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DFBX _feed-box_ -- resolution of design issues

VIEWS: 6 PAGES: 17

  • pg 1
									 US LHC ACCELERATOR PROJECT
      brookhaven - fermilab - berkeley




  Key Design Issues
 and Recent Reviews
  Tom Peterson, Fermilab

DFBX PRR, October 23, 2002
            DFBX (feed-box) -- design status


• One of six design variants
  (BFBXC/G, points 2 and 8
  left) is complete and
  released (271 drawings)
• Engineering and top level
  drawings for the other five
  design variants are done.
• Some detailed drawings
  remain (about 100 unique
  drawings)

DFBX PRR 10/23/02   Tom Peterson -- US LHC Project   2
                      DFBX design meetings
                    at LBL within the past year
• December 11, 2001, review of results of November 2001
  vendor fabrication study (PHPK and Meyer Tool, also
  Tom Peterson review of drawings)
• February 25-26 (with Fermilab)
• April 17-18 (with Fermilab, including Tom Nicol)
• June 18-19 (with Fermilab and Don Brown)
• August 6-8 (Don Brown reviewing drawings)
• August 21-22 (with Fermilab, including Kerry Ewald)
• September 4-5 (with Fermilab, Rob Van Weelderen and
  Vladislav Benda from CERN)
• September 25-26 (with Fermilab)

DFBX PRR 10/23/02       Tom Peterson -- US LHC Project    3
                    Vendor fabrication study
• In October and November, 2001, PHPK and Meyer Tool
  reviewed the full (but at the time incomplete) set of
  drawings for DFBXC/G
• Their charge was to “review the designs for
  manufacturability, including suggestions for design
  changes that would lead to cost reductions or more rapid
  fabrication.”
• The issues outlined during the fabrication study set the
  design agenda for the past year. The recommendations
  have almost all been incorporated into the design.
• In particular, a lot of attention has been given to tolerances,
  one of the main vendor recommendations

DFBX PRR 10/23/02       Tom Peterson -- US LHC Project          4
          Design issues and their resolution–
            tolerances and dimensioning
• Tolerances were brought to the highest possible assembly
  level, such that they define the actual requirement




DFBX PRR 10/23/02   Tom Peterson -- US LHC Project           5
          Design issues and their resolution--
                helium vessel design
• Helium vessel access port
  weld detail with
  provisions for cutting
• Helium vessel supports
  carry bus duct bellows
  pressure forces; bus duct
  gusseted for stiffness
• Attachment of power lead
  chimney to top plate of
  vacuum vessel
• Vessel meets ASME code
  except helium access door
  weld

DFBX PRR 10/23/02   Tom Peterson -- US LHC Project   6
          Design issues and their resolution--
            helium vessel support design
Static and dynamic load analyses
for the vessel and support
elements are complete

 Thin vertical invar rods
 carry vertical loads;
 helium vessel hangs from
 vacuum vessel top plate

         Horizontal invar rods
         carry axial loads and
         provide lateral stability
DFBX PRR 10/23/02       Tom Peterson -- US LHC Project   7
          Design issues and their resolution--
                helium piping design
Pipes hang from G-10 support plates
in the vertical risers.
Braided flex hose takes
magnet interconnect motion
as well as DFBX
contraction; used
extensively to prevent
transmission of axial
pressure loads at flex
elements
Bellows remain
only in the main bus
ducts and large                                 Pipes are free to slide in the
pumping line.                                   other support plates.

DFBX PRR 10/23/02      Tom Peterson -- US LHC Project                            8
              Special design features--
         lambda plate, buswork, current leads

                                                     • Lambda plate
                                                       R&D phase at
                                                       LBL including
                                                       prototype is a
                                                       success. LBL
                                                       will produce a
                                                       pre-production
                                                       unit with full
                                                       length leads.

DFBX PRR 10/23/02   Tom Peterson -- US LHC Project                  9
               Special design features--
          lambda plate, buswork, current leads

• Completed
  specification for
  splicing
  superconducting
  leads and
  qualification
  contract with
  each vendor.


 DFBX PRR 10/23/02    Tom Peterson -- US LHC Project   10
              Special design features--
         lambda plate, buswork, current leads

                                              • Pirelli is
                                                expected to
                                                deliver the first
                                                pair of HTS leads
                                                in November.
                                                Testing of the
                                                leads will be at
                                                Fermilab.


DFBX PRR 10/23/02   Tom Peterson -- US LHC Project             11
              Special design features--
         lambda plate, buswork, current leads

                                              • Completed
                                                specification and
                                                RFP for purchase
                                                of conventional
                                                vapor cooled
                                                leads.




DFBX PRR 10/23/02   Tom Peterson -- US LHC Project              12
              DFBX remaining design details

• Some details for five
  remaining variants
    – Some new pipe
      routing arrangements
    – Variations of large
      pumping line supports
    – Variations of small
      pipe G-10 supports
    – Beam tube cooling
      details
    – These details are just
      “variations on a
      theme”

DFBX PRR 10/23/02       Tom Peterson -- US LHC Project   13
              DFBX remaining design details

• Some interconnect weld details are not resolved with
  CERN but need not be resolved before contract is placed




DFBX PRR 10/23/02   Tom Peterson -- US LHC Project          14
              DFBX remaining design details

• Some instrumentation details
    – Two instrument conduits are still under design. LBL will provide
      these subassemblies to the vendor.
    – Naming convention for magnet thermometers still not resolved
      with CERN
    – These are not problems for the RFP




DFBX PRR 10/23/02       Tom Peterson -- US LHC Project               15
                       Design status for RFP
• Engineering is complete for all boxes; remaining details
  are variations on the complete design and do not present
  any new engineering problems
• One drawing package is complete
• The vendors will have one complete design package with
  which to start making their estimates
• The vendors have requested the one complete drawing
  package, rather than our holding the package until the
  other details are complete
• The vendors will have all remaining details well before
  their final proposals are due


   DFBX PRR 10/23/02      Tom Peterson -- US LHC Project     16
                     Design Summary
• The DFBX design has been very thoroughly engineered,
  documented and reviewed.
• Issues raised by the various reviewers including the
  vendors have been addressed in the design and
  documentation.
• Vendors will have the option to make modifications in
  order to follow their standard practices, reduce their cost,
  or speed up production, with LBL approval.
• But the vendors have an excellent, detailed design as a
  baseline guide.
• Fermilab will continue to work closely with LBL
  throughout the contract negotiations and fabrication.

DFBX PRR 10/23/02     Tom Peterson -- US LHC Project             17

								
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