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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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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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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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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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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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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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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Organization

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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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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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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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ES&H


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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

https://docs.anl.gov/main/groups/intranet/@shared/@fms/@div/documents/procedure/157876.pdf

https://docs.anl.gov/lms/documents/search/results/ESH-13.1

https://docs.anl.gov/lms/documents/search/results/ESH-4.10

https://icmsdocs.aps.anl.gov/docs/groups/anl/@apsshare/@ppadmin/documents/policy_procedure/aps_000031.pdf

https://webapps.inside.anl.gov/wpc/

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


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.


SPX Mechanical Systems and IntegrationObligation Profile - U1.02.01.03 & U1.03.03

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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


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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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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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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


Benjamin Stillwell Mechanical Engineering Specialist

Documents

review of aps

aps upgrade project

design doe lehman cd

commissioningdoe lehman

horizontal testdoe lehman

design effort projectwide

gpm hlrf test

significant new hardware