LHC-DFBX

1
US LHC ACCELERATOR PROJECT

Brookhaven - Fermilab - Berkeley

• LHC-DFBX
• DFBX Production Readiness Review
• Project Overview
• Joseph Rasson
• LBNL
• 23-24 October 2002, LBNL

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
IP1 IP5
IP2 IP8

• IR Cryogenic and Electrical Distribution Box

4
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

5
DFBX Components

• Major subsystems
• Power leads HTS VC leads
• Vacuum vessel
• Cryogenic piping
• LHe vessel
• Thermal shield
• Power lead chimneys
• Instrumentation leads
• Super insulation

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DFBX Components (cont.)

• Other subsystems
• Jacketed beam tube
• Bus duct assembly
• Busses
• Lambda plate
• Bus duct
• Interconnect hardware
• Alignment tools
• Support 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 RD
• SUPERCON technician group headed by Roy Hannaford
  is supporting Jon Zbasniks 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

10
Recent Technical Design Reviews
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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

13
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, Ts 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 RD
• Completed RD 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

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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

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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
• Transfer the technology by training the vendors
  before the RFP is released
• Assess vendors capabilities
• 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

18
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

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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

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
• Pirellis initial production schedule slipped 1.5
  months
• Latest Pirelli schedule as of 21 Oct
• 1st 5 pairs _at_ FNAL Dec. 2002
• 2nd 5 pairs _at_ FNAL Jan. 2003
• 3rd 5 pairs _at_ FNAL Feb 2003
• 4th 5 pairs _at_ FNAL Mar. 2003
• Leads for first box will be delivered to the
  vendor at least 4 months before they are needed

23
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_at_ LBNL May 2003
• 3rd shipment _at_LBNL Jun 2003
• Leads for DFBX-G will be delivered to the vendor
  3 months before they are needed for installation

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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

26
Acceptance Specifications and Travelers (cont.)

• CERN acceptance from US-LHC is based on
• Approval of LBNL-vendor Acceptance
  Specification,mainly
• In-process tests and inspection
• Final test/inspection prior to shipping
• 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

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Project Schedule

• 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
• Meets CERN requirement
• Last (8th) DFBX Delivered 27-29 months ARO
• 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