Design & Planning Status Update Cory Crowley Proton Management - - PowerPoint PPT Presentation

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Design & Planning Status Update Cory Crowley Proton Management - - PowerPoint PPT Presentation

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NuMI Target Systems AIP Design & Planning Status Update Cory Crowley Proton Management Group Meeting 2/08/2018 General Status of AIP Project Level Continue to move forward at a rate that can be supported by NuMI Operations.

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SLIDE 1

Cory Crowley Proton Management Group Meeting 2/08/2018

NuMI Target Systems AIP Design & Planning Status Update

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SLIDE 2

General Status of AIP

Project Level

  • Continue to move forward at a rate that can be supported by NuMI Operations.
  • Still waiting for funding approval from DOE / Fermilab.
  • Successful news received from ESH&Q regarding Environmental Assessment.

– Existing assessment under NOvA is sufficient for planned upgrades. – Have passed a procedural / analysis hurdle on way to 1MW. 2

Activity Level

  • 10 out of 16 major activities have had, and are continuing to have, a significant amount of effort put forth

towards analysis and design.

  • Engineering, analysis, and drafting contributions from AD TSD / MSD / APC , + PPD & TD.
  • Starting prototyping activities.
  • Preparing shutdown plans + vendor quotes for imminent procurement of long lead items in attempt to meet

project milestones despite funding hold. 2/08/18

  • C. Crowley | Proton Management Group Meeting
  • On schedule to completing shielding assessment in March / April timeframe.
  • Higher beam power to NuMI will then be limited by our own engineering constraints, and

available beam from Main Injector.

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SLIDE 3

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2/08/18

  • C. Crowley | Proton Management Group Meeting

Outline

  • Scope of Work / Systems
  • Design Effort

– Work Completed to Date – Remaining Activities – Design Reviews

  • Outstanding Items / Summer Shutdown Plans
  • Current AIP Needs & Project Summary
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SLIDE 4

NuMI AIP Design Goals

600 700 800 900 1000 1100 1200

Beam Parameters Pre-Target Window Target Baffle & Fins Horns (Horn 1) Horn & Target Modules Stripline Penetrations Power Supply NuMI RAW Skids Target Hall Chiller Target Chase Air Cooling Target Chase Shielding Tritium Mitigation Decay Pipe Windows Absorber Hadron Monitors MARS Simulations

BEAM POWER (KW) NUMI SYSTEMS

NUMI SYSTEMS CAPABILITIES

Current Capability Upgrade Option 1 Upgrade Option 2

AIP Design Goal

4

2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 5

Pre-Target Window - Design Status

High Power Limitation

  • Identified as likely weak point past 700kW: Poor braze quality, marginal window strength.
  • Requires end cap redesign and increase in beam spot size for 1MW operation.

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Analysis Credit: Raul Campos Work to Date

  • Original window remodeled in ANSYS and

analyzed for temperature and stress at 1MW (failed on fatigue life).

  • Proposed revision to existing design is an

increase in beryllium thickness from a nominal .010” to .015”.

  • Has negligible effect on neutrino flux.
  • Thermal and stress analysis completed;

provides a 57% stress reduction with minimal increase in steady state temperature.

  • Analysis and design work is scheduled for final

review (2/16/18). 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 6

Pre-Target Window – Fabrication Plans

Production Window

  • Window design has been presented to Vacuum Window Committee and passed requirements set forth.
  • Engineering note is being formalized and will be available after final review.
  • Drawing package is being prepared and will be available for bid submittal week of 2/19.

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Fabrication Improvements

  • Recent work with lab vendor has markedly improved braze alloy coverage; nearly 100% on recent scans.

– Best defense against corrosive atmosphere. – Eliminates stress concentrations at interface.

  • Christine Ader / VWC, to implement new production guidelines on braze assembly drawings.

2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 7

Target Baffle - Design Status

Target Baffle

  • Thermal and structural analysis of existing design at 1MW completed.
  • Graphite internal diameter scaled with beam spot size to reach 15mm diameter.
  • No unforeseen issues with temperature / stress / fatigue life on both graphite collimation slugs, as well as

external aluminum cooling shroud.

  • Air cooling still sufficient.

Summary

  • Minimal drawing revisions to baffle sub-assembly required; Existing production can continue.
  • Analysis scheduled for engineering review week of February 26th.

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Analysis Credit: Kavin Ammigan 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 8

Target Core - Design Status

Target Core

  • Existing model has been updated with new core geometry.

– Fin width increase to 9.0mm from 7.4mm. – New cooling rail placement and re-centering of internals.

  • Core Analysis.

– ANSYS model is being built. – Will complete steady state and transient thermal and structural analysis. – focusing on fins, cooling rail, outer containment can, and windows. – Goal is providing confirmed heat load to RAW systems engineering.

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2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 9

Horn 1 - Design Status

Inner & Outer Conductors

  • Thermal analysis of conductors is complete.
  • Assumes new water based cooling convection coefficients from planned RAW system upgrades.
  • Structural analysis underway and expected to be complete within 4-6 weeks.
  • Increase in neck or weld diameter not believed to be required at this time.
  • Analysis of existing design will be peer reviewed in March.
  • Stripline analysis to start soon; completion expected to

follow in ~2 months.

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Analysis Credit: Yun He 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 10

Horn 1 - Design Status

Conductor Temperatures

  • Neck and D.S. end get hot as

expected.

  • Analysis is promising thus far.

Possible Project Scope Reduction

  • If existing 6061-T6 aluminum

withstands stresses, no new inner conductor needed; risk goes away.

  • Provision exists for new conductor

made from 6013-T6 aluminum, but will wait to remove until analysis complete.

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Analysis Credit: Yun He 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 11

Module Drive Components – Design Status

Module Drive Components

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Design Credit: Vladimir Sidorov

  • Fresh 3D model (portion shown below) has been generated in lab’s current

CAD software.

  • Prototyping efforts for vertical and horizontal sliders are underway.

– Anodized 6061-T6 aluminum bushings. – CrN plated 316SS linear rods w/flat cuts for dust accumulation.

  • Prototype testing to start in March timeframe.
  • Will have engineering review / approval after testing complete.

– Production drawings of new components will follow. – Revising materials, tolerances, and adding rad-resistant coatings. 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 12

Horn Power Supply – Design Status

Power Supply / Capacitor Bank

  • Currently provides 200KA @ ~2.3ms pulse width. Accounts for large portion of H1 neck heating.
  • EE Support investigating new capacitor cost which provides a 20-25% reduction in joule heating.
  • Existing capacitors cannot be reconfigured to provide shorter pulse width.
  • New caps with shorter pulse width drives voltage higher.
  • Horns capable of 3kV to ground isolation; further testing planned once spare horn is removed from

MI-8 test stand.

  • Hoping to have new capacitor cost comparison within a few months to update project plan if needed.

Project Scope Change

  • If horn structural analysis with transient temperature inputs shows acceptable fatigue life, we could

entertain the possibility of changing capacitors to increase design life of power supply, and further reduce stress on horn inner conductor.

  • Should move ahead with costing replacement capacitors, as they are currently assumed to be required to

bring horn fatigue life within TSD guidelines (1E8 pulses).

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2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 13

RAW Skids – Design Status

Target & Horn 1 Skids

  • Target and Horn 1 skids represent the bulk of the RAW systems upgrades.
  • Target RAW system has redesign in process for pumps / piping / instrumentation.
  • Horn 1 RAW system has redesign in process for pumps / piping / instrumentation + ejector system in TH.
  • Horn 2 RAW skid changes are minimal and are being purposefully delayed to focus on immediate

bottlenecks in target and horn 1 systems for FY18.

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Long Lead Items Required

  • Heat exchangers.
  • Upgraded Pumps.
  • New PEEK sealed Valves.

Current Status

  • Drafter assigned and P&ID’s in progress.
  • Bids in hand for custom heat exchangers.
  • Budgetary quote in hand for all piping upgrades from

Pipefitters. 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 14

RAW / Chase Cooling Standby Generator

Analysis of MI-65 Generator Capacity

  • Power distribution and excess capacity study completed by FESS

/ Randy Wielgos.

  • Would need to support 30hp worth of pumps / secondary chillers /

remote instrumentation.

  • Requires new circuit from MI-65 backup generator for process

load.

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Analysis of Critical Component Temperatures

  • Assumed worst location in chase (just

D.S. of Horn 1 stripline).

  • All shielding blocks set to 1MW steady

state temperature based on extrapolated NOvA 700kW analysis temps with actual NuMI 640kw temperatures as analysis validation. Confirmed Project Scope Reduction

  • Analysis of critical component temperatures in target chase was reviewed and found to be accurate by

TSD engineering on 2/7/18.

  • Results showed wide margin of allowable temperature increase in Horn 1 stripline before material is

compromised.

  • Generator tie-in portion for backup cooling as part of NuMI AIP is no longer warranted.

Analysis Credit: Zhijing Tang 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 15

Target Chase Shielding - Design

Chase Shielding

  • Design for cover plates over Horn 2 is complete.
  • Additional shield wall envisioned for separating D.S. end of

Horn 1 from Horn 2; vice-versa for upstream end of Horn 2 to Horn 1.

  • Design review planned for week of 2/19/18.
  • Production drawings anticipated by end of March for April

procurement start.

  • NuMI AIP plan was to have ready by FY18 shutdown for dose

rate reduction during water line revisions.

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Design Credit: Joe Angelo 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 16

Decay Pipe Windows - Design

U.S. Decay Pipe Window

  • NuMI AIP included provision for production of spare decay pipe

window, as well as remote controlled robot or tooling capable of repair / replacement.

  • Current design work has focused on the prospect of repairing

window as opposed to full fledged replacement.

  • Accurate chase model being created for repair mechanism design.
  • Repair mechanism investigation / prototyping to start soon.
  • Thermal & structural analysis of window is ready to begin.

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Design Credit: Mike Campbell 2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 17

Hadron Monitor Design & MARS Simulations

Hadron Monitor

  • Removed spare hadron monitor # 4 from storage.
  • Designer / drafter assigned & documentation phase has

commenced.

  • Will determine existing boundaries to stay within for new design.

MARS Simulations

  • MARS Analysis is on track for completion by March.
  • Kamran Vaziri, Igor Rakhno, and Katsuya Yonehara are handling documentation needs and submittal to

the shielding assessment committee for review.

  • Current limitation of ~740kW for NuMI target hall should be revised to allow 1MW by early / mid summer

2018.

17

2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 18

Outstanding Items / Summer Shutdown Plan

Outstanding Items for NuMI AIP

  • A few activities are purposefully delayed due to project timeline and prioritizing resources.
  • Absorber analysis @ 1MW.
  • Absorber RAW skid improvements.
  • Tritium mitigation efforts (modifications to existing infrastructure).
  • Decay pipe D.S. chiller maintenance / changes.
  • Horn 2 RAW skid improvements.
  • Horn 1 Stripline*
  • AIP can refocus on these issues if funding becomes available and 2018 summer shutdown is successful

and on schedule.

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Planned Activities

  • 1MW Pre-target Window Assembly Installation
  • Target RAW Skid Upgrades
  • Horn 1 RAW Skid Upgrades
  • Auxiliary shielding procurement / placement / testing + possible use during Horn 1 RAW piping upgrades.

2/08/18

  • C. Crowley | Proton Management Group Meeting
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SLIDE 19

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Current Needs / AIP Summary

Current Needs

  • Pre-target Window.

– Need to successfully pass the 2/16/18 review. – Immediate funding required thereafter to meet fabrication timeline for 2018 shutdown installation

  • RAW Systems.

– Immediate funding required by 3/1/18 to procure long lead time heat exchangers. Vendor timeline

  • ut of our control.

– Additional funding required thereafter every month for pump, sensor, piping, etc… procurement. – Major Pipefitting contract to be placed in May / June for work that should start 7/9/18.

  • Chase Shielding.

– Planned for spring / summer 2018 fabrication & installation during 2018 summer shutdown. – Will need funding by 4/1/18 to make fabrication deadlines due to outside vendor lead times. Summary

  • TSD / MSD continues to do preliminary and final design work until M&S funding is approved.
  • Most major analysis activities are successfully moving forward; reviews on schedule.
  • On track for all planned activities as part of 2018 summer shutdown, but continued funding delays past

2/19/18 will put project milestones at risk.

  • The AIP cannot advertise ability to accept higher beam power after 2018 shutdown regardless of funding
  • availability. Project works towards 1MW capability, not constant revisions to make 50kW increases.

2/08/18

  • C. Crowley | Proton Management Group Meeting