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 2 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
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] 3 M. Tartaglia | Stand 4 Refurbishment Status Update 6/08/2017
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 4 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
T&I FTE Summary FY17 FY18 FY18 Task Labor Type OFF FY17 ON FY17 TOT OFF FY18 ON 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 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 0.13 0.13 0 0.22 0.22 Quench Protection E-ENG 0 0.8 0.8 E-TECH 0 0.57 0.57 S-DEV 0 0.14 0.14 DOES NOT INCLUDE INTERCONNECTS, COMMISSIONING TOTALS BY FY FY17 FY18 TOTAL OFF TOTAL ON 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 0.8 0.80 - E-TECH 0 0.57 0.57 - S-DEV 0 0.14 0.14 - 5 M. Tartaglia | Stand 4 Refurbishment Status Update 6/08/2017
BOE Summary T&I ON Project plus interconnect & commissioning estimates (TPage) Resource Role Year 1* Notes Estimate Source Mechanical Technician 2,635 Past experience with the old LHC quadrupole Various assembly and fabrication work magnets Mechanical Technician Sr 2,634 Various assembly and fabrication work QC Technician 160 Inspection and QC of test stand components and equipment Past experience with the old LHC quadrupole Procurement Specialist 160 Procurement and communication with outside vendors magnets Mechanical Engineer 1,568 Past experience with the old LHC quadrupole Design of components magnets Mechanical Engineer Sr 1,704 Design of components Cryogenics Engineer 480 Past experience with the old LHC and mu2e cryo Design of cryogenics system components systems Cryogenics Engineer Sr 520 Past experience with the old LHC and mu2e cryo Design of cryogenics system, components systems Electrical Engineer 300 Electrical wiring and checkouts Electrical Engineer Sr 300 Electrical wiring and checkouts Designer 3,248 Past experience with the old LHC quadrupole Design and drafting of test stand components magnets Welder 112 Past experience with the old LHC quadrupole Welding cryogenics system components magnets *This work is likely to extend into FY19 6 M. Tartaglia | Stand 4 Refurbishment Status Update 6/08/2017
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 [ In Progress ~40%] 7 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
Test Stand 4 Upgrade – Cryogenics • Buffer Tank 1 will capture quench gas. New piping required Stand 4 [ In Progress ~40%] 8 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
Test Stand 4 Upgrade – Cryogenics 4.5 K LHe Operations – Test Stand Upgrades/Modifications New piping/transfer lines required (controlled D T 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] 9 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
Test Stand 4 Upgrade – Control & Monitoring Systems • 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) 10 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
Cost & Labor Overview • Cryo (Rabehl) Schedule M&S (Fully Weld+MachineShop Stand 4 Upgrade Summary SWF (Fully Loaded) Loaded) M&S (Fully Loaded) FY18 FY17 FY18 FY17 FY17 FY18 FY18 System Task FY17 OFF FY17 ON OFF FY18 ON FY17 OFF ON OFF FY18 ON OFF ON OFF ON Cryo Safety Documentation 5,702 42,527 20,500 0 0 0 0 0 0 0 0 Quench Line 20,621 6,216 16,329 Stand Hardening 6,534 0 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 0 1,243 0 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 0 LN2 supply to FB 14,054 4,973 1,941 Valve & Instrument Upgrades 21,783 14,918 3,234 Cryogenic Safety Review 40,999 0 0 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 11 M. Tartaglia | Stand 4 Refurbishment Status Update 6/08/2017
Test Stand 4 Upgrade – Mechanical Systems • Principal Mechanical Upgrade elements – Disassemble, refurbish and re-assemble the Feedbox Top Plate insert • Two “15 kA” AMI vapor-cooled current leads; remove 3 rd 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 12 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL 8/02/2017
Test Stand 4 Upgrade – Mechanical • Refurbishing the Feed Box • Note: No modifications to the Feedbox ASME Code vessel required 8/02/2017 13 Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL
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