Progress report on the test facility project design and construction P. Schnizer and L. Serio on behalf of bldg. 180 test facility project team members (TE and EN) and GSI/FAIR colleagues

Outline Introduction Project Plan update – Scope of work, financing and organization Progress report – Executive summary – Schedule – Individual WPs reports Conclusions CERN – GSI c.tte meeting L. Serio3

Introduction  Following the decisions at the last collaboration meeting we have: - worked and finalised the test program and functional requ.ts - proceeded with the review of the internal / external interfaces - developed a detailed project plan and resource loaded schedule - implemented the new scope of work and financing  Several meetings have taken place between CERN and FAIR personnel leading to the definition and technical agreement of the requirements, plans, resources and design reported hereafter - over 50 EDMS technical documents were produced - 5 general technical coordination meeting (CERN-GSI) were held - several specific technical meetings for individual WPs took place  Detailed design activities were started according to the maturity reached and the agreed schedule.  Procurements have been launched for the main long lead items. CERN – GSI c.tte meeting L. Serio4

Introduction CERN – GSI c.tte meeting L. Serio5

Outline Introduction Project Plan update – Scope of work, financing and organization Progress report – Executive summary – Schedule – Individual WPs reports Conclusions CERN – GSI c.tte meeting L. Serio6

Project Plan: Scope of Work  Addendum n.2 to the 2010 Agreement K1727/DG CERN - GSI ‐Cryogenic testing at CERN of Super Fragmentation Separator (SUPER-FRS) Magnets for FAIR ‐3 prototypes, 52 series and 2 spares magnets ‐Refurbishing and upgrade of the existing cryogenic test facility located in the test hall n. 180 at CERN - Meyrin  Addendum n.4 to the 2010 Agreement K1727/DG CERN - GSI ‐Additional equipment requested by GSI for the implementation of Addendum n.2 ‐Pre-cooler ‐Quench detection and energy extraction system ‐Survey tools CERN – GSI c.tte meeting L. Serio7

Implementation status Scope of work – done Preliminary requirements fixed with GSI/FAIR Test program and WBS established Interface functional document released Schedule- done; magnets procurement reviewed schedule (?) Test phases, sequence and overall testing rate established Overall schedule and action plan established Long lead items procurement phase launched Cost- done PBS, WBS and financing plan established according to SOW Issue the Project Plan- done Implement the Project Plan – done; activities started CERN – GSI c.tte meeting L. Serio8

Project Plan: Financing Additional cost to refurbish the existing facility excluding available CERN infrastructure (e.g. building, cranes, cold box, …) and CERN staff involved in the project (evaluated at ~ 1 MCHF): CERN – GSI c.tte meeting L. Serio9

Project Plan: Organization The project is part of the global cryogenics test facility refurbishment project of the TE department by Volker Mertens. CERN – GSI c.tte meeting L. Serio10

Outline Introduction Project Plan update – Scope of work, financing and organization Progress report – Executive summary – Schedule – Individual WPs reports Conclusions CERN – GSI c.tte meeting L. Serio11

Progress report: Overall Status – Project Plan finalised and implemented – Integrated planning prepared – Some resources still involved in the LHC re-commissioning – Functional requirements received, discussed, reviewed and finalised 2 months delay – Detailed interface requirements pending expected to be finalised by November 2015 (!) – Ready to proceed with procurement of 60 to 70 % of the assets – CWS on time with procurement activities launched (MS, IT) – CRYO delayed about 3 months (MS and IT in preparation) – Remaining systems not on critical path CERN – GSI c.tte meeting L. Serio12

Main interface documents CERN – GSI c.tte meeting L. Serio13

Outline Introduction Project Plan update – Scope of work, financing and organization Progress report – Executive summary – Schedule – Individual WPs reports Conclusions CERN – GSI c.tte meeting L. Serio14

Schedule Fix layout interfaces LLI procurements Commissioning CERN – GSI c.tte meeting L. Serio15

Outline Introduction Project Plan update – Scope of work, financing and organization Progress report – Executive summary – Schedule – Individual WPs reports Conclusions CERN – GSI c.tte meeting L. Serio16

WP: Integration 1/4 DONE Review of the general layout Integration of all the different magnets types/dimensions/layout Definition of the position, size and layout of the main equipment (ALL) Routing of the main piping (CWS, CRYO) IN WORK Integration meeting on-going to support design integration and procurement activities Routing of cabling DELAYED Layout and interface of magnets supporting system Final layout of platforms and routing of water cooling cables, DAQ and control cables, proximity cryogenics REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio17

WP: Integration 2/4 CERN – GSI c.tte meeting L. Serio18

WP: Integration 3/4 CERN – GSI c.tte meeting L. Serio19

WP: Integration 4/4 CERN – GSI c.tte meeting L. Serio20

WP: Safety DONE Launch Safety Agreement prepared, reviewed and released Review of magnets pressure ratings, safety devices and test needs Definition of safety requirements applicable to the facility and the magnets Review of overall layout of the facility from a safety point of view IN WORK Update of the Launch Safety Agreement according to the design maturity and procurement activities DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio21

WP: Cooling and Ventilation 1/3 DONE Preliminary design and interfaces (users) requirements definition Layout and integration Market Survey, firms selection Technical Specification IN WORK Call for tender sent to firms DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio22

WP: Cooling and Ventilation 2/3 CERN – GSI c.tte meeting L. Serio23

WP: Cooling and Ventilation 3/3 CERN – GSI c.tte meeting L. Serio24

WP: Cryogenics CRITICAL PATH WP DONE Functional requirements for the cryogenic system Preliminary design of the cryogenics production plant PFDs of the overall system Definition of the utilities requirements (EL, CW) Preparation of bldg 279 and galleries sites (cleaning and clearing) Preparation of the refrigerator cold box cabling and instrumentation (cleaning and clearing) Draft Market Surveys for the Compressor Station, Pre-cooler, Transfer lines and Satellite Boxes IN WORK Market Survey dispatch to firms Draft of the technical specifications Review of cryogenic interfaces with magnets Minimum required consolidations for abandoned facilities (bldgs repairs, clearing and cleaning) DELAYED MS and IT – about 2 months REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio25

WP Cryogenics Progress in the detailed definition Revised Block Diagram for Cryogenic Infrastructure Detailed scheme of Pre-cooler #2 Goal: producing a temperature difference of 50 K at 50 g/s of helium flow during warm up and cool down. Finalization of the configuration Production of PFDs & PIDs Naming of components List of instrumentation Market surveys and technical specification documents in preparation CERN – GSI c.tte meeting L. Serio26

WP Cryogenics: Integration & buildings B180 integration: most aspects frozen Integration study of compressors in B279 by using the existing concrete blocks done. Options limited and not optimum. Decision taken to redo the compressor supports. Integration studies Buildings preparation B279 B180 de-cabling nearly completed B279 (compressors) stripped to walls B180 CERN – GSI c.tte meeting L. Serio27

WP: Magnetic Measurements DONE Review of magnet test program, time and tools requirements Measurement strategy within the boundary constrains reviewed (streamlined tests, analysis and overall test time assessed) Specification of the required measurements, program and precision targets – Flux meters and rotating coil probes – Main field component: – Field quality dipole: – Other harmonics quadrupole: – Other magnets: and IN WORK Development on the fluxmeter and rotating coils (challenging precision measurements, high cost of industrially available instruments) Review of finalised magnet database and required test data – September 2014 in order to launch the required development and procurements DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio28

WP: TF and ICE DONE Facility test program and optimised activities duration Instrumentation list review and finalisation IN WORK Specifications for DAQ and signals exchange being prepared Specifications for main powering cables Specifications for signal and acquisition cables DELAYED PBS, WBS and detailed schedule REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio29

WP: Power Converters DONE Detailed technical specification of power converters and utilities requirements Procurement of Power Converters launched (PCs expected at CERN mid-2015) IN WORK Interfacing with Energy Extraction System and Powering Interlock System DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio30

WP: Platforms and Structure DONE Layout and integration with all magnets types and dimensions Review of the interfaces requirements IN WORK Freezing of magnets interfaces / final design Requirements for magnets support and anchoring Layout of the cryogenic distribution and cabling routing DELAYED Detailed design and cost optimisation REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio31

Magnets interfaces and dimensions CERN – GSI c.tte meeting L. Serio32

Platform review and optimization CERN – GSI c.tte meeting L. Serio33

Platform review and optimization CERN – GSI c.tte meeting L. Serio34

WP: Quench Protection DONE Review of requirements Plan to use LHC type QPS and DAQ for voltage signals IN WORK NA DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio35

WP: Energy Extraction DONE Review of requirements Conceptual design of EE system Use of LHC extraction system with classical dump resistor IN WORK NA DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio36

WP: Energy Extraction No R&D, design/ordering of 1.4 Ω - 1MJ dump-resistors (one per system) Consolidation of the existing 6 extraction systems (from the LHC 2013) CERN – GSI c.tte meeting L. Serio37

WP: Survey DONE Review of requirements and definition of measuring points IN WORK Definition and layout of surveying tools based on layout and optimization of measuring points DELAYED NA REFERENCE DOCUMENTS CERN – GSI c.tte meeting L. Serio38

Conclusions 1/2 Functional requirements and testing scenario finalised Integrated schedule and detailed workplan established Procurement of long lead items launched Minimal delays wrt original plan due to – Lack of maturity of SFRS design for interface definition – Resources availability (LHC commissioning) Cryogenics (production part) on critical path for test infrastructure availability in summer 2016 Proximity cryogenics pending interface detailed design definition CERN – GSI c.tte meeting L. Serio39

Conclusions 2/2 Detailed interface requirements for magnets interface still pending design development (November 2015 (!)) – Proximity cryogenics, platforms, support structure impacted – Remaining system can, in principle, proceed according to plan Proposal is to continue with what is fixed and review remaining parts later according to – Detailed design/construction planning from magnets manufacturers – Availability of detailed design interfaces Advantages: less integrated resources usage, fixing of interfaces with a mature design not leading to changes and cost for CERN and GSI Risks: unknown availability of resources by CERN at a later stage CERN – GSI c.tte meeting L. Serio40

References Project Plan (contains all up to date information): – EDMS: Technical coordination meetings and reviewed interface parameters: – EDMS: :V0/P:FAIR :V0/TAB3https://edms.cern.ch/nav/P:FAIR :V0/P:FAIR :V0/TAB3 Interface requirements documents: – :V0/P:FAIR :V0/TAB :V0/P:FAIR :V0/TAB3 CERN – GSI c.tte meeting L. Serio41