 Upgrade – Control & Monitoring Systems

Cost & Labor Overview

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• M. Tartaglia | Stand 4 Refurbishment Status Update

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• Cryo (Rabehl)

Schedule

Stand 4 Upgrade Summary SWF (Fully Loaded) M&S (Fully Loaded) Weld+MachineShop M&S (Fully Loaded) System Task FY17 OFF FY17 ON FY18 OFF FY18 ON FY17 OFF FY17 ON FY18 OFF FY18 ON FY17 OFF FY17 ON FY18 OFF FY18 ON Cryo Safety Documentation 5,702 42,527 20,500 Quench Line 20,621 6,216 16,329 Stand Hardening 6,534 3,140 Pumping Line Tie-in 9,118 1,243 6,280 Xfer Line, LN2 to subcooler 14,254 4,973 6,908 GN2 Vent from subcooler 16,303 2,486 6,908 GHe inlet to subcooler 6,499 2,486 5,024 GHe oulet from subcooler to FB 8,558 8,059 1,243 4,528 Xfer Line, Distribution Manifold 21,204 27,350 6,469 Xfer Line, Storage Dewar to Dist. Manif. 27,590 27,590 7,459 Insulating Vacuum System 11,433 11,433 24,864 22,378 3,234 3,234 Test Stand Controls PLC Upgrade 102,363 59,674 LN2 supply to FB 14,054 4,973 1,941 Valve & Instrument Upgrades 21,783 14,918 3,234 Cryogenic Safety Review 40,999 TOTALS 41,975 88,141 162,589 116,829 7,459 9,946 139,478 43,512 25,749 18,841 17,162 12,937

• Principal Mechanical Upgrade elements

– Disassemble, refurbish and re-assemble the Feedbox Top Plate insert

• Two “15 kA” AMI vapor-cooled current leads; remove 3rd lead (?)
• New 10 A lead (SSW of ea. Cold mass) + New: 20A TRIM Leads
• 80 K thermal shield and baffles, current lead vacuum sleeves
• Rework LTS bus sections
• Integrate the CLIQ Leads with (6) existing 500 A corrector leads
• Provide enhanced Hipot stand-off voltage of 1.8 kV

– Provide/preserve the ability to perform full aperture Magnetic Measurements (2 [3 ?] leads at 18 kA) and SSW (10 A) at 1.9K

• Design, fabricate components, and assemble a Warm Finger optimized for

the 150 mm aperture (100 mm diam. Probe)

• Refurbish existing/develop new probe drive, optimized for FERRET probe
• Enlarge Return End opening for larger aperture Warm Finger

– Develop Test Stand Interfaces to Magnet and modify the Feed Box and Return End Can piping

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Test Stand 4 Upgrade – Mechanical Systems

• Refurbishing the Feed Box
• Note: No modifications to the

Feedbox ASME Code vessel required

Test Stand 4 Upgrade – Mechanical

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• End Box Interfaces, Adapters

– Mech. interface from the Feed Box and Return end can to the cryogenic, vacuum, power, and instrumentation features on the cold mass. [some design, modeling effort already in progress]

• No valves are envisioned in these interface/adaptor “box/es”
• Only comprised of piping, (with provisions for thermal contraction), a

nitrogen cooled thermal shield, and MLI

• If this is a separate “box” at the Feed End then it is likely to remain as a

“permanent” extension of the feedbox after the initial setup and use

– Tasks to Perform: [starting Jan ‘18]

• Develop a Layout and Design for the Lead and Return End Interfaces
• Specify and procure the Adapter/Interface Box/es
• Perform acceptance tests and install

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Test Stand 4 Upgrade – Mechanical

Cost & Labor Overview

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• M. Tartaglia | Stand 4 Refurbishment Status Update

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• Mechanical (Sylvester)

Schedule

Stand 4 Upgrade Summary SWF (Fully Loaded) M&S (Fully Loaded) Weld+MachineShop M&S (Fully Loaded) System Task FY17 OFF FY17 ON FY18 OFF FY18 ON FY17 OFF FY17 ON FY18 OFF FY18 ON FY17 OFF FY17 ON FY18 OFF FY18 ON Mechanical Feed Box 30,929 15,978 27,005 Lead End Interface Box 32,443 12,432 5,652 Return End Interface Box 20,745 12,432 2,512 Return End Can 12,155 3,140 Warm Finger Assembly 41,518 18,648 10,048 Power 44,283 15,751 3,140 Cryostat Supports 48,293 12,432 31,401 Magnetic Meas. Drive System (Refurb.) 55,248 43,512 TOTALS 116,729 55,248 113,635 50,377 43,512 37,296 0 40,193 0 42,705

Reminder: Interconnects, commissioning not included here

• 30 kA Power System

[in good shape]

– 6 5000 A/ 30V PEI supplies – Configurable Dump Switch & Resistor (2.5 to 90 W)

• In continuous use at VMTF, very good condition
• Connects to VMTF or Stand 4 via flex water-cooled cables
• Will upgrade to 1500 MCM flex leads [req in process]
• Will perform LCW system maintenance

– (hoses, T-switches, interlocks)

• Hard copper bus is adequate for >20 kA
• Quench Detection System

– Existing VME/Unix system to be completely replaced

• Isolation Amplifiers – replicate new design (in use 4 yrs)
• Redundant AQD and DQD; new AQD designed, now prototyping

– Programmable validation time for spikes

• DQD & Quench Logic in cRio/PXI FPGA-based system with Labview Interface
• Will replicate system currently at Mu2e Solenoid Test Facility, MICE (in use 4 yrs)
• Must develop/improve a new Labview Power Supply Controller w/ QD interface

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Test Stand 4 Upgrade – Power & Protection Systems

• Heater and CLIQ Protection Systems

– Assume CERN will provide heater and CLIQ power supply units – FNAL interface them to QD system and Test Stand

• CLIQ units in use at VMTF with old QD interface
• New heater interface, number of supplies = 16
• Protection System-Magnet Interfaces

– Hipot requirement

• IsoAmps tested to 1.8 kV
• Current Lead rating – verifying 4.5 kV insulation rating (15kA, 500A)

– Surface re-sealing, GN2 purge in “clam-shells” to prevent moisture

• Existing VT, Heater wires rated much higher, but need testing
• Must test and verify/fix current-limiting resistors
• Potted Instrumentation connectors should be OK; tested to 4 kV pin-pin

– Voltage Taps

• Awaiting decision: Existing Hypertronics in He pipes, vs vacuum feed-throughs
• New Cabling effort; cable length considerations

– Heater Connections

• Same question; how many?

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Test Stand 4 Upgrade – Power & Protection Systems

Cost & Labor Overview

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• M. Tartaglia | Stand 4 Refurbishment Status Update

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• Quench Protection & Monitoring (Orris)
• T&I Summary (no interfaces & commissioning)

Stand 4 Upgrade Summary SWF (Fully Loaded) M&S (Fully Loaded) Weld+MachineShop M&S (Fully Loaded) System Task FY17 OFF FY17 ON FY18 OFF FY18 ON FY17 OFF FY17 ON FY18 OFF FY18 ON FY17 OFF FY17 ON FY18 OFF FY18 ON Protection Systems Quench Protection & Monitoring 344,047 0 126,897 SWF FY17 OFF FY17 ON FY18 OFF FY18 ON M&S FY17 OFF FY17 ON FY18 OFF FY18 ON WELD/VMS FY17 OFF FY17 ON FY18 OFF FY18 ON ALL TOTALS $41,975 $204,870 $561,885 $230,464 $7,459 $60,323 $309,887 $80,808 $25,749 $59,034 $17,162 $55,643 $1,655,257 TOTAL OFF PROJECT $435,334 $317,346 $42,911 $795,591 TOTAL ON PROJECT $603,860 $141,131 $114,676 $859,667

• Separate BOE exists
• FERRET Probe

– For precision end field scans

• Translation System

– 2 options considered

• Refurbish Old
• Develop New/modern

– If Refurbish:

• Inspect and/or replace

internal components & rubber drive belt

• Service pneumatic and

electronic components

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Test Stand 4 Upgrade – Magnetic Measurement Systems

– Magnetic Measurement DAQ solutions exist

• Newly developed SSW software and hardware now deployed

– First of a series in new extensible Labview framework

• Old Rotating Coil DAQ and software can be used

– Some concern about age, reliability, support

• Improved rotating coil system desired

– development in progress

• DAQ and motion control hardware and software

– resource limited effort

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Test Stand 4 Upgrade – Magnetic Measurement Systems

• Test Stand upgrade designs are mature

– Result of considerations that began several years ago – At the “Advanced Preliminary” level, in good shape for CD-1 – Highly detailed cost/labor estimates and schedules developed – Risks are low, Project schedule is achievable – Final design details require final FRS and acceptance requirements

• Cryogenic and Mechanical upgrades have begun

– Quench, Power, Control, Monitoring, Measurement Systems in FY18

• Resource Concerns

– Need to revisit Interface/Commissioning labor needs (Jan ‘18)

• Will Tom Page lead, or other (e.g., LK)?

– Mechanical Technicians

• Progress has been slower than planned due to Mu2e activities

– Electrical Technicians and Engineers

• Big Mu2e commitment on same time scale; techs always a limitation

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Test Stand 4 Upgrade – Conclusions

• Backup Slides

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Test Stand 4 Upgrade – Cryogenics

• The upgraded Stand 4 cryogenic system will allow controlled cool-

down and controlled warm-up

– Successfully implemented at VMTF, MICE/Mu2e Solenoid Test Facility

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Test Stand 4 Upgrade – Cryogenics

• Design aims to minimize

LHe usage by:

– Using an external LN2 bath for controlled cool- downs/warm-ups. (repurpose Tevatron sub-cooler) – Replumbing the LHe supply to the test stand to eliminate the Distribution Box from the

• circuit. (very old, high heat

load; build new He transfer line)

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4.5 K LHe Operations – Test Stand Design

Test Stand 4 Upgrade – Cryogenics

• Controlled cool-down

– Magnet can be cooled from 300 K to 180 K by mixing 300 K GHe with 80 K GHe from the LN2 bath (100 K DT). GHe of the appropriate temperature is supplied to the feed box GHe supply port. – The remainder of the controlled cool-down below 180 K will mix LHe and 80 K GHe in the feed box tubing. – Feed box temperature sensor needs to be added to the insert and located near the bottom fill port.

• Controlled warm-up

– Warming the magnet using an LN2 bath and a 100 K DT would not require any LHe.

• Otherwise, Test Stand 4 can operate at

4.5 K as presently configured.

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4.5 K LHe Operations – Test Stand Design

Feed box GHe supply

L FC FC

T

Feed box LHe supply

Test Stand 4 Upgrade – Cryogenics

• 15 kA vapor-cooled leads can operate at 18 kA with sufficient

mass flow. Lower static heat load than new 20 kA leads

– Recently tested at VMTF under varied conditions (He vapor content) – Demonstrated stable operation up to 20 kA – Will add a heater in feedbox to assure adequate lead flow

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0.1 V max allowed

Return End Can (as installed for IR Quads)

• Disassemble the existing End Can
• Machine larger openings (vacuum

vessel and thermal shield) and flange for HiLumi WF pass through

– WF, probe insertion through Return End

• Weld Pipe stub and flange

assembly for WF interface/vacuum seal

• Adapt/re-route existing piping to

match up with cold mass piping

• Relocate bus port to above beam

port

• Re-assemble

Test Stand 4 Upgrade – Mechanical

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• Return End Can Modifications

– Provides a “turnaround” for the cryogenics and power

• End Box Interfaces, Adapters: Designer Modeling

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Test Stand 4 Upgrade – Mechanical Feed End

1 – Heat Exchg 2 – Bus Ports 3 – Cooldn Ports 4 – Beam Tube 5 – Connector Port 1 2 3 5 4

What provisions? Assumed no Service Module Sliding Ring (O-ring provision) trapped at ends, for mating to vacuum sleeve?

• End Box Interfaces, Adapters: Designer Modeling

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Test Stand 4 Upgrade – Mechanical Turnaround End

1 – Heat Exchg 2 – Bus Ports 3 – Cooldn Ports 4 – Beam Tube Port 5 – Connector Port 1 2 2 3 4

Needed details: port terminations, flange sizes, thermal shield, seal design; beam screen?

Test Stand 4 Upgrade – Mechanical

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• New Vacuum Vessel Supports

Features will include:

• Ability to precisely move the

cryostat assembly in X,Y, and Z; and to fix the support once desired movement is achieved

• Ability to stably support the weight
• f the cold mass and cryostat

assembly

• Ease of installation and removal
• Note: 25 ton crane capacity

Test Stand 4 Upgrade - Quench Protection Design

– Implement redundancy from the connection to the magnet voltage tap wires through to the power supply and dump circuit – no single point failure modes – Implement a three tier quench protection system

• Tier 1 – Digital Quench Detection (FPGA) will be used for the

Primary QP

• Tier 2 – Analog Quench Detection will be used for the Reductant

QP

• Tier 3 – System Monitor, Logic Analyzer with First Fault Detection,

Fast Logger, Data management – Standard quench signals include: Whole Coil, Whole Coil – IDot, Bucked Half Coils, Cu Leads , SC Leads, and Ground Fault

• The two magnet whole coils will be treated as half coils for bucking
• The SC thru bus will have to be protected – Summed with SC

Leads

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Test Stand 4 Upgrade - QD Isolation Amplifiers

Custom Versus Commercial – – Custom hardware solutions will only be used when necessary

• The isolation amplifiers are a custom design but will be outsourced for

commercial fabrication

• 32 Channel Isolation Amplifier Box: Uses AD215 IA isolation amplifiers
• Fisher HV connectors will be used for the inputs, which will match the

existing test stand 4 HV quench cables

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Test Stand 4 Upgrade – Cryogenics Risk

• Available LHe inventory remains a risk.

– Re-ran the IB1 LHe usage model with the same parameters used previously….

• 255 l/hr average liquefaction rate
• 8,000 liter usable LHe inventory
• A second liquefier is not installed

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Test Stand 4 Upgrade – Cryogenics Risk

• Available LHe inventory remains a risk.

– …but with updated loads.

• Latest Stand 4 run plan and 18 kA operation (2 x 15 kA leads)
• Only VTS-2 & 3 are used for LCLS-II production testing
• VTS LHe usage rates from operational data
• Interdewar transfer between VTS-2 and VTS-3

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Test Stand 4 Upgrade – Cryogenics Risk

• Results show Stand 4 + 3 VTS-2/3 test cycles/week cannot be

supported.

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Prototype and first 2 Production Production

Test Stand 4 Upgrade – Cryogenics Risk

• Stand 4 + 2 VTS-2/3 test cycles/week also cannot be

supported.

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Prototype and first 2 Production Production

Test Stand 4 Upgrade – Cryogenics Risk

• Support of Stand 4 + 1 VTS-2/3 test cycle/week will require

close coordination of the test programs.

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Good days – some inventory margin Bad days – no inventory margin