1 LHC-DFBX DFBX Production Readiness Review Project Overview Joseph Rasson LBNL October 2002, LBNL Brookhaven - Fermilab - Berkeley US LHC ACCELERATOR PROJECT

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 IR Cryogenic and Electrical Distribution Box IP1 & IP5 IP2 & IP8

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

6 DFBX Components (cont.) Other subsystems:  Jacketed beam tube  Bus duct assembly:  Busses  Lambda plate  Bus duct  Interconnect hardware  Alignment tools  Support jacks

7 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 R&D  SUPERCON technician group headed by Roy Hannaford is supporting Jon Zbasnik’s effort  Vapor Cooled Lead  SUPERCON group supporting the mechanical design and layout  Ron Scanlan prepared the lead design specification document

8 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

9 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

11 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

12 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

14 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, T’s and rearrange routing  Simplify welding and assembly process  Added weld rings to address warping during welding which allows vendor to meet the design intent

15 Design Change Summary (cont.) Bus Duct and Lambda Plate R&D:  Completed R&D 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

16 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

17 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: 1.Transfer the technology by training the vendors before the RFP is released 2.Assess vendors’ capabilities 3.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 of Mechanical 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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20 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:  Pirelli’s initial production schedule slipped 1.5 months  Latest Pirelli schedule as of 21 Oct: 1 st 5 FNAL Dec nd 5 FNAL Jan rd 5 FNAL Feb th 5 FNAL Mar  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 RFQ7 Oct Bidder responses8 Nov Place order10 Dec 2002 Deliver leads for DFBX-GApr nd LBNLMay rd 2003  Leads for DFBX-G will be delivered to the vendor 3 months before they are needed for installation

25 Acceptance Specification and Traveler status 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: oIn-process tests and inspection oFinal test/inspection prior to shipping oInspection 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

27 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

28 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 oMeets CERN requirement  Last (8th) DFBX Delivered months ARO oMeets DOE-LHC requirement  However, production schedule is aggressive  To meet schedule extensive oversight is required  Highlights the urgency to get process started

30 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