Operation phase technical requirements, testing plan, resources and cost estimates

Operation phase technical requirements, testing plan, resources and cost estimates

P. Schnizer on behalf of FAIR project team membersL. Serio on behalf of bldg. 180 test facility project team members

(TE and EN departments)

L. Serio, P. Schnizer et al. 3

Outline• Introduction• Technical Requirements• Testing Plan

– Baseline– Alternatives– Reduced number of benches

• Resources and cost estimates• Conclusions

Introduction

According to the last collaboration meeting we have proceeded with the review, optimisation and minimization of the test program and overall test plan in order to fit within the allocated 3 years for the testing phase.

Several meetings have taken place between CERN and FAIR personnel leading to the baseline scenario, the minimized plan and alternative reduced scope proposal.

A preliminary resources and cost estimate has been prepared together with the main competences (field of expertise required).


Technical requirements• A magnetic measurement request template has been prepared by CERN to provide the detailed

requirements of the tests to be performed at ambient temperature and cold conditions• This database is being populated by FAIR • A preliminary review of the requirements and optimisation (reduction) of tests in order to reduce

the cold testing to 13 days; main points:• Measure of field maps and harmonics only for dipoles and for each prototype only• No warm up before processing of the data and assessment; preliminary assessment after one week; this

requires an on-site assessment team to take on-line decision on acceptance of tests and warm up• Can use the same fluxmeter for all dipole magnets with 3 segments• Absolute field integral measured with 5 *10^-4 accuracy• All the same hysteresis cycle but no demagnetisation cycle required• Longitudinal magnetic centre to be measured (exact center of the magnet)• After prototype detailed measurement only need magnet to magnet relative measurement; thus expected

tp go from 12 down to only 4 points current level testing• Measure magnets reproducibility (harmonics) instead of individually map the field;• Proposal to reduce the number of current level for everything else than main dipole and quadrupole• High voltage tests only between neighbouring magnets and ground• Testing of voltage taps and DAQ preparation in parallel

• Increase cool-down / warm-up speed from 1 K/h up to about 2 K/h (maximum cryogenics capabilities, to be checked on prototypes)

• Installation, preparation and dismantling activities streamlined




– Baseline and minimised– Alternatives– Reduced number of benches


8

Testing Program Evaluation– Test Program

• Industry Tests• Tests on Test Benches

– Preparation Tests– Cold Tests– Final Tests

• Tests during Installation and Commissioning

L. Serio, P. Schnizer et al.

9

Testing Program Evaluation: Industry Test I/II

selected Tests:– Material Tests

• Conductor: critical current, n-Value, geometry, CuSc ratio, RRR• Yoke material: BH – curve, Hc value (for each roll)• Cryostat / cold mass components: certificates, approved welding etc.

– Magnets• Magnet geometry:

– punch die, – lamination geometry, – magnet geometry, – magnet pole assembly geometry– coil geometry

• Magnet weight• High voltage Tests• Polarity Tests


10

Testing Program Evaluation: Industry Test II/II

selected Tests:– Magnet Assembly:

• Geometrical tests of magnet column (multiplett)• Fiducalisation / transfer:

– magnet column– cold mass vessel– cryostat fiducials

• Sensor Tests• Continuity Tests• High Voltage Tests

– Pressure Vessel Tests• compliance with European rules• in particular “TÜV”• acceptance as pressure vessel


11

Testing Program Evaluation: Reception Tests

– Proper Transportation• Shock Sensors • Visual Inspection• Papers delivered

– “Worth to put on bench”• Test Sensors functional• High voltage tests


12

Testing Program Evaluation: On Bench at Warm

– On bench• test equipment preparation• sensor tests• high voltage tests• continuity tests

– During cool down• leak test monitoring• sensor tests

– Cool down finished• sensor tests (all active)• high voltage tests


13

Testing Program Evaluation: Test At Cold

– Power tests• Voltage taps tests• Quench Detection System check• Ramp up to 110% of nominal• Ramp of all Magnets up and down (three times)

– Magnetic Measurement• Measurement of integral strength and axis (SSW)• Information to GSI • Measurement of field quality• Agreement with GSI on warm up• Comments: Reduced current levels in series: magnet to magnet

comparison, adjustment in series• Test of Stationary Loss• boil off during weekend L. Serio, P. Schnizer et al.

14

Testing Program Evaluation: Finalisation

– Test after Warmup• Test of Sensors• High voltage Tests


15

Testing Program Evaluation: Commissioning I/II

– Commissioning Tests• Repetition of:

– Transport Checks– Visual Inspections– Documentation Checks– High voltage Tests– Instrumentation Tests– Leak Tightness Tests– Electrical Parameters (inductance, resistance)

• Connection – Electrical– Cryogenic

• Tests– High voltage tests– tightness of process lines– polarity– sensors / instrumentation


16

Testing Program Evaluation: Commissioning II/II

– Cool down• check of sensors during cool down• vacuum / leak tightness• temperatures

– At cold:• High voltage tests• Continuity Tests / Voltage Taps Tests• Magnet Powering:

– Polarity tests (assymmetric voltage taps)– Magnet Protection System– Magnet Powering to Nominal– Ramping individual magnet assemblies to nominal– Ramping all magnets to nominal


Reviewed test program and time


Test sequencing optimization installation & preparationcooling4 K testswarm upwarm tests and disconnect

closureshutdowninstallation & preparation 1 1 1 1 1 1 1cooling4 K tests . . . . . . .warm upwarm tests and disconnect 1 1 1 1 1 1 1 1 1

closureshutdowninstallation & preparation 1 1 1 1 1 1 1 1cooling4 K tests 3 3 3 3 3 3 . . . . . . . . . . . . . . 3 3warm upwarm tests and disconnect 1 1 1 1 1 1 1 1number of benches 0 0 0 1 1 2 2 3 3 4 4 5 4 5 4 5 4 5 4 . . . . . . . . . . . . . 5 4 4 4 3 2 2 1 1 0 0 0cooling power 4 K 0 0 0 0 0 4 2 6 4 6 4 6 4 6 4 6 4 . . . . . . . . . . . . . . . . 4 6 4 2 2 0 0 0 0 0 0cooling power 300 - 80 K 0 0 0 0 1 1 1 1 1 2 2 2 2 2 2 2 2 . . . . . . . . . . . . . . . . 2 2 1 1 1 1 1 0 0 0 0power supply 0 0 0 0 0 0 1 1 2 1 2 1 2 1 2 1 2 1 2 . . . . . . . . . . . . . . 2 1 2 1 1 0 0 0 0 0 0

available cooling 4 Kavailable cooling 300-80 Kavailable power supply

1015

14

number of magnets tested

2

23

2 2 23 3

2 22

3

23 3

3

52 weeks46 weeks (44 weeks cold)

10

53 days (44 working days - cryo also during non working days)

4

5

2 2

2 2 2 2 23 3 3


installation & preparationcooling4 K testswarm upwarm tests and disconnect


1013

446 days (41 working days - cryo also during non working days)

410

number of magnets tested per year

or 1.35 magnets per month16with 3 test benches and 13 days cold magnetic

Optimal overall duration


closureshutdown 2 2 number of magnets tested per yearinstallation & preparation 1 1 1 1 1 1 1 1 1cooling or 2 magnets per month testing rate4 K tests . . . . . . . . . . . . .warm upwarm tests and disconnect 1 1 1 1 1 1 1 1number of benches 0 0 0 1 1 2 2 3 3 3 3 3 3 3 3 3 3 3 3 . . . . . . . . . . . . . 3 3 3 3 3 2 2 1 1 0 0 0cooling power 4 K 0 0 0 2 2 4 4 4 4 4 4 4 4 4 4 4 4 . . . . . . . . . . . . . . . . 4 4 4 4 4 2 2 0 0 0 0cooling power 300 - 80 K 0 0 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 . . . . . . . . . . . . . . . . 2 2 2 2 2 1 1 1 1 0 0power supply 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 . . . . . . . . . . . . . . 1 1 1 1 1 0 0 0 0 0 0

available cooling 4 Kavailable cooling 300-80 Kavailable power supply

42 days (37 working days - cryo also during non working days)4

22 2 2 2 2

21

52 weeks46 weeks (42 weeks cold)

2 2

with 3 test benches and 2 weeks cold magnetic measurements

1010

103

2 2 2 2 2 222 22 22 2 2 2 2 2

2

6 g/s2*10 kW

1


Tests duration comparison


• Request → investigate number of test benches• originally

• 4 benches to match FAIR master schedule demanded • 3 test benches: maximum feasible:

• space• precoolers• cooling capacity• → best use of infrastructure

• 2 test benches:• reduce measurement program• increase overall project time line

• outlined on the next slides

Tests duration comparison


• 3 benches• 15 days of cold test: solid test program• 13 days of cold test: test program, no margins, no slips

• 2 benches• extend schedule to 6 years (2023)• or no magnetic measurement (spectrometer!)

• not included (further extend): Panda• mapping of dipoles with „branch exit“: currently assumed to be mapped within the

2 weeks of magnetic measurement

TB ... test benchPC ... precooler

Schedule updateUPDATE Planning 6.2014

3 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 MA MJ J A S O N D J F MA MJ J A S O N DConceptual DesignPreliminary DesignFinal DesignProcurementManufacturingInstallationCommissioningProto 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 ?

3 test benches, 2 precooler, 13 days cold testingmagnet testing rate1.35 magnets modules/month

0.8 multiplets/months0.55 dipoles/month

2019 20202014 2015 2016 2017 2018

Fix layout interfaces

LLI launch procur. commissioning

CERN – GSI c.tte meeting 20140625 L. Serio 24

LS2

Alternative scenarios (2TB-2PC with a later upgrade to 3TB-2PC)

2/3 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 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 DConceptual DesignPreliminary DesignFinal DesignProcurementManufacturingInstallationCommissioningUPGRADEProto magnets testingSeries Magnets TestingShort Multiplets Proto . . .Long Multiplet Proto . . . .Dipole Proto . . . . .First Series Short MultipletFirst Series Long MultipletFirst Series DipoleFirst Energy BuncherLast Energy BuncherPANDA testing ?

3 test benches, 2 precooler, 13 days cold testingmagnet testing rate1.35 magnets modules/month

0.8 multiplets/months0.55 dipoles/month

2014 2015 2016 2017 2018 2019 2020 2021

Nota: a. Delayed decision / financingb. Increased overall costc. Reduced testing capabilities and time for prototypes

CERN – GSI c.tte meeting 20140625 L. Serio 25

LS2


Resources and cost estimate(core operation team not inclusive of GSI acceptance team and CERN on-call support

for troubleshooting)

2016 2017 2018 2019

BUDGET kCHF 1,070 1,120 1,120 1,120

3.1 3.1 3.1 3.1

3.5 3.5 3.5 3.5 13.8

Cat 2 FTE-y

TOT.OPERATION

TOTAL

4,430

12.2TOTAL

Cat 3+4 FTE-y

OPERATION


Resources and cost estimate

Conclusions 1/2


• The test requirements, program and duration have been reviewed and optimized

• A parametric study of various alternatives and configuration has been performed• The baseline test program of 15 days at cold requires an overall testing time of almost 4 years• If the test programm is reduced to 13 days the cool down and warm up speed of 1K/h are the

limiting path and the total test time will take less than 3.5 years• The minimum overall test duration is reached with 10 days at cold and reduced

cool-down/warm up and/or installation/dismantling (2.5 years)

• There is no contingengy, margins or time to repeat tests or perform adjustments

• Short multiplets will be tested first in order to have some margins (time) during the start of series testing operation

• It is not possible to postpone the decision of the second pre-cooler • thus financing is required now

• It would be possible to delay the decision on the financing of the 3rd test bench later during the prototype tests but the overall program will be delayed by about 9 months, the cost will be significantly higher and start of the test facility will run in parallel with the preparation of LS2

Conclusions 2/2


• The required material cost and resources during a 4 years operation period corresponding to the baseline (0.5 years prototypes and 3.5 years series testing) have been estimated:

• material cost (inclusive of electricity): 4.4 MCHF (1.1 MCHF/year)• material cost (w/o electricity): 3 MCHF (0.75 kCHF/year)• resources: 12 FTE-y ENG (3 ENG); 14 FTE-y technicians (3.5 TECH-ENG)

• A preliminary inventory of competences has been made• a part time cryogenic supervisor engineer and one operation team leader technical engineer + operators• a magnetic measurements and analysis engineer + support technicians/operators• a test facility test coordination and operation engineer• two test facility electromechanical technicians• a part time survey technicians• a part time data acquisition and industrial control engineer

• These resources, if made available in the next 6 months, can provide part of the missing construction support and be trained for the future operation of the facility

Operation phase technical requirements, testing plan, resources and cost estimates

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