Transcript Slide 1

DFB Project
LHC Machine Advisory Committee Meeting no. 19, June 2006
DFB status
R. van Weelderen AT/ACR
on behalf of the DFB project team
data provided by A. Ballarino, V. Benda, C. Bertone, R. Folch, R. Girardot, J. Miles, G. Mugnai, A. Perin,
J.P. Tock, F. Rodriguez-Mateos, L. Serio,
DFB Status, LHC-MAC no. 19, June 2006
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overview
DFB Project
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•
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Introduction to Electrical Distribution Feed Boxes for LHC (function, quantity,
location)
Main design features
Project organization
Status of key tasks and supplies (assembly & tests, current leads, IHEP
components, proximity equipment, local integration, connections, transport
& installation, commissioning)
Production schedule
Summary
DFB Status, LHC-MAC no. 19, June 2006
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Introduction: function, quantity, location
DFB Project
Functionalities
Current supply to the LHC cryomagnets (all DFBs)
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Functionalities of the DFBs
1300 current leads, 2900 kA total current,
44 boxes, incorporating from 2 to 71 current leads in 3
main types
16 DFBA: powering the arcs
23 DFBM: powering of standalone magnets in the LSS
5 DFBL: powering of the superconducting links
Arc termination (DFBAs only)
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–
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Deliverable:
installed in the LHC tunnel
fitted with all proximity equipment
connected to the LHC magnets, ready to be
operated.
End of arc pressure forces recovery
Support of beam tubes + cold-warm transition
Supply of cryogenics to the arc
Supply of cryogenics to the superconducting links (DFBL
only)
Key facts
1300 current leads, 570 “chimneys”
Numerous variants: 44 DFBs, 56 modules, 31 variants (drawings
sets), from 2 to 71 current leads
DFBAs are in the beam lines, high mechanical constraints
Highly integrated into LHC machine
Sensitive components (current leads, busbars, lambda plates)
Very diverse components: cryogenic, electrical, vacuum, etc.,
implying several groups at CERN
High number of interfaces
DFB
Powering
function
Location
Nb of current
leads
DFBA
Arc magnets
At arc end (usually at Q7)
2 to 73
DFBM
Standalone
magnets
Besides magnets in the
LSS
4 to 17
DFBL
Superconducting
links
In the RRs (caverns)
23 to 44
DFB Status, LHC-MAC no. 19, June 2006
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Introduction: function, quantity, location (4 out of 8
sectors shown)
DFB Project
Functionalities of the DFBs
DFB Status, LHC-MAC no. 19, June 2006
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Introduction: main design features
DFB Project
Connection to
magnets
12x120A CLs
Functionalities of the DFBs
Vacuum equipment VAA
Sh
Current lead chimneys
uff
lin
gm
od
u
11x6kA CLs
DFBLA
service chimney
6kA leads
13kA leads
le
Hi
gh
interface to DSL
cu
rre
SHM/HCM
interconnect
nt
Jumper cryo
connection to QRL
mo
du
le
13
kA
&
Supporting beam
6k
Al
ea
ds
6kA leads
16 x DFBA
removable door
Removable door
600A leads
HCM/LCM
interconnect
Lo
w
cu
rre
nt
interface to QRL
5 x DFBL
mo
du
le
6
kA
&6
00
Al
ea
ds
connection to magnet
5x6kA CLs
service chimney
12x120A CLs
Vacuum equipment
Jack
Warm beam pipes
DFBMA
removable door
Longitudinal
support
13kA busbars
Arc termination module (ATM)
23 x DFBM
Jack
Current leads modules
[email protected]
DATE: 23-APR-2003
EUCLID: D0102798PL
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Introduction: function, quantity, location
DFB Project
Water cooled cables
Transformers
Instrumentation rack
Shuffling module
Cryogenic jumper
6 kA current lead
13 kA current lead
RT beam pipes
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Project organization
DFB Project
Agreement with AT and TS departments for responsibility of specific tasks to be
taken by various groups corresponding to their expertise:
- construction@cern,
- construction@IHEP,
- integration,
- proximity equipment assembly,
- transport/positioning/alignment,
- interconnection (in tunnel),
- warm&cold commisioning.
Below is the resulting organizational chart with as much as possible the specific
persons, departments and groups involved indicated
DFB Status, LHC-MAC no. 19, June 2006
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Project organization
DFB Project
DFB Status, LHC-MAC no. 19, June 2006
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Project organization: production scheme
DFB Project
Components
Design & preparation
Subassemblies
Modules assembly
Final assembly & test
RT vac equipment
Local integration
drawimgs
Transport &
installation
Proximity
equipment
Frames
Piping
Manifold
CL Valves + instrum
Transformers+ cabling
CL proximity equimt.
Instrumentation
Assembly of Low
Current module
Busbars
Plugs components
Final assembly &
Test of DFBA LCM
Transport
Busbar system
Installation +
connection
Piping 13kA
Piping 6kA&600A
Execution drawings for ATM
Current leads
CL modules
Specifications & documents
Reference drawings
Specification drawings
Detailed design of DFBA
Pigtails components
CL cartridges
CL therm. + elec insul
Chimneys
MLI
Final assembly & test
of DFBA HCM + ATM
Cold supports
Thermal screen
Manufacturing drawings
Vacuum tank parts
Preassembly of CL
modules
Assembly of High
Current module
Transport
Non busbar piping
Installation +
connection
LCM feet
IC components
Raw materials
& components
Arc termination
module
Vacuum tank
A. Perin, AT-ACR, Jun 06
DFB Status, LHC-MAC no. 19, June 2006
Thermal screen
Legend
ATM preassembly
I beam
Assembly of ATM
Instrumentation
Busbars
SHM Cold mass
Shuffling box
Beam screens
Beam screen install
CERN
TS-IC
AT-ACR
AT-CRI
AT-MEL
ICS
AT-VAC
TS-MME
IHEP@CERN
TS-SU
IHEP@Russia
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Project organization: production scheme, IHEP/CERN
DFB Project
DFBAO& DFBAN
Schematic view of the production scheme
of the DFBs by IHEP
CERN
IHEP
Specifications & documents
Reference drawings
Specification drawings
Manufacturing drawings
QAP
Test procedures
Detailed design of DFBA
at IHEP premises
Raw materials &
components
Manufacturing of
components and
subassemblies
Preassembly
Transport to CERN
Components
Facilities
Technologies
Tooling
Transport to LHC tunnel
at CERN
Assembly at CERN
Supplied by CERN
Supplied by CERN
Specification drawings
Specification drawings
Execution drawings
Raw materials
Definition of raw
materials
Busbar system + cold
mass
Supply of raw materials
for DFBs
Proximity equipment
All components
Arc termination modules
Busbar system + cold
mass
Test tools
Warm GHe +
transformers support
Installation
Current leads + pigtails
Assembly of DFBAHCMs at CERN
Current leads + pigtails
Supplied by IHEP
Tooling for assembly
Execution drawings
Test tools
Definition of raw
materials
Assembly of the DFBs
at CERN
Supplied by IHEP
MLI
Tooling
All other DFBs
CL modules
components
MLI
Assembly tooling
Assembly of the
DFBMs, DFBLs and
DFBA-LCMs at CERN
Tooling for assembly
Test tools
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Status of key tasks: assembly & tests
DFB Project
Components
DFBA busbar bundles lambda plates
CL cartridges assembly area
Assembly of current
leads cartridges
Assembly of the
busbar bundles
Assembly of the Arc
Termination Module
(ATM)
Assembly of DFBM, DFBL,
LCM
Assembly of DFBA HCM
Final assembly + tests
Final assembly and tests
Assembly of DFBA shuffling boxes
CL modules assembly stands
AT-ACR
IHEP / AT-ACR
TS-MME
ICS / AT
Pressure test area for DFBAs
Global leak test of DFBM
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Status of key tasks: assembly & tests
DFB Project
Main tooling installed in B183
• 4 assembly stands for DFBA
modules
• 2 assembly stands for DFBM
modules
• 2 assembly & test stands for ATM/
DFBA
• 10 assembly stands for cartridges
• Workshop and office/rest areas
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Status of key tasks: assembly & tests
DFB Project
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Status of key tasks: assembly & tests ATM and HTM
assembly WP by TS-MME
DFB Project
ATM - Arc Termination Modules
Activity: Mounting, welding, handling
Status:
DFBAO, DFBAN (7.8): completed
DFBAA, DFBAP (8.1): completed
DFBAH, DFBAI (4.5): under way
Assembly rate: 2 ATM / 5 weeks
Major concern: Special design K, L
16 units for the DFBA
SHM (shuffling module)
DFBA HCM – High Current Modules
Activity: Mounting, welding, brazing
Status:
DFBAO, DFBAN (7.8): completed
DFBAA, DFBAP (8.1): under way
Assembly rate: 2 HCM / 5 weeks
Major concern: Missing components
Current leads:
13kA, 6kA, 600A
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Status of key supplies: current leads
DFB Project
Current leads
delivery on time
(compare LHC
dashboards for 600
A and 6 kA leads)
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Status of key supplies: IHEP components
DFB Project
Except for DFBLA, all major IHEP components for sector 7-8 and 8-1 have been delivered to CERN, components for sector 4-5
to be complete by end of June.
Percentage of supply of incomplete chimneys, because of sub-components delivery by CERN on the critical path.
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Status of key tasks: proximity equipment
DFB Project
Includes
• GHe piping & valves
• transformers
• all cabling
• design includes warm beam pipes
Design & production of frame & piping
Performed by TS-MME
Integration of electrical equipment
Performed by AT-MEL
Installation of the transformers on DFBAN frame
CL instr. cabling
CL heaters
transformers
DFB Status, LHC-MAC no. 19, June 2006
CL control
valve
Status
Sector 7-8
DFBMA Delivered. ELQA done (Davide).
DFBMC Delivered. ELQA done (Davide).
DFBAO Delivered. ELQA not yet requested.
DFBMH(X2) Delivered. ELQA not yet requested.
DFBAN Delivered. ELQA not yet requested.
Sector 8-1
600A
DFBMB Ready to be Delivered. ELQA not yet requested.
current lead
DFBMI Ready to be Delivered. ELQA not yet requested.
DFBMJ Ready to be Delivered. ELQA not yet requested.
DFBAA Assembling ongoing
DFBAP Waiting for assembly
DFBLA Study ongoing. DFB scheduled for LHC tunnel by October
6, 2006.
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Local integration: mandate of the interfaces working
group (DFBI-WG)

DFB Project
The mandate of this WG comprises the coordination for:
 clarification and documentation of all DFB interfaces, including
integration studies

And for all DFBs with the exception of DFBX, the coordination for:
 definition of sequences and procedures for the connexion of DFBs to
their interfaces (mechanical, electrical, vacuum, cryogenic,
instrumentation,…)
 transport (from assembly hall to their final position in tunnel or
underground area) and alignment
 interconnections in times defined which are in agreement with respect to
the installation planning
 definition of procedures to be applied during interventions for
commissioning and operation phases of LHC
about 30 members representing the groups concerned (AB/PO, AT/ACR, AT/CRI, AT/MEL, AT/VAC, TS/CV,
TS/EL, TS/IC, TS/MME & TS/SU)
meetings take place every second week, 17 meetings held up to now
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Local integration: DFBI-WG status
DFB Project
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Integration studies for DFBs and ancillary equipment in sector 78 have been
completed and are well advanced for sector 81. Studies for sectors 45 and 34 have
started.
Procedure for transport of DFBM and DFBA-LCM; document prepared by TS-IC
discussed and approved. Procedure for DFBA-HCM in preparation
Studies pertaining to the mechanical support of the DFBA and DFBM have been
presented and final solutions decided and agreed upon
Ongoing studies on the interconnection sequences and procedures as well as
required times for connections between:
• DFB-magnets (standard interconnect and through links)
• DFB-QRL
• DFB-power cables
• DFB modules
Studies for the preparation of DFB zones prior to DFB transport have been carried
out, especially with respect to power and instrumentation cabling
Overall sequences, co-activities and responsibilities are continuously monitored,
discussed and clarified when needed
Permanent communication exchanges with the planning and installation coordination
teams
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Status of key tasks: connections Surface activities at 183
DFB Project
Electrical Interconnections between SHM-HCM for 16 DFBA:
Completed for 13 kA and well advanced for 6 kA
for DFBAO (R8)
6 kA connection
600 A : Under realisation ;
1st use of ultrasonic welding machine in actual conditions
Tooling and preliminary procedures are available.
Optimisation is very likely.
Sharing of tasks with TS, ACR, MEL, VAC is defined.
13 kA connection
DFB Status, LHC-MAC no. 19, June 2006
These activities will require 3 trained and qualified
operators (presently, 2 are under qualification); the
team is under construction ; it is foreseen to work on
two benches in parallel
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Status of key tasks: connections Tunnel activities
DFB Project
16 DFBA: HCM/LCM and LCM/Q6
Sequences are defined ; adaptation of the procedures of the standard
interconnections is going on.
23 DFBM: Link between QX and DFBM
Sequences are defined ; preliminary procedures are available.
DFBMA is installed ; half of the link has been assembled. Electrical connections will
start on 19/6/2006.
Tooling and operators will be shared with surface
activities and standard interconnections to carry out
the first ones.
Components availability has been checked for DFMA
and DFBMC (8R) ; to be done and improved for the
next ones
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Status of key tasks: connections Tunnel activities
DFB Project
5 DFBL:
The interconnection design is under verification. Team was reinforced by having a part
time engineer, specialised in the cryomagnet interconnections.
CONCLUSION:
- Work is progressing ; a lot has been learnt and implemented in a short time
- Room for improvement (preparation, optimisation of procedure) to be more
efficient for future activities ; this requires human resources now but it is worth
investing them now
- Tooling :
* TIG welding tooling for tunnel activities is defined and ordered
* Electrical connection tooling (ultrasonic welding machine, resistive
soldering ovens, ancillary tooling) are under definition, manufacturing
but sharing with other interconnections allows to progress Advantage of working with IEG-F523
- Operators : team is under construction ; difficult to plan for all the activities Internal CERN resources are redirected to this project with a possible
negative impact on other interconnection activities
- DFBL : Still a lot to do and (bad) surprises could be expected
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Status of key tasks: transport & installation LIFTING
DFB Project
DFBMA
DFBA-dummy
Short items: DFBMs and DFBA-LCMs,
3 dedicated C-shaped frames
(allows lifting, traction, and sliding down tunnel shafts)
DFB Status, LHC-MAC no. 19, June 2006
DFBA-HCM+ATMs “short”, non-inclinable,
DFBA-HCM+ATMs long
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Status of key tasks: transport & installation Rolling
DFB Project
Short items: DFBMs and DFBA-LCMs,
bogies
DFB Status, LHC-MAC no. 19, June 2006
DFBMA
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Status of key tasks: transport & installation Rolling
DFB Project
Long items: DFBA-HCMs,
bogies
Status:
• DFBM C-shapes and bogies ok, simplified items under way.
• DFBA bogies under validation, successful test transport (3rd of June), speed ~1km/h,
difficult steering from behind, more tests foreseen 16th of June.
• DFBL procurement of very flat transport platform for 4 boxes, fifth box needs specific
adaptations on IHEP side to enable using DFBX transport system, extremely tight (point 3).
DFB Status, LHC-MAC no. 19, June 2006
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Status of key tasks: commissioning
DFB Project
4 documents on the cryogenic commissioning and 1 document on the global
hardware commissioning of the DFB. 1 under approval, 2 under engineering check
and 2 being written. Control logic documents and supervision screens have also been
issued for implementation in the control system.
1) Circuits and PFD during the DFB commissioning phases (cooldown, LHe filling, normal
operation, powering and warm-up): the Engineering Specification LHC-Q-ES-0004
has been written, checked and is under approval.
2) The process control specification and definition of operational phases: The
Engineering Specification on the process of the cryogenic system for LHC (inclusive
of the DFB), LHC-Q-ES-0003 has been written and is under engineering check.
3) The commissioning of the DFB (global): LHC-DFB-HCP-0001 has been written and is
under engineering check.
4) The commissioning of the cryogenic system of the LHC inclusive of the DFB cryogenic
commissioning: LHC-Q-ES-0002 is currently being written and should go to
engineering check in July.
5) Failure scenarios and reliability of the cryogenic system of the LHC (inclusive of the
DFB): LHC-Q-ES-0005 is currently being written and should go to engineering check
in July.
DFB Status, LHC-MAC no. 19, June 2006
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Production schedule: ready for transport into the tunnel
DFB Project
DFB Status, LHC-MAC no. 19, June 2006
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Summary
DFB Project
• Assembly teams up to capacity
• IHEP supply rate sets the pace; just in-time for LHC
•
•
•
•
•
schedule
Current leads supply; ok
Transport; ok, just in time, few open points for special
cases
In-tunnel and HCM-ATM connection work; ok, just in
time, few open points for special cases
Integration ok, just ahead of production
Components on the critical path (no buffer): proximity
equipment, busbar bundles, drawings verification, subcomponents for current-lead cartridges
DFB Status, LHC-MAC no. 19, June 2006
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Extra slides, Assembly at CERN: Status Legend
TSC
600 A
600 A
600 A
600 A
600 A
600 A
600 A
600 A
600 A
600 A
13 kA
13 kA
600 A
20 K collector
50 K collector
Bus bar bundle LCM
ATM
Thermal screen
Vacuum envelop
Jumper
DFB Project
Bus bar bundle 13 kA
Proximity equipment
DFBAN
DFB Status, LHC-MAC no. 19, June 2006
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Extra slides, Assembly at CERN: Status for Sector 7-8
DFB Project
DFB Status, LHC-MAC no. 19, June 2006
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Extra slides, Assembly at CERN: Status Sector 8-1
DFB Project
DFB Status, LHC-MAC no. 19, June 2006
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Extra slides, Assembly at CERN: Status Sector 4-5
DFB Project
DFB Status, LHC-MAC no. 19, June 2006
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