Upgrade of the Horizontal Test Facility at FNAL · 2017. 8. 2. · Measurements (2 [3 ?] leads at 18 kA) and SSW (10 A) at 1.9K •Design, fabricate components, and assemble a Warm

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

8/02/2017Michael Tartaglia | Upgrade of Horizontal Test Facility at FNAL2

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]

6/08/2017M. Tartaglia | Stand 4 Refurbishment Status Update3

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


T&I FTE Summary


Task Labor Type

FY17

OFF FY17 ON FY17 TOT

FY18

OFF FY18 ON

FY18

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

TOTALS BY FY FY17 FY18 TOTAL OFF TOTAL ON

DOES NOT INCLUDE INTERCONNECTS, COMMISSIONING

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 -

BOE Summary


Resource Role Year 1* Notes Estimate Source

Mechanical Technician 2,635Various assembly and fabrication work

Past experience with the old LHC quadrupole

magnets

Mechanical Technician Sr 2,634Various assembly and fabrication work

QC Technician 160 Inspection and QC of test stand components and

equipment

Procurement Specialist 160Procurement and communication with outside vendors


magnets

Mechanical Engineer 1,568Design of components


magnets

Mechanical Engineer Sr 1,704Design of components

Cryogenics Engineer 480

Design of cryogenics system components

Past experience with the old LHC and mu2e cryo

systems

Cryogenics Engineer Sr 520

Design of cryogenics system, components

Past experience with the old LHC and mu2e cryo

systems

Electrical Engineer 300Electrical wiring and checkouts

Electrical Engineer Sr 300Electrical wiring and checkouts

Designer 3,248Design and drafting of test stand components


magnets

Welder 112Welding cryogenics system components


magnets

T&I ON Project plus interconnect & commissioning estimates (TPage)

*This work is likely to extend into FY19

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%]


• Buffer Tank 1 will capture quench gas.


New piping required

Stand 4

[ In Progress ~40%]


• New piping/transfer lines required (controlled DT 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]


4.5 K LHe Operations – Test Stand Upgrades/Modifications

• 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)


Test Stand 4 Upgrade – Control & Monitoring Systems

Cost & Labor Overview


• Cryo (Rabehl) Schedule

Stand 4 Upgrade Summary SWF (Fully Loaded)

M&S (Fully

Loaded)

Weld+MachineShop

M&S (Fully Loaded)

System Task FY17 OFF FY17 ON

FY18

OFF FY18 ON FY17 OFF

FY17

ON

FY18

OFF FY18 ON

FY17

OFF

FY17

ON

FY18

OFF

FY18

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

https://fermipoint.fnal.gov/organization/cto/td/tid/ts4u/Shared Documents/Schedules/LARP HILUMI_Stand 4 estimate_cryo_170210.pdf?Web=1

• Principal Mechanical Upgrade elements

– Disassemble, refurbish and re-assemble the Feedbox Top Plate insert

• Two “15 kA” AMI vapor-cooled current leads; remove 3rd 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


Test Stand 4 Upgrade – Mechanical Systems

• Refurbishing the Feed Box

• Note: No modifications to the

Feedbox ASME Code vessel

required

Test Stand 4 Upgrade – Mechanical


• End Box Interfaces, Adapters

– Mech. interface from the Feed Box and Return end can to the

cryogenic, vacuum, power, and instrumentation features on the cold

mass. [some design, modeling effort already in progress]

• No valves are envisioned in these interface/adaptor “box/es”

• Only comprised of piping, (with provisions for thermal contraction), a

nitrogen cooled thermal shield, and MLI

• If this is a separate “box” at the Feed End then it is likely to remain as a

“permanent” extension of the feedbox after the initial setup and use

– Tasks to Perform: [starting Jan ‘18]

• Develop a Layout and Design for the Lead and Return End Interfaces

• Specify and procure the Adapter/Interface Box/es

• Perform acceptance tests and install





• Mechanical (Sylvester) Schedule


M&S (Fully

Loaded)

Weld+MachineShop

M&S (Fully Loaded)


FY18


FY17

ON

FY18

OFF FY18 ON

FY17

OFF

FY17

ON

FY18

OFF

FY18

ON

Mechanical Feed Box 30,929 15,978 27,005

Lead End Interface Box 32,443 12,432 5,652

Return End Interface Box 20,745 12,432 2,512

Return End Can 12,155 0 3,140

Warm Finger Assembly 41,518 18,648 10,048

Power 44,283 15,751 3,140

Cryostat Supports 48,293 12,432 31,401

Magnetic Meas. Drive System

(Refurb.) 55,248 43,512

TOTALS 0 116,729 55,248 113,635 0 50,377 43,512 37,296 0 40,193 0 42,705

Reminder: Interconnects, commissioning not included here

https://fermipoint.fnal.gov/organization/cto/td/tid/ts4u/Shared Documents/Schedules/LARP HiLumi_Program_Stand Preparation_July2017.pdf?Web=1

• 30 kA Power System [in good shape]

– 6 5000 A/ 30V PEI supplies

– Configurable Dump Switch & Resistor (2.5 to 90 W)

• In continuous use at VMTF, very good condition

• Connects to VMTF or Stand 4 via flex water-cooled cables

• Will upgrade to 1500 MCM flex leads [req in process]

• Will perform LCW system maintenance

– (hoses, T-switches, interlocks)

• Hard copper bus is adequate for >20 kA

• Quench Detection System

– Existing VME/Unix system to be completely replaced

• Isolation Amplifiers – replicate new design (in use 4 yrs)

• Redundant AQD and DQD; new AQD designed, now prototyping

– Programmable validation time for spikes

• DQD & Quench Logic in cRio/PXI FPGA-based system with Labview Interface

• Will replicate system currently at Mu2e Solenoid Test Facility, MICE (in use 4 yrs)

• Must develop/improve a new Labview Power Supply Controller w/ QD interface


Test Stand 4 Upgrade – Power & Protection Systems

• Heater and CLIQ Protection Systems

– Assume CERN will provide heater and CLIQ power supply units

– FNAL interface them to QD system and Test Stand

• CLIQ units in use at VMTF with old QD interface

• New heater interface, number of supplies = 16

• Protection System-Magnet Interfaces

– Hipot requirement

• IsoAmps tested to 1.8 kV

• Current Lead rating – verifying 4.5 kV insulation rating (15kA, 500A)

– Surface re-sealing, GN2 purge in “clam-shells” to prevent moisture

• Existing VT, Heater wires rated much higher, but need testing

• Must test and verify/fix current-limiting resistors

• Potted Instrumentation connectors should be OK; tested to 4 kV pin-pin

– Voltage Taps

• Awaiting decision: Existing Hypertronics in He pipes, vs vacuum feed-throughs

• New Cabling effort; cable length considerations

– Heater Connections

• Same question; how many?


Test Stand 4 Upgrade – Power & Protection Systems



• Quench Protection & Monitoring (Orris)

• T&I Summary (no interfaces & commissioning)


M&S (Fully

Loaded)

Weld+MachineShop

M&S (Fully Loaded)


FY18


FY17

ON

FY18

OFF FY18 ON

FY17

OFF

FY17

ON

FY18

OFF

FY18

ON

Protection

Systems Quench Protection & Monitoring 0 0 344,047 0 0 0 126,897 0 0 0 0 0

SWF FY17

OFF FY17 ON FY18 OFF FY18 ON

M&S FY17

OFF FY17 ON FY18 OFF FY18 ON

WELD/VMS

FY17 OFF FY17 ON

FY18

OFF FY18 ON ALL

TOTALS $41,975 $204,870 $561,885 $230,464 $7,459 $60,323 $309,887 $80,808 $25,749 $59,034 $17,162 $55,643 $1,655,257

TOTAL OFF

PROJECT $435,334 $317,346 $42,911 $795,591

TOTAL ON

PROJECT $603,860 $141,131 $114,676 $859,667

• Separate BOE exists

• FERRET Probe

– For precision end field

scans

• Translation System

– 2 options considered

• Refurbish Old

• Develop New/modern

– If Refurbish:

• Inspect and/or replace

internal components &

rubber drive belt

• Service pneumatic and

electronic components


Test Stand 4 Upgrade – Magnetic Measurement Systems

– Magnetic Measurement DAQ solutions exist

• Newly developed SSW software and hardware now deployed

– First of a series in new extensible Labview framework

• Old Rotating Coil DAQ and software can be used

– Some concern about age, reliability, support

• Improved rotating coil system desired

– development in progress

• DAQ and motion control hardware and software

– resource limited effort


Test Stand 4 Upgrade – Magnetic Measurement Systems

• Test Stand upgrade designs are mature

– Result of considerations that began several years ago

– At the “Advanced Preliminary” level, in good shape for CD-1

– Highly detailed cost/labor estimates and schedules developed

– Risks are low, Project schedule is achievable

– Final design details require final FRS and acceptance requirements

• Cryogenic and Mechanical upgrades have begun

– Quench, Power, Control, Monitoring, Measurement Systems in FY18

• Resource Concerns

– Need to revisit Interface/Commissioning labor needs (Jan ‘18)

• Will Tom Page lead, or other (e.g., LK)?

– Mechanical Technicians

• Progress has been slower than planned due to Mu2e activities

– Electrical Technicians and Engineers

• Big Mu2e commitment on same time scale; techs always a limitation


Test Stand 4 Upgrade – Conclusions

• Backup Slides



• The upgraded Stand 4 cryogenic system will allow controlled cool-

down and controlled warm-up

– Successfully implemented at VMTF, MICE/Mu2e Solenoid Test Facility



• Design aims to minimize

LHe usage by:

– Using an external LN2 bath

for controlled cool-

downs/warm-ups. (repurpose

Tevatron sub-cooler)

– Replumbing the LHe supply

to the test stand to eliminate

the Distribution Box from the

circuit. (very old, high heat

load; build new He transfer

line)


4.5 K LHe Operations – Test Stand Design


• Controlled cool-down

– Magnet can be cooled from 300 K to 180 K

by mixing 300 K GHe with 80 K GHe from

the LN2 bath (100 K DT). GHe of the

appropriate temperature is supplied to the

feed box GHe supply port.

– The remainder of the controlled cool-down

below 180 K will mix LHe and 80 K GHe in

the feed box tubing.

– Feed box temperature sensor needs to be

added to the insert and located near the

bottom fill port.

• Controlled warm-up

– Warming the magnet using an LN2 bath

and a 100 K DT would not require any LHe.

• Otherwise, Test Stand 4 can operate at

4.5 K as presently configured.


4.5 K LHe Operations – Test Stand Design

Feed boxGHe supply

L

FC

FCT

Feed boxLHe supply


• 15 kA vapor-cooled leads can operate at 18 kA with sufficient

mass flow. Lower static heat load than new 20 kA leads

– Recently tested at VMTF under varied conditions (He vapor content)

– Demonstrated stable operation up to 20 kA

– Will add a heater in feedbox to assure adequate lead flow


Projected - LQXF

Stand 4 –

LQXB01

VMTF with 500 liter

dewar supply

VMTF with

cryoplant supply

0.1 V maxallowed

Return End Can (as installed for IR Quads)

• Disassemble the existing End Can

• Machine larger openings (vacuum

vessel and thermal shield) and

flange for HiLumi WF pass through

– WF, probe insertion through Return

End

• Weld Pipe stub and flange

assembly for WF interface/vacuum

seal

• Adapt/re-route existing piping to

match up with cold mass piping

• Relocate bus port to above beam

port

• Re-assemble



• Return End Can Modifications

– Provides a “turnaround” for the

cryogenics and power

• End Box Interfaces, Adapters: Designer Modeling



Feed End1 – Heat Exchg2 – Bus Ports3 – Cooldn Ports4 – Beam Tube5 – Connector Port

12

3

5

4What provisions?Assumed no Service Module

Sliding Ring (O-ring provision)trapped at ends, for mating to vacuum sleeve?

• End Box Interfaces, Adapters: Designer Modeling



Turnaround End

1 – Heat Exchg2 – Bus Ports3 – Cooldn Ports4 – Beam Tube Port5 – Connector Port

1 2

2

3

4

Needed details: port terminations, flange sizes, thermal shield, seal design; beam screen?



• New Vacuum Vessel Supports

Features will include:

• Ability to precisely move the

cryostat assembly in X,Y, and Z;

and to fix the support once desired

movement is achieved

• Ability to stably support the weight

of the cold mass and cryostat

assembly

• Ease of installation and removal

• Note: 25 ton crane capacity

Test Stand 4 Upgrade - Quench Protection Design

– Implement redundancy from the connection to the magnet voltage tap

wires through to the power supply and dump circuit – no single point

failure modes

– Implement a three tier quench protection system

• Tier 1 – Digital Quench Detection (FPGA) will be used for the

Primary QP

• Tier 2 – Analog Quench Detection will be used for the Reductant

QP

• Tier 3 – System Monitor, Logic Analyzer with First Fault Detection,

Fast Logger, Data management

– Standard quench signals include: Whole Coil, Whole Coil – IDot,

Bucked Half Coils, Cu Leads , SC Leads, and Ground Fault

• The two magnet whole coils will be treated as half coils for bucking

• The SC thru bus will have to be protected – Summed with SC

Leads


Test Stand 4 Upgrade - QD Isolation Amplifiers

Custom Versus Commercial –

– Custom hardware solutions will only be used when necessary

• The isolation amplifiers are a custom design but will be outsourced for

commercial fabrication

• 32 Channel Isolation Amplifier Box: Uses AD215 IA isolation amplifiers

• Fisher HV connectors will be used for the inputs, which will match the

existing test stand 4 HV quench cables


Test Stand 4 Upgrade – Cryogenics Risk

• Available LHe inventory remains a risk.

– Re-ran the IB1 LHe usage model with the same parameters used

previously….

• 255 l/hr average liquefaction rate

• 8,000 liter usable LHe inventory

• A second liquefier is not installed



• Available LHe inventory remains a risk.

– …but with updated loads.

• Latest Stand 4 run plan and 18 kA operation (2 x 15 kA leads)

• Only VTS-2 & 3 are used for LCLS-II production testing

• VTS LHe usage rates from operational data

• Interdewar transfer between VTS-2 and VTS-3



• Results show Stand 4 + 3 VTS-2/3 test cycles/week cannot be

supported.


Prototype and first 2 Production Production


• Stand 4 + 2 VTS-2/3 test cycles/week also cannot be

supported.


Prototype and first 2 Production Production


• Support of Stand 4 + 1 VTS-2/3 test cycle/week will require

close coordination of the test programs.


Good days – some inventory margin Bad days – no inventory margin