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. • 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. • 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. 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 C. Crowley | Proton Management Group Meeting 2/08/18
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 3 C. Crowley | Proton Management Group Meeting 2/08/18
NuMI AIP Design Goals NUMI SYSTEMS CAPABILITIES AIP Design Goal BEAM POWER (KW) 600 700 800 900 1000 1100 1200 Beam Parameters Pre-Target Window Target Baffle & Fins Horns (Horn 1) Horn & Target Modules Stripline Penetrations NUMI SYSTEMS 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 Current Capability Upgrade Option 1 Upgrade Option 2 4 C. Crowley | Proton Management Group Meeting 2/08/18
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. Work to Date • Original window remodeled in ANSYS and analyzed for temperature and stress at 1MW Analysis Credit: Raul Campos (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). 5 C. Crowley | Proton Management Group Meeting 2/08/18
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. 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. 6 C. Crowley | Proton Management Group Meeting 2/08/18
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. Analysis Credit: Kavin Ammigan 7 C. Crowley | Proton Management Group Meeting 2/08/18
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. 8 C. Crowley | Proton Management Group Meeting 2/08/18
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. Analysis Credit: Yun He 9 C. Crowley | Proton Management Group Meeting 2/08/18
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. Analysis Credit: Yun He 10 C. Crowley | Proton Management Group Meeting 2/08/18
Module Drive Components – Design Status Module Drive Components • 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. Design Credit: Vladimir Sidorov • 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. 11 C. Crowley | Proton Management Group Meeting 2/08/18
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). 12 C. Crowley | Proton Management Group Meeting 2/08/18
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. 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. 13 C. Crowley | Proton Management Group Meeting 2/08/18
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. Analysis of Critical Component Analysis Credit: Zhijing Tang 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. 14 C. Crowley | Proton Management Group Meeting 2/08/18
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