DFH Collaboration visit of Uppsala University & RFR ... · DFH - UU & RFR visit - 10th Dec 2019 –P. Cruikshank 6 Assembly & cold testing of key components validated before installation

DFH Collaboration – visit of Uppsala

University & RFR Solutions

DFH Status Overview

Paul Cruikshank for WP6a

10 December 2019 - CERN

Today’s plan

DFH - UU & RFR visit - 10th Dec 2019 – P. Cruikshank 2

DFHX pre-serie (#1)

New concept of DFH - Q3, 2019

CDR - 15/10/2019

Advanced 3D design – on-going

Integration in HL-LHC underground – on-going

Detail Design Review – mid Feb 2020

Production Readiness Review - April 2020

3DFH - UU & RFR visit - 10th Dec 2019 – P. Cruikshank

4

DFHX Design EvolutionDFH Working Reference up to mid-2019

DFH - UU & RFR visit - 10th Dec 2019 – P. Cruikshank

5

13

kA

18

kA

2 kA

DFHX

CDB

DFHX Design EvolutionNew concept & preliminary layout

DFH - UU & RFR visit - 10th Dec 2019 – P. Cruikshank

Why change concept ?


Assembly & cold testing of key

components validated before

installation in the underground areas.

SC link + DFH + Current leads

Compact design avoids dis-assembly

for installation and re-assembly in the

tunnel – transport as a system.

12

M

DFH Conceptual Design Review 15 Nov 2019, CERN

PH 10 PH 20 PH

30

DFHx sub-components


Vacuum

instrumentation

HTS cable

Current leads

& housings

(yellow)

Link cryostat

MgB2 link cable

Vacuum

vessel

Helium

vessel

& MLI

Internal

supports

Thermal

shield

& MLI

External

supports

Assembly

rail & tooling

(not shown)

Rupture disc,

safety valve

(not shown)

Uppsala Collaboration Hardware Deliverables

DFHx cryostat cannot be fully

assembled (welded) without the

MgB2 cable and current leads:

At RFR, assemble & cut welds

or assemble without welding &

demonstrate that parts fit

together.

Final assembly & test at Cern

(Cern responsibility)

+ manu drg

+ QA doc

+ testing

+ PED

+ packaging

+ transport

Milestones – DFHx & DFHm


Milestones are indicative – need to be confirmed within the Uppsala Collaboration Agreement

Assembly of DFHx #1 will provide feedback for optimization of the series units

Each series DFH is assembled with current leads and SC link, then cold tested before installation in the LHC underground in Long Shutdown 3 (2024-2026).

Dates coherent with WP6a global planning

Technologies Technologies are the same as previous concept, presented in

UU/Cern meetings of June ’18 & April ’19 (Yann & Vittorio)


Procurement Strategy Manufacturing & qualification strategy same as previous concept,

presented at UU/Cern meetings June ’18, Jan ‘19 (Yann & Vittorio).


PED Conformity Assessment

According to the CERN safety rules GSI-M4 “The manufacture […] by collaborating institutions, of all new cryogenic equipment shall comply with the applicable CERN Safety Rules, European directives and harmonised standards” implies PED 2014/68/EU.

UU & RFR transform Cern’s specification drawings into manufacturing drawings (with or without changes) and perform the structural analysis according to EN13445.

Concerning deliverables, welding and re-cutting the helium pressure vessel is a solution, but WP6a is open to proposals from UU & RFR (& its NoBo).

Next presentations from J. Fleiter & R. Betemps will highlight the proposed assembly sequence and joining details.


Key documents


Tech Spec

(for comments)

Func SpecCollaboration

agreement

Latest drafts to Uppsala next week

Jan 2020

April 2020

Specification

drawings

Thanks for your attention


Spare slides (from CDR)


What can Uppsala & industrial partner already do ?


Follow the design development and provide feedback on solutions

Review factory infrastructure needs for the manufacturing, assembly and testing area Separation from incompatible co-activities, handling, etc.

Seek potential suppliers of long lead items Bellows, Forged material, MLI, others.

Study approach to PED conformity assessment Welder and welding qualification, NDT, NoBo advice, strategy for subassemblies

Review approach to leak testing Work with sub-contractor, train personnel, buy testing equipment, etc

Review approach to cleaning Facilities required, handling, training, etc.

Evaluate if personnel can benefit from a short stay at Cern Techniques: MLI, insulating supports, leak testing, cleaning, clean (HV) assembly,

auto welding & cutting solutions, etc.

Prepare the quality assurance follow-up Establish contact with the Cern QA representative

Prepare the Manufacturing and Test Folder

Manufacturing, qualification and QADesign phase : CERN supply specification drawings acc. ISO-GPS

Procurement

Design, calculation reports, Technical specifications (PED, HL-LHC QA spec., CE certif.)

CERN approval before release

Manufacturing

MIP, welding book, cleaning, inspection procedures.

Manufacturing drawings produced from CERN specification dwg

CERN approval

Manufacturing process Inspection reports (including certifications)

CERN reports approval

Assembly & qualification phase

Assembly procedures / Inspection and qualification plan

CERN assembly approval

Assembly process Inspection reports

QA follow-up

Upload documentation to MTF

Detailed installation and maintenance procedures

CERN approval

Delivery to CERN

Packing and shipping to CERN

17

CERN database MTF for manufactured products

Non exhaustive list of QA requirements for illustration

From Jan ‘19 meeting

Milestones – DFHx #1


DFH – Manufacture DFHx #1

Test Proto – assemble & cold test DFHxwith current leads, 100m SC link & DFX in standalone configuration in SM18.

String – (re)assemble* & cold test (as above) as cold powering system to HL Triplet String in SM18.

Spare - Operational spare with SC link attached (DFX proto removed).

*will be possible to keep DFH & SC link attached after the ‘Test Proto’.

2020

2021

2022-2023

2024

WP6a global planning

DFHx Design Development


Today Design phase 1 Design phase 2

CDR

3D model

3D mock-up

Func spec

Interfaces

Integration

Tech* & Interface spec,

Instrumentation PIDs,

Integration studies,

PED calcs* & 3D iteration,

Risk analysis,

Assembly procedure

DDR,

Manu 2D drgs,

Safety file*,

PED report*,

Manu/insp plan,

PRR (with Uppsala).

Coordination P. Cruikshank

Engineering Y. Lecercq

Design R. Betemps

Integration P. Fessia

Transport & handling C. Bertone

MgB2 & HTS splices J. Fleiter

Warm powering M. Martino

Cryogenics S. Claudet

Quench protection F. Rodriguez-Mateos

Safety V. Parma, T. Otto.

Roles:

Priorities:

• Restart DFH technical meetings in

parallel with integration studies.

• Create a planning with above phases.

• Identify resources for PED analysis.

• Produce specification documents.

*Compliance with:

Cern safety rules,

GSI-M-04 (cryo),

PED 2014/68/EU.

Preparing for DFH cryostat manufacture


Build the relationship with the Uppsala Collaboration Uppsala Uni team – contacts at Fermilab, CDR, regular dialogue via teleconference (TBD)

Uppsala industrial partner – visits to Cern (next one 10th December), visits to Sweden (to plan).

Formalise the Uppsala Collaboration Finalise the Agreement with scope of supply, deliverables and dates (December)

Agree the communication lines between Cern and the Collaboration.

Knowledge exchange with the Uppsalla Collaboration Identify missing competences (if any) and facilitate a dialogue with TE and EN technical groups as required eg best-

practice solutions (CRG, MSC, EN-MME workshop, etc)

Integrate solutions from the University and industrial partner.

Provide opportunities for learning with Cern teams.

Collaboration shall contribute to the DDR.

Collaboration shall play a leading role in the PRR.

Manage & share the evolution of cryostat interfaces Documents and drawings for internal interfaces - current leads & SC link

Documents and drawing for external interfaces - handling, warm powering, cryo, instrumentation.

3D design pre-validated with mock up

DFH Conceptual Design Review 15 Nov 2019, CERNDFH Conceptual Design Review 15 Nov 2019, CERN

DFHx #1 Cryostat manufacturing & assembly


Assembly of the DFHx #1 cryostat can’t be made without the DSHx link or HTS current leads

Trial assembly of DFHx cryostat (without lip weld execution) shall be performed in industry using rail system.

Cern may provide subcomponents for trial assembly or instrumentation for final integration.

The methodology to ensure PED compliance of the helium pressure vessel must be agreed.

Technology experts responsible for the DFHx assembly works at Cern (splice, welding, instrumentation, testing, etc) can provide advice on technical solutions being implemented in the production of the cryostat.

Assembly validation at Cern provides the go-ahead for DFH series production.

Preparation of infrastructure and resources for the DFHx #1 assembly works at Cern will begin Q3 2020.

Design & Integration - DFHX


Integration review, end Jan.

Interfaces OK.

OK for DFH detail design

CDR

DDR PRR