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

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

L. Serio 3

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 20141205

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 20141205 L. Serio 4

46 days (41 working days - cryo also during non working days)installation & preparation number of magnets tested per yearcooling4 K tests or 1.5 magnets per monthwarm upwarm tests and disconnect

16with 3 test benches and 13 days cold magnetic 4

10

1013

4

Introduction

CERN – GSI c.tte meeting 20141205 L. Serio 5

Outline



• Conclusions


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


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


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):

item budget# kCHF

1 12002 2603 1504 250

TOTAL 1860

Energy Extraction system (3 circuits)Test stand QPS based on LHC techn

description

Additional precooler w warm upAdditional survey tools

96100

7001728

78604179

12038 12039 1

Costing 3 test benches & 2 precooler - Construction - [kCHF]Material

staff (16 FTE-y but 1/3 for constr)non staff (17.3 FTE-y)GSI contributionCERN contribution

Contingency


Project Plan: Organization

The project is part of the global cryogenics test facility refurbishment project of the TE department by Volker Mertens.


CERN – GSICollaboration Committee

F. Bordry, M. JimenezO. Kester, E. Fischer

CERNTechnical Coordinator

Luigi Serio

FAIR Technical Coordinator

Pierre Schnizer

Magnetic Measurements

Stephan Russenschuck

Test FacilityMarta Bajko

Electrical Power Rene Necca

Power ConvertersHugues Thiesen

CryogenicsAntonio Perin

Quench ProtectionReiner Denz

Cooling and Ventilation

Michele Battistin

SurveyDominique Missiaen

Cryogenic Testing at CERN of SUPER -FRS Magnets for FAIROrganization Chart

EN Dept.

TE Dept.

HSEAndre Henriques

FAIR Mirror Organization

ICEPhilippe Gayet

IntegrationYvon Muttoni

Energy ExtractionKnud Dahlerup-

Petersen

Handling and transport

Ingo Ruehl

Platforms and structures

Mats Willhelmson

Project Mgt. support

David Hay

Outline



• Conclusions


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


Main interface documents


Outline



• Conclusions


ScheduleFix layout interfaces

LLI procurements

Commissioning

3 test benches, 2 CWUs12 days cold testing J F A J J A S O N D J F A J J A S O N D J F A J J A S O N D J F A J J A S O N D J F A J J A S O N D J F A J J A S O N D J F A J J A S O N D J F A MJ J A S O N DConceptual DesignPreliminary Design/InterfFinal DesignProcurementManufacturingInstallationCommissioningMultiplet contract signDipole FDR, contract signMultiplet design, manufctDipole Design, ManufctProto magnets testingSeries Magnets TestingShort Multiplets Proto . . .Long Multiplet Proto . . .Dipole Proto . . .First Series Short MultipletFirst Series Long MultipletFirst Series DipoleFirst Energy Buncher ?Last Energy Buncher ?PANDA testing ?

2021


Accruals of activitiesForecasted planning wrt current delayForecasted planning according to delayed activitiesBaseline

Main critical milestones3 test benches, 2 CWUs12 days cold testing J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F MA MJ J A S O N D J F A J J A S O N D J F A J J A S O N D J F A J J A S O N DConceptual DesignPreliminary Design/InterfFinal DesignProcurementManufacturingInstallationCommissioningMultiplet contract signDipole FDR, contract signMultiplet design, manufctDipole Design, ManufctProto magnets testingSeries Magnets TestingShort Multiplets Proto . . .Long Multiplet Proto . . .Dipole Proto . . .First Series Short MultipletFirst Series Long MultipletFirst Series DipoleFirst Energy Buncher ?Last Energy Buncher ?PANDA testing ?

2014 2015 2016 2017 2018

Outline



• Conclusions


WP: Integration 1/4DONE• 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• https://edms.cern.ch/document/1314744/1• https://edms.cern.ch/document/1437783/1• https://edms.cern.ch/document/1422391/1• https://edms.cern.ch/document/1440542/1


https://edms.cern.ch/document/1314744/1





WP: Integration 2/4


WP: Integration 3/4


WP: Integration 4/4


WP: SafetyDONE• 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• https://edms.cern.ch/document/1326801/1• https://edms.cern.ch/document/1364870/2• https://edms.cern.ch/document/1419927/1







WP: Cooling and Ventilation 1/3DONE• 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• https://edms.cern.ch/document/1435672/1• https://edms.cern.ch/document/1421010/2





WP: Cooling and Ventilation 2/3


WP: Cooling and Ventilation 3/3


WP: CryogenicsCRITICAL 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• https://edms.cern.ch/document/1355497/1• https://edms.cern.ch/document/1430162/0.1




https://edms.cern.ch/document/1430162/0.1

https://edms.cern.ch/document/1430162/0.1

WP Cryogenics Progress in the detailed definition

Revised Block Diagram for Cryogenic Infrastructure Detailed scheme of Pre-cooler #2Goal: 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


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


WP: Magnetic MeasurementsDONE• 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: 5 10-4

– Field quality dipole: 5 10-5

– Other harmonics quadrupole: 5 10-5

– Other magnets: 1 10-3 and 2 10-4

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• https://edms.cern.ch/document/1416580/1



WP: TF and ICEDONE• 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• https://edms.cern.ch/document/1416581/1• https://edms.cern.ch/document/1431417/1• https://edms.cern.ch/document/1431421/1• https://edms.cern.ch/document/1450763/1







WP: Power ConvertersDONE• 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





WP: Platforms and StructureDONE• 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• https://edms.cern.ch/document/1416776/1• https://edms.cern.ch/document/1314744/1• https://edms.cern.ch/document/1437783/1• https://edms.cern.ch/document/1422391/1• https://edms.cern.ch/document/1440542/1










Magnets interfaces and dimensions


Platform review and optimization


Platform review and optimization


WP: Quench ProtectionDONE• Review of requirements • Plan to use LHC type QPS and DAQ for voltage signals

IN WORK• NA

DELAYED• NA





WP: Energy ExtractionDONE• Review of requirements • Conceptual design of EE system• Use of LHC extraction system with classical dump resistor

IN WORK• NA

DELAYED• NA





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)


WP: SurveyDONE• 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




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


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 stageCERN – GSI c.tte meeting 20141205 L. Serio 40

References

• Project Plan (contains all up to date information): – EDMS: https://edms.cern.ch/document/1370663/3

• Technical coordination meetings and reviewed interface parameters:– EDMS: https://

edms.cern.ch/nav/P:FAIR-000001263:V0/P:FAIR-000002500:V0/TAB3

• Interface requirements documents:– https://

edms.cern.ch/nav/P:FAIR-000001263:V0/P:FAIR-000002718:V0/TAB3 CERN – GSI c.tte meeting 20141205 L. Serio 41



https://edms.cern.ch/nav/P:FAIR-000001263:V0/P:FAIR-000002500:V0/TAB3






Documents

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