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Progress report on the test facility project, design and construction

Progress report on the test facility project, design and construction. L. Serio on behalf of bldg. 180 test facility project team members (TE and EN departments). O utline. Introduction Project Plan Scope of work and implementation strategy Organization Action plan and schedule

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Progress report on the test facility project, design and construction

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  1. Progress report on the test facility project, design and construction L. Serio on behalf of bldg. 180 test facility project team members (TE and EN departments)

  2. Outline • Introduction • Project Plan • Scope of work and implementation strategy • Organization • Action plan and schedule • Resources and cost • Financing • Progress report • Test program and acceptance tests • Test benches scenarios • Design and construction activities • Conclusions L. Serio

  3. Introduction According to the last collaboration meeting we have proceeded with the review and optimisation of the test program and the internal / external interfaces in order to fix the requirements and develop a detailed project plan and resource loaded schedule. Several meetings have taken place between CERN and FAIR personnel leading to the requirements, plans, resources and preliminary designreported hereafter. Design and construction activities have started. L. Serio

  4. Outline • Introduction • Project Plan • Scope of work and implementation strategy • Organization • Action plan and schedule • Resources and cost • Financing • Progress report • Test program and acceptance tests • Test benches scenarios • Design and construction activities • Conclusions L. Serio

  5. Implementation status • Scope of work – done; review of scope/financing required • Fix the preliminary requirements with FAIR • Review the existing implementation constraints • Establish a preliminary test program and WBS • Schedule- done; review required • Establish the test phases, sequence and overall testing rate • Establish the overall schedule and action plan • Cost- done; review of scope/financing required • Establish the PBS and corresponding material and personnel budget • Issue the Project Plan- done • Implement the Project Plan – started; review of scope/financing required L. Serio

  6. Project Plan: Scope of Work 1/2 • Addendum n.2 to the 2010 Agreement K1727/DG between CERN and GSI • Testing of 3 prototypes and 52 series magnets: • MULTIPLETS: • SHORT: 1 prototype and 7 series magnets • LONG: 1 prototype and 22 series are magnets • DIPOLES: 1 prototype and 23 series magnets • Schedule: • prototypes 1.2016 – 6.2016 • series testing 7.2016 – 1.2019 • Refurbishing and upgrade of the existing cryogenic test facility located in the test hall n. 180 at CERN - Meyrin L. Serio

  7. Project Plan: Scope of Work 2/2 • Design a facility adequate for the testing of SFRS magnets • Make extensive use of the existing CERN infrastructure • Refurbish the available equipment, within the existing limitations and space constraints • Testing according to the magnet production schedule and optimised test program • Design the facility according to the following magnets test phases: • Acceptance, preparation, installation and connection • Check electrical integrity of the magnet and its instrumentation at warm • Cool-down • Cold powering, magnetic field and heat-load measurements • Warm-up • Check electrical integrity of the magnet and its instrumentation at warm • De-mounting of magnet from test-bench • Storage of raw data, data analysis and report on magnet performance L. Serio

  8. Implementation strategy: WBS L. Serio

  9. Organization Chart Nota: The construction of this facility has been grouped together with the upgrade of the SM18 test facility in a new project with Volker Mertens as Project Leader L. Serio

  10. Baseline test sequencing L. Serio

  11. Baseline Action Plan and Schedule * • * If approved by CERN management • DIPOLES: 1 prototype, 23 series magnets, 2 spares cryostat • MULTIPLETS: 2 prototypes (L and S), 22 (L) and 7 (S) series, 2 spares (L and S) • 3 prototypes, 52 series magnets in total (plus 2 spares) L. Serio

  12. M+P estimate L. Serio

  13. Financing(Construction) L. Serio

  14. Options according to financing availabilities L. Serio

  15. 2 versus 3 test facilities • Presently agreed budget allows only for two TBs • Implications of 2 versus 3 test benches analyzed • Main WPs affected: • Cryo, Platforms&Supports, Test Stand L. Serio

  16. Project Plan L. Serio

  17. Outline • Introduction • Project Plan • Scope of work and implementation strategy • Organization • Action plan and schedule • Resources and cost • Financing • Progress report • Test program and acceptance tests • Test benches scenarios • Design and construction activities • Conclusions L. Serio

  18. Reviewed test program and time L. Serio

  19. Reviewed overall duration(3 test benches and 2 precoolers) L. Serio

  20. Optimal overall duration(3 test benches and 2 precoolers) L. Serio

  21. Series tests duration comparison L. Serio

  22. Schedule update Fix layout interfaces LLI launch procur. commissioning LS2 L. Serio

  23. Alternative scenarios (2TB-2PC with a later upgrade to 3TB-2PC) Nota: a. Delayed decision / financing b. Increased overall cost c. Reduced testing capabilities and time for prototypes L. Serio

  24. Outline • Introduction • Project Plan • Scope of work and implementation strategy • Organization • Action plan and schedule • Resources and cost • Financing • Progress report • Test program and acceptance tests • Test benches scenarios • Design and construction activities • Conclusions L. Serio

  25. WP: all DONE Overall scope, WBS, resources, budget and schedule reviewed and agreed IN WORK Detailed PBS, WBS and resource loaded schedule RASCI DELAYED Interface documents (ext and int) – September 2014 EVM based project reporting – October 2014 L. Serio

  26. WP: Cryogenics DONE CERN-GSI agreed design and main specifications parameters for the cryogenic components (pre-cooler) - https://edms.cern.ch/document/1355497/1 Preparation of bldg 279 and galleries sites (cleaning) Updated naming, database, PFDs, P&IDs, controls specifications of the helium refrigerators IN WORK Writing of the pre-cooler technical specification Review and approval of final PFDs and P&IDs DELAYED Finalised interface documents (requirements) – September 2014 Market survey LLI– October 2014 Procurement documents – December 2014 L. Serio

  27. WP: Magnetic Measurements DONE Magnet tests database definition Review of magnet test program, time and tools requirements IN WORK Development on the fluxmeter and rotating coils (challenging precision measurements, high cost of industrially available instruments) Measurement strategy within the boundary constrains being reviewed in order to streamline tests, analysis, time DELAYED Review of finalised magnet database and required test data – September 2014 in order to launch the required development and procurements L. Serio

  28. WP: TF and ICE DONE Facility test program and optimised activities duration in collaboration with FAIR IN WORK Specifications for DAQ and signals exchange being prepared L. Serio

  29. WP: Power Converters DONE Procurement of Power Converters launched (PCs expected at CERN mid-2015) IN WORK Definition of detailed requirements and interface specifications (in particular Energy Extraction system) L. Serio

  30. WP: Cooling and Ventilation DONE Conceptual Design and preliminary interface data IN WORK Layout and implementation Measurement strategy within the boundary constrains being reviewed in order to streamline tests, analysis, time DELAYED Finalised interface documents (requirements) – September 2014 Market survey LLI– October 2014 Procurement documents – December 2014 L. Serio

  31. WP: Cooling and Ventilation DONE Conceptual Design and preliminary interface data IN WORK Equipment layout and general integration DELAYED Finalised interface documents (requirements) – September 2014 Market survey LLI– October 2014 Procurement documents – December 2014 L. Serio

  32. WP: Platforms and Structure DONE General layout and concept Interfaces with magnets IN WORK Freezing of magnets interfaces Detailed design and cost optimisation L. Serio

  33. Platform review and optimization L. Serio

  34. WP: Integration DONE General layout and concept PANDA space sharing agreement IN WORK Review and freezing of individual system routings and layout L. Serio

  35. FAIR and PANDA layout Panda assembly and testing area L. Serio

  36. WP: Handling and Transport DONE Modifications for coupling of two existing cranes IN WORK Industrial survey for the procurement of interface lifting spreader (coupling) and dedicated magnets lifting spreaders (to be decided if procured directly by FAIR or via CERN) L. Serio

  37. Outline • Introduction • Project Plan • Scope of work and implementation strategy • Organization • Action plan and schedule • Resources and cost • Financing • Progress report • Test program and acceptance tests • Test benches scenarios • Design and construction activities • Conclusions L. Serio

  38. Conclusions 1/2 • Conceptual design, project plan, financing and resources (limited to two test benches) agreed upon • Financing issues (choice of 2 or 3 test benches) and possible staging option analysed • Test program optimised and finalised • Launch Safety Agreement prepared and issued • GSI to review and accept safety requirements • Cryogenic layout and precooler requirements agreed to proceed with Specification and Tendering phase • PANDA issues solved but no synergy implemented yet L. Serio

  39. Conclusions 2/2 September 2014 freezing of interface requirements (internal &external) to launch final design phase and procurement Formal agreement (technical reached) on cryogenic layout and components (with financing for second pre-cooler) required asap in order not to delay the project (LLI) L. Serio

  40. References • Project Plan (contains all up to date information): • EDMS: https://edms.cern.ch/document/1370663/3 • Technical coordination meetings and reviewed interface parameters: • EDMS: https://edms.cern.ch/nav/P:FAIR-000001263:V0/P:FAIR-000002500:V0/TAB3 L. Serio

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