Benjamin Stillwell Mechanical Engineering Specialist
description
Transcript of Benjamin Stillwell Mechanical Engineering Specialist
SPX Mechanical Systems –
Infrastructure, Integration,
InstallationWBS U1.2.1.3.6, U1.2.1.3.11, U.1.3.3.10
Benjamin StillwellMechanical Engineering SpecialistAPS Engineering Support/Mechanical Engineering and Design
DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012
Outline
Importance Scope Organization Technical Requirements Design Interfaces Risks ES&H Cost Schedule
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Importance of Infrastructure, Installation, and Integration
SPX cryomodules require significant new hardware and infrastructure accommodations at the APS to function.
Design effort project-wide requires information and problem-resolution for mechanical interfacing.
Integration of superconducting RF cryomodules into the existing storage ring vacuum system must be carefully planned to ensure that cavities and/or storage ring operations are not compromised.
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Cryogenic supply and distribution systems Deionized water delivery and distribution systems Infrastructure in building 400A for cryomodule and vacuum
component preparation and testing Mechanical components to perform cavity testing and
accommodate storage ring installations
Scope - Hardware Deliverables
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Scope - Hardware DeliverablesR&D Mechanical Components
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012SPX0 Straight Section Vacuum System (Bellows Test Configuration)
Scope - Hardware DeliverablesR&D Cryogenics
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Kinney-Tuthill vacuum pump
Feedbox, neck insert, and top plate for vertical test cryostat
Input coupler, top plate, support frame, and cryogenic plumbing for horizontal test
Scope - Hardware DeliverablesCryoplant
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Similar-scale system used at ELBE
Turn-key system includes:320W at 2K (100% margin) and 500W at 5KCompressors“Cold Box”Gaseous and liquid helium storageInstallation supervision and commissioning
Scope - Hardware DeliverablesCryogenic Distribution System
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Includes:Approx. 70m of 4-circuit transfer lineMain distribution box (valves)Two local end boxes (valves)U-tubes and assorted suppliesMechanical supports
Scope – Hardware DeliverablesDeionized Water Systems
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
600 gpm of additional capacity provided for a total of >900 gpm serving: HLRF amplifiers – 440 gpm HLRF test stands – 125 gpm Cryoplant-related – 150 gpm Conventional facilities – 50 gpm
Total projected DI water need: 765 gpm
Cryomodule mechanical installation support and planning. Top-level mechanical assembly model. Mechanical interface drawings and 400A space use plan.
Scope - Integration and Installation Deliverables
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Organization
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Ben Stillwell – Section lead/mechanical engineer Joel Fuerst – Lead cryogenics engineer John Noonan – Mechanical engineer (vacuum design and storage ring integration) Bran Brajuskovic – Mechanical engineer (dampers) Jie Liu – Mechanical engineer (analysis) Stan Reeves (Espo) – Mechanical engineer (ANL cryomodule hardware) Rich Hrebic (Espo) – Mechanical engineer (cryogenics systems) Bill Soldwisch (Espo) – Mechanical engineer (integration) Dave Fallin – Mechanical designer/drafter Neil Bartkowiak – Mechanical designer/drafter Jason Lerch - Mechanical designer/drafter
Technical Requirements
Physics Requirement Documents (PRDs) – SPX0, SPX Engineering Specification Documents (ESDs):
SPX CryomoduleSPX HLRF SPX DampersSPX Windows
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Design Status Summary
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
System Design Status
R&D Mechanical ComponentsR&D Cryogenics
Most drawings complete and released, most hardware has been fabricated and/or procured.
SPX0 cryogenic supply/distribution is not yet determined.
DI Water Systems ESD drafted. Top-level supply system drawings and BOM have been provided by vendor. Parts for local circuits
have been determined.
400A Infrastructure ESD for cleanroom drafted. Final design will be included in design/build procurement.
Cryogenic Plant ESD drafted and externally reviewed. ICD drafted. Final design will be included in design/build procurement.
Cryogenic Distribution System ESD and ICD drafted. P&ID and CAD models have been generated. Pressure drop and heat leak calculations have been generated. Final design will be included in
design/build procurement.
Interfaces
Top-level mechanical models and drawings. System-specific mechanical interface drawings:
o Cryomodule – Storage Ring (Long Straight Section)o HLRF – Storage Ringo Cryogenic Distribution System – Storage Ringo 400A Space Use
Cryomodule installation plan ICDs:
o Cryoplant o Cryogenic Distribution Systemo Cryomodule Mechanical Systems– Long Straight Section
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Risks
1. Cryoplant cooling capacity
Mitigation:– Cryoplant procured with 100% additional performance margin– Experience with SPX0 cryomodule will give confidence to estimates
and help to optimize thermal design
2. Mechanical interference discovered during installation
Mitigation: – Maps of existing storage ring configuration have been generated by
APS survey and alignment team.– Mock-up of cryomodule has been transported through storage ring
tunnel.
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
ES&H
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
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Integrated Safety Management System (ISMS)– APS-U Project following Argonne’s ISMS program requirements – Argonne Integrated Safety Management System (ISMS) Description recently
revised and submitted to DOE ASO• Describes framework for integrating ESH requirements with mission
objectives• References Argonne LMS procedures which implement specific portions
of the ISMS General Requirements
– ANL Pressure Systems Safety Manual– ESH-13.1 Pressure Safety – Systems– ESH-4.10 Hazardous Materials - Cryogenic Liquid Safety
System-Specific Requirements– Designs subject to formal, documented design review –
APS Design Review Procedure– Work control determined from hazard analysis (ANL WPC system)– Approvals by division management
SPX Mechanical Systems and IntegrationScope and WBS - U1.02.01.03 & U1.03.03
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Labor Non-Labor TOTAL ($k)
U1 Short Pulse X-Ray (SPX) 1,814 8,071 1,301 780 11,966 U1 02.01.03 - SPX R&D 463 640 23 141 1,266
02.01.03.06 - Cryogenics R&D 222 420 15 71 727 02.01.03.11 - Mechanical Systems 241 220 8 70 540
U1 03.03 - SPX Production 1,351 7,431 1,278 640 10,700 03.03.10 - Mechanical Systems 1,351 7,431 1,278 640 10,700
WBS DIV OH + ANL
G&A ($k)ESCALATION
($k)
DIRECT ($k)
Mechanical systems costs are roughly 25% of total SPX project cost 22% of direct cost is labor
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Mechanical Systems and IntegrationScope and WBS - U1.02.01.03 & U1.03.03
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Labor Non-Labor TOTAL ($k)
U1 Short Pulse X-Ray (SPX) 1,814 8,071 1,301 780 11,966 U1 02.01.03 - SPX R&D 463 640 23 141 1,266
02.01.03.06 - Cryogenics R&D 222 420 15 71 727 02.01.03.06 - ACWP 102 79 - 27 209 02.01.03.06.01 - ANL/PHY SC Cavity Test Areas (Vertical & Horizontal) 40 135 2 15 193 02.01.03.06.03 - Cryogenics for Storage Ring Test 79 205 12 28 325
02.01.03.11 - Mechanical Systems 241 220 8 70 540 02.01.03.11 - ACWP 95 14 - 26 135 02.01.03.11.01 - Water Modification for Building 400-A 15 28 1 4 48 02.01.03.11.02 - SPX0 Mechanical Components 132 179 7 39 357
U1 03.03 - SPX Production 1,351 7,431 1,278 640 10,700 03.03.10 - Mechanical Systems 1,351 7,431 1,278 640 10,700 03.03.10 - ACWP 61 16 0 16 93 03.03.10.01 - 400A Infrastructure for Cryomodule Test & Preparation 74 60 12 20 166 03.03.10.02 - DI Water Systems 66 862 119 48 1,095 03.03.10.03 - Mechanical Components 187 180 40 58 464 03.03.10.04 - Cryoplant 460 5,653 960 329 7,402 03.03.10.05 - Cryogenics Distribution 505 660 146 168 1,478
WBS DIV OH + ANL
G&A ($k)ESCALATION
($k)
DIRECT ($k)
Most-costly deliverable remaining for R&D phase is SPX0 in-ring cryogenics. Most-costly deliverables for production phase are cryoplant, cryogenic
distribution system, and deionized water systems.
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Mechanical Systems and IntegrationObligation Profile - U1.02.01.03 & U1.03.03
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
u START: Preliminary Design - SPX0 4/10
u START: Preliminary Design - SPX 2/12
u COMP: PDR - SPX0 7/12
u COMP: PDR - SPX 1/13
u SHIP: SPX0 Cryomodule to ANL 4/14
u COMP: SPX0 Cryomodule Test 6/14
u START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)
u COMP: SPX0 Installation 10/14
u AVAIL: SPX0 Ready for Operation 1/15
u START: Final Design - SPX 6/14
u COMP: Final Design 9/15
u START: Major Procurement 10/15
u AWARD: Cryoplant Contract 10/15
u START: Cryoplant Installation 9/17
u COMP: Cryoplant 3/18
SHIP: Cryomodule #1 to ANL 10/17 uSTART: Cryom #1 Installation 5/18 u
COMP: Cryom #1 Installation 6/18 uAVAIL: Cryomodule #1 Ready for Operation 8/18 u
SHIP: Cryomodule #2 to ANL 8/18 uSTART: Cryom #2 Installation 12/18 u
COMP: Cryom #2 Installation 1/19 uAVAIL: Cryomodule #2 Ready for Operation 3/19 u
SPX SYSTEM
FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
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SPX R&D and Production Milestones - U1.02.01.03 & U1.03.03
SPX Mechanical Systems and IntegrationMilestones - U1.02.01.03 & U1.03.03
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q COMP: Dress Cavities - SPX0 1/13
q AVAIL: 400A Water System Modifications - SPX0 7/13
q AVAIL: Cryomodule Support Girder - SPX0 9/13
q AVAIL: Straight Section Vacuum System - SPX0 9/13
q COMP: Mechanical Integration and Installation Plan - SPX0 10/13
q COMP: Mechanical System - SPX0 5/14
q START: Final Design 6/14
q COMP: Final Design 9/15
q AWARD: Cryoplant Design Built Contract 10/15
q AVAIL: Water Distribution System in 400A 10/16
q START: Cryoplant Installation 9/17
q COMP: Cryoplant 3/18
START: Mech Installation for Cryom #1 5/18 qCOMP: Mech Installation for Cryom #1 6/18 q
START: Mech Installation for Cryom #2 12/18 qCOMP: Mech Installation for Cryom #2 1/19 q
COMP: Mechanical System 2/19 q
INTEGRATION
&
MECH
FY16 FY17 FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15
SPX Mechanical Systems and IntegrationSummary Schedule - U1.02.01.03 & U1.03.03
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R&D phase and preliminary design for production phase run concurrently (now).
Final design begins after installation of SPX0 cryomodule. Some small early procurements and installations are necessary to
prepare for future installations (clean room, facility modifications).DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Mechanical Systems and IntegrationBOE Contingency – 1.02.01.03 & 1.03.03
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Work between CD-2 and CD-3
Final design, fabrication, and installation of cryogenics for the SPX0 in-ring test.
Design review for SPX0 cryogenic and pressure systems. Detailed installation plan for SPX0 cryomodules in the APS
storage ring. Completion of preliminary design for production-phase
deliverables. Continued mechanical integration support – top level CAD
model and additional interface drawings as-needed.
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Summary
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The SPX mechanical systems WBS areas supply needed infrastructure, hardware, and installation support to the project.
The preliminary design is expected to be complete in mid-2013. Presently, most deliverables are well defined with regard to scope, cost, and schedule.
Total cost is $11,966k and is dominated by cryo plant procurement in 2016.
Installation• Installation plan complete by Jan 2014 (r&d) and May 2017 (prod.)• SPX0 cryomodules: Aug 2014 – Sept 2014• SPX production mechanical components: Aug 2013 – Jan 2019• SPX production cryogenics: Sept 2016 – March 2018• SPX production cryomodules: April 2018 – March 2019
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012