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									  Division Head’s Internal
  Assessment of the Test &
Instrumentation Department

      Ruben Carcagno
         March 4, 2009
                                    Outline
•    T&I Department Overview
      – T&I Organizational Structure
      – T&I Allocation of Effort
      – T&I M&S Summary
•    T&I Support of Programs
      –   Accelerator Support
      –   SRF Program Support
      –   HINS Program Support
      –   HFM/LARP Program Support
      –   Cavity Tuning Machine
•    T&I Improvement Plan Progress
      –   Downtime Risk
      –   Operational Constraints
      –   Efficiency and Reliability
      –   Operating M&S Cost
      –   Industrial Space Usage
•    Big Issues, Big Challenges, Some Actions

    3/4/2009              Div. Head's Internal Self-Assessment - T&I Dpt.   2
     T&I Organizational Structure
• Matrix organization in place since November 2007
   – http://tiweb.fnal.gov/website/controller/272




               Min Jeong Kim     Engineer I Opening




                                                                     Bill Andrews (C)




 3/4/2009          Div. Head's Internal Self-Assessment - T&I Dpt.                      3
                   T&I Allocation of Effort

                                                                                      Actual vs. FY09 Plan
                                                                                 30
                                                                                 25      YTD    FY09 Plan
                                                                                 20




                                                                      % Effort
                                                                                 15
                                                                                 10
                                                                                  5
                                                                                  0




•     Total Hours: 27,730 (OT: 946, T&I Contractors: 1,176)
•     PPD Help ~ 790 hours




    3/4/2009                     Div. Head's Internal Self-Assessment - T&I Dpt.                             4
                             M&S Summary
• Two Categories:
      – Department (30.12…)
      – MTF/VCTF Test Facilities Support (30.9.10.5.2…)
• First 4 months of FY09 (33% of the year)
                  Department M&S                          MTF/VCTF Test Facilities Support M&S
      $16                                               $60
      $14                                                                         Budget: $429K
                             Budget: $186K              $50
      $12                                                                         16% spent
      $10
                               15% spent                $40




                                                   $K
 $K




       $8                                               $30

       $6                                               $20
       $4
                                                        $10
       $2
       $-                                                $0

            Oct        Nov         Dec    Jan                  Oct       Nov       Dec           Jan

                       FY09 Month                                        FY09 Month




 3/4/2009                    Div. Head's Internal Self-Assessment - T&I Dpt.                           5
            Accelerator Support (3%)
• Mostly Conventional Magnet Testing
   – Completed production testing of all Booster Corrector
     Magnets
        • Now testing AD power system with a few corrector magnets
        • Expected completion: end of May 2009
   – Installed and commissioned a pulsed power system




 3/4/2009           Div. Head's Internal Self-Assessment - T&I Dpt.   6
      SRF Program Support (16%)
• VTS1 Maintenance, Operations, and Improvements
• VTS2 & 3 Design, Fabrication, Installation, and
  Commissioning
   – Supporting a collaboration with Indian Institutions
• IB1 Cryogenics Infrastructure Upgrade
   – Portion of T&I IB1 Improvement Plan funded by SRF program
• Cryomodule Instrumentation
   – CM1, 3.9 GHz, CM2
• HTS internal instrumentation support
• NML instrumentation support
   – Piezo tuner, vibration, fast thermometry
• Cavity Resonance Control
   – Piezo Tuner R&D (Lorentz Force and Microphonics detuning
     compensation)


 3/4/2009          Div. Head's Internal Self-Assessment - T&I Dpt.   7
      HINS Program Support (7%)
• Production Testing of HINS Solenoids and HTS leads started
   – Test Stands 3 and Test Stand 6 modified to support production
     testing
   – Testing AD solenoid power system in Stand 6
• Spoke Resonator SSR1 VTS test support
   – VTS1 modified to support 325 MHz testing of SSR1 spoke
     resonator
   – Need to fabricate a dedicated VTS1 top plate for SSR1 test
     support
• Spoke Resonator SSR2 and TSR cavity test support
   – Designing VTS2 and 3 with larger diameter to accommodate
     these cavities
• HINS cryostat integration and cryogenic test at IB1 and
  solenoid magnetic field mapping



 3/4/2009          Div. Head's Internal Self-Assessment - T&I Dpt.   8
    HFM/LARP Program Support (2%)

• Testing at a rate of ~ 1 magnet/month
• Developments needed in FY09 to support 4-m long quad
  LARP test in July
   – Heaviest VMTF load to date:
        • New procedures to handle, upright, and test long, heavy magnet
        • Top Plate structure safety analysis and load test (heaviest VMTF load to date)
   – Symmetric 30 KA Power Supply grounding
   – Two additional Heater Firing Unit circuits
   – Adaptive quench detection threshold



                                                              Weight ~ 13,000 lbs




 3/4/2009              Div. Head's Internal Self-Assessment - T&I Dpt.                     9
     Cavity Tuning Machines (8%)
• Collaboration with DESY and KEK
   – http://tiweb.fnal.gov/ctm
• T&I scope: Development, Fabrication, and
  Commissioning of control system hardware and
  software for four machines
• Overall Project is ~ 1 year late
   – Schedule: http://tiweb.fnal.gov/website/controller/164
        • Machines mechanical assemblies delivery delayed by a year
   – Expected completion: end of CY09
        • Remaining FNAL effort ~ 3 FTEs
        • Remaining FNAL M&S ~ $165K




 3/4/2009             Div. Head's Internal Self-Assessment - T&I Dpt.   10
    IB1 Maintenance and Operations (28%)

• Two IB1 test areas (MTF, VCTF), Nine IB1 Test Stands
• IB1 Auxiliary Systems
   – Process (Cryo, Water), Mechanical, Electrical, Instrumentation,
     Software, etc
• Very busy test schedule:




 3/4/2009          Div. Head's Internal Self-Assessment - T&I Dpt.     11
          IB1 Developments and Improvements (13%)

•    T&I Improvement Plan provides guidance for IB1 Developments and
     Improvements
      –    Released June 12, 2008
      –    TID-N-8: http://tiweb.fnal.gov/website/controller/338




          Progress in highlighted
                sections




    3/4/2009                  Div. Head's Internal Self-Assessment - T&I Dpt.   12
                                Downtime Risk
•    2.1 Inadequate Helium Purification System
      – Designed and procured parts to improve existing partial flow IB1 purifiers (items
           (b), (c), and (d) in improvement plan)
            •   TID-N-30: “IB1 Purifier Modifications”, 9/3/2008
            •   Will be implemented during the 2009 IB1 refrigerator maintenance shutdown
      –   Modified contamination recovery procedures to reduce unscheduled downtime.
            •   Turnaround reduced from days to 8 hours in most cases
      –   Procured and installed additional N2 and O2 analyzers for early detection of
          contamination
      –   Sized a compressor/purifier system for high-throughput cavity test operations
            •   TID-N-23: “Sizing of a Purifier Compressor for the Industrial Building 1 Helium Plant Based on VTS-1
                Operations”, 12/17/08
      –   Specification to procure a new purifier nearly complete

                                            Contamination downtime
                                      60
                                      50
                                      40
                               Days




                                      30
                                      20
                                      10
                                       0
                                             FY07         FY08        Q1FY09
                                                       Fiscal Year




    3/4/2009                           Div. Head's Internal Self-Assessment - T&I Dpt.                            13
                      Downtime Risk
• 2.2 Water cooling system performance and
  reliability
   – Procured and replaced the broken IB1A chiller during the
     2008 IB1 refrigerator maintenance
        • Successfully supported summer 2008 operations
   – Replaced all IB1 flowmeters having a temperature rating
     below the power system trip setpoint of 80 C
        • Response to CPS3 LCW spill incident of March 13, 2008:
            – http://tiweb.fnal.gov/website/controller/276
   – Analyzed existing ICW/LCW heat exchange limitations
        • TID-N-24: “LCW/ICW Heat Exchanger Thermal Performance Based on Design
          Conditions”, 4/28/2008
        • Not sufficient to sustain 30KA for more than a few minutes
        • Needs to be upgraded




 3/4/2009             Div. Head's Internal Self-Assessment - T&I Dpt.             14
            Operational Constraints
• 3.1 Low Liquefaction Rate (~60% design value)
   – Replaced undersized gas management valve
   – Two maximum liquefaction tests:
        •   TID-N-31: “Liquefaction Test – Part I (September 24, 2008)
        •   TID-N-33: “Liquefaction Test – Part II (December 29, 2008)
   – Findings:
        •   Second Stage compressor motor trips on over temperature
        •   Cold Box thermo acoustic oscillation

• 3.3 Insufficient helium gas storage capacity
   – Three 30,000 gallon tanks were procured and installed
        •   Integration with the IB1 cryoplant scheduled during 2009 IB1 refrigerator maintenance

• 3.4 Shared superfluid pumping system for magnets and
  cavities
   – Four 4 g/s @ 23 Torr Kinney pumps are on order.
        •   Three for VCTF, one for MTF
        •   Delivery expected May 2009
        •   Installation and commissioning in FY10




 3/4/2009                  Div. Head's Internal Self-Assessment - T&I Dpt.                          15
            Efficiency and Reliability
• 4.3.1 Unbalanced IB1 and IB1A AC Power Feed Distribution
   – Power Meters for IB1 transformers were procured and installed
   – A detailed study of IB1 power usage and upgrade options was
     conducted
        • TID-N-18: “Test and Instrumentation Department Analysis for IB1 Power
          System Improvements”, 11/18/08
             – An additional 1,500 KVA Transformer was recommended to support IB1
               cryogenic upgrade
• 4.5.1 Old, Unreliable IB1 Network System
   – The IB1 Network system was upgraded to a 100 Mbits/s network with a
     central switch and fiber optic links to modern switches at strategic
     locations throughout the building
   – This work was conducted in collaboration with the Computing Division
   – User access points to the IB1 network can be found at:
        • http://tiweb.fnal.gov/website/controller/410




 3/4/2009              Div. Head's Internal Self-Assessment - T&I Dpt.              16
            Efficiency and Reliability
• 4.4.1 Incomplete Instrument Calibration System
   – Progress: T&I Calibration Rack with NIST traceable standards,
     Calibration Programs, Inventory Database updated with Calibration due
     date information




 3/4/2009           Div. Head's Internal Self-Assessment - T&I Dpt.          17
            Efficiency and Reliability
• 4.6.1 Documents
   – Developed and deployed a department web-based document system
     (tiweb.fnal.gov)
        • Supports versioning, registration, and publishing of department documents
        • Includes a feature to automatically generate department notes (TID-N-XX)
   – Created a physical “Department Files” system in compliance with TID-N-
     19: “Test and Instrumentation Department Records”. Signed originals
     are kept at this location.




 3/4/2009             Div. Head's Internal Self-Assessment - T&I Dpt.                 18
            Efficiency and Reliability
• 4.6.2 Procedures
   – Created new department procedures to comply with new department
     policy TID-N-15: “Conduct of IB1 Test Facility Operations”
        • Device Under Test (DUT) Description
             – Each complex DUT has a written description
             – Example for SR07: http://tiweb.fnal.gov/website/controller/375
        • Device Under Test (DUT) Safety Data Sheet
             – Each DUT must have a safety data sheet filled out according to this procedure
             – Data sheet must be approved by test area leader prior to test activity
             – Example safety data sheet procedure for SC magnets:
               http://tiweb.fnal.gov/website/controller/388
             – Example approved safety data sheet for SR07:
               http://tiweb.fnal.gov/website/controller/374
        • List of Authorized Users
             – Each IB1 Test Stand has a list of authorized users
             – Must be approved by corresponding test area leader and Department Head
             – Example for VMTF: http://tiweb.fnal.gov/website/controller/494




 3/4/2009               Div. Head's Internal Self-Assessment - T&I Dpt.                        19
            Efficiency and Reliability
• 4.6.3 Department Policies
   – New:
        • TID-N-15: “Conduct of IB1 Test Facility Operations”, 10/20/08
             – Describes compliance with Integrated Safety Management
             – http://tiweb.fnal.gov/website/controller/429
        • TID-N-19: “Test and Instrumentation Department Records”, 12/16/08
             – Specifies how department records are organized, stored, controlled, and maintained
             – http://tiweb.fnal.gov/website/controller/446

   – Revised:
        • TID-N-16: “Guidelines for Working in Industrial Buildings 1 and 1A”,
          Rev. 10/20/08
             – Revised for VTS addition and associated hazards
             – http://tiweb.fnal.gov/website/controller/250




 3/4/2009               Div. Head's Internal Self-Assessment - T&I Dpt.                             20
                  Operating M&S Cost
• 5.1 Helium Losses
   – Installed additional N2 and O2 analyzers, optimized
     procedures, and systematic leak hunting and repair
        •   Result: saved the lab close to $85K in CY08 (compared to prior 5-year average), and on
            track to repeat this performance in CY09




 3/4/2009                 Div. Head's Internal Self-Assessment - T&I Dpt.                            21
            Industrial Space Usage
• 7.2 Storage
   – Phase 2 (of 6) of the IB1 storage improvement plan was
     completed:
        • Procured and assembled several storage cabinets
   – Storage improvement plan at:
        • http://tiweb.fnal.gov/website/controller/501




 3/4/2009              Div. Head's Internal Self-Assessment - T&I Dpt.   22
                   Space Usage
• Need to move tooling and existing Kinney Pumps I
  and II away from IB1
   – Compensate for IB1 Industrial floor area taken by VTS1, 2,
     and 3 (e.g., for magnetic probe fabrication)




 3/4/2009        Div. Head's Internal Self-Assessment - T&I Dpt.   23
                                 Big Issues
•    Must obligate more than $3M before end of FY09 for IB1 Vertical Cavity Test Facility
     Expansion (VTS2&3 plus IB1 infrastructure upgrade)
      – Funding from American Recovery and Reinvestment Act plus SRF Program
      – Space for new cryogenic equipment
           • Modify IB1/IB1 Midway area and IB1A North end
                 – Foundation, walls, access doors, motor power feed, ODH, sprinklers,
                   noise insulation, duct relocation, process piping, etc
                 – Must be ready in FY09
      – IB1 Civil Construction for VTS2&3
           • Two larger diameter pits plus trenches, VCTF 10-ton crane bridge, VCTF
              staging area
           • Must place POs before end of FY09 (construction FY10?)
           • Very disruptive (~ 6 weeks IB1 downtime)
      – VTS2&3 cryostat procurement as a joint FNAL-India collaboration
           • Complexities due to new venture, unfamiliar industry and unfamiliar
              collaborator’s processes
      – New 1,500 KVA IB1 Transformer
           • Must be ready to commission new cryo equipment in FY10




    3/4/2009               Div. Head's Internal Self-Assessment - T&I Dpt.                  24
                       Big Challenges
•    T&I Cryo Mechanical Engineers in short supply!
      – Expected to support IB1 cryo upgrades, VTS 2&3, APUL, mu2e,
         Engineering Notes safety reviews, PLUS demanding ongoing IB1
         cryogenic operations, maintenance, and improvements
•    Inadequate availability of experienced mechanical designers intimately
     familiar with IB1 systems
      – Lots of designer effort for detailed building modifications, process
         piping layout, VTS cryostat, staging area, etc
      – Need Clark Reid assigned full-time for the next six to eight months
      – Need to contract additional mechanical drafters/designers to help Clark
•    FESS and TD HQ Support Services will become extremely busy with other
     high-priority GPP work
      – Needed for:
           • Building Modifications
           • VTS2&3 Civil Construction procurement
           • VCTF 10-ton Crane Bridge procurement




    3/4/2009            Div. Head's Internal Self-Assessment - T&I Dpt.           25
                    Some Actions
• Postponed 2009 annual refrigerator maintenance (normally
  scheduled for ~ April)
• Reduced or eliminated effort on IB1 cryogenic improvements
• Minimized VTS2 design changes with respect to VTS1
• Resisting requests for T&I cryo engineers help for other
  projects (e.g., mu2e, APUL)
• Requested Clark Reid to be assigned full-time to IB1 Test
  Area work for the next 6 to 8 months
• Trying to make progress on items requiring FESS and TD HQ
  Support Services before ramp up of GPP activities
   – Cosmore Sylvester is the T&I department point of contact for
     VTS2&3 Civil Construction and 10-ton crane bridge
     procurements
   – Barry Norris is the T&I department point of contact for building
     modifications


 3/4/2009          Div. Head's Internal Self-Assessment - T&I Dpt.      26
           Backup Slides




3/4/2009   Div. Head's Internal Self-Assessment - T&I Dpt.   27
           Present IB1 Configuration
                                                                                •   Disadvantages
                                           Gas Storage                               –   Shared VCTF/MTF
                                    (3 x 30,000 Gallon Tanks)                            Vacuum Pumping
                                                                                     –   Limited suction
                                                                                         pressure control
                                                   Refrigerator                      –   High He
                                                   Compressors                           contamination risk
                                                                     Partial             from sub atmospheric
                                                                    Purifiers            operations
                                                                   (~ 50 g/s)        –   Undersized Gas
                                                   Refrigerator                          Storage capacity
                                                                                         relative to LHe
                                                    Cold Box
                                                                                         inventory
                                                                                     –   Shared VCTF/VMTF
                                                                                         10-ton crane bridge
                           VCTF/MTF                       LHe                   •   Consequences
                         Kinney Pumps                    Dewar
                                                                                     –   Unable to support
                         (6 g/s@23Torr)                 (10,000
                                                                                         high cavity test
                                                         Liters)
                                                                                         throughput
                                                                                     –   Excessive
      VCTF                                 MTF                                           interference with
  (1 Test Stand)                      (5 Test Stands)                                    magnet testing




         10-ton Crane Bridge




3/4/2009                       Div. Head's Internal Self-Assessment - T&I Dpt.                             28
        Upgraded IB1 Configuration
                                                                                       •   Advantages
                        Expanded Gas Storage                                                –   Independent VCTF/MTF
                      (6 x 30,000 Gallon Tanks)                                                 Vacuum Pumping
                                                                                            –   Adequate suction
 New Purifier                                          Refrigerator                             pressure control
  (~ 50 g/s)                                           Compressors                          –   Minimize He
                                                                            Partial
                                                                                                contamination risk from
                                                                           Purifiers
                                                                                                sub atmospheric
                                                                          (~ 50 g/s)
New Compressor                                                                                  operations
   (~ 50 g/s)                                          Refrigerator
                                                                                            –   Matched GHe capacity
                                                        Cold Box
                                                                                                with Lhe inventory
                                                                                            –   Independent VCTF/MTF
                                                                                                10-ton crane bridge
       New VCTF             Expanded MTF                      LHe
      Kinney Pumps          Kinney Pumps                     Dewar                     •   Consequences
     (12 g/s@23Torr)        (8 g/s@23Torr)                  (10,000                         –   Can support high cavity
                                                             Liters)                            test througput
                                                                                                  •   250 “standard cavity
                                                                                                      test cycles/year,
       VCTF                                    MTF
                                                                                                      three VTS cryostats,
   (3 Test Stands)                        (5 Test Stands)                                             two cavities per VTS
                                                                                                      cryostat
                                                                                            –   Low interference with
                                                                                                magnet testing
10-ton Crane Bridge             10-ton Crane Bridge
                                                                      Procured
                                                                      To be procured


3/4/2009                         Div. Head's Internal Self-Assessment - T&I Dpt.                                   29
      Remaining Equipment Choices
•    TID-N-23: “Sizing of a Purifier Compressor for the IB1 Helium Plant
     Based on VTS Operations”
      –   http://tiweb.fnal.gov/website/controller/458




AD-Cryo 58 g/s                     AD-Cryo ~ 50 g/s Oil              IB1 ~ 50 g/s Purifier
Mycom Compressor                   Removal System                    Quote: $133K
Quote: $680K                       Estimate: $115K
    3/4/2009                Div. Head's Internal Self-Assessment - T&I Dpt.                  30
           Space Solution for New Equipment

•    Use existing TD building space for Kinney Pumps, Compressor
•    Oil Removal, Purifier located outdoors




    3/4/2009         Div. Head's Internal Self-Assessment - T&I Dpt.   31
   Cost Estimate of Remaining Items




3/4/2009   Div. Head's Internal Self-Assessment - T&I Dpt.   32

								
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