LBNF LongBaseline Neutrino Facility Neutrino Beamline Modules Preliminary
LBNF Long-Baseline Neutrino Facility Neutrino Beamline Modules Preliminary Design Review General Overview: Parameters, Interfaces, Requirements Cory Crowley 13 August 2020
Outline • Overview / Position in Beamline - System Interfaces & Parameters - Design Approach / Assumptions • Requirements & Specifications - Project Requirements - Specifications Worksheet • ESH&Q - Safety Considerations - Engineering Risk Assessment • Schedule / Cost Overview • Summary 2 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
System Scope – Arrangement in Target Chase + Major Components • Four Module System – Baffle + Horns A, B, & C – Includes electrical bus (Strip. Line) shielding penetration Blocks (SLB) & Target Utility Block (TUB). – Target is integrated into Horn A & both are supported from a single module. – Modules provide motion control, utility, & instrumentation paths to focusing system. – Designed for 2. 4 MW (life of facility design) with upgradable cooling. 3 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
System Scope – Interfaces • • • 4 Modules interface to nearly all Target Hall Complex (THC) subsystems. Modules are link to critical beamline elements. These protection and focusing elements drive design of the THC. Module placement and interfaces are best locked down as soon as possible. Immediate interfaces shown; more exist; – Remote Handling. – Conventional Facilities. – Baffle (RAL). 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Module Structure • • • 5 Primary components are steel endwalls & side-walls that form a 4 sided box. Open on top and bottom. All horn modules must provide an extension to support the SLB Horn A SLB also has TUB fastened to it. Baffle module does not require SLB or TUB; steel walls only. 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Engineered Module Parameters • Modules are packaged into chase to maintain baffle & horn position per the Beam Optimization Task Force report, DUNE-doc-2901. • Key inputs are overhead crane capacity, required shielding thickness, and remote handling points. 6 Major Module Parameters Life of Facility Values Maximum Assembly Weight Main Wall Construction Maximum Temperature Minimum Shielding Height Minimum Labyrinth Count Nominal Shielding Gap 120, 000 lbs (54, 545 kg) A 36 or Equiv. 212 F (100 C) 106” (2. 692 m) 1 0. 75” (19 mm) Vertical Positioning +/- 0. 25” (6. 35 mm) All Horns +12” / -0. 25” (+305 mm / -6. 35 mm) Baffle Only Horizontal Positioning Axial Positioning Stability Utility / Instrumentation Penetration Radial Clearance +/- 0. 25” (6. 35 mm) Fixed +/- 0. 010” (0. 25 mm) 0. 125” (3. 18 mm) Minimum U. S. / D. S. Remote Handling Clearance 6” (152. 4 mm) 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Design Approach: Vertical Kinematics 7 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Design Approach: Horizontal Kinematics 8 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Design Approach: Stripline Block Kinematics 9 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Design Approach: Target Utility Block Kinematics 10 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Baffle Module + Baffle 11 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Horn A Module + Horn A + Target Package 12 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Horn A Module Spacing / Limitations / Labyrinths • THC crane limit @ 60 T. • Horn A + Target budget of 2. 5 T. • Stripline shield block @ 22. 5 T • Target Utility Block (TUB) weight budget of 6 T. • Lifting fixture budget of 2. 5 T • Module budget is balance of weight @ 26. 5 T. • With a 78” wide chase & 120” of shielding, module end & side walls are thin. 13 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Horn B Module + Horn B 14 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Horn C Module + Horn C 15 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Utility / Instrumentation Line Locations 16 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Major Requirements • Proton beam Proton Beam Energy (Ge. V) Protons per Cycle Time (s) Beam Power (MW) 60 7. 5 E+13 0. 7 1. 03 80 7. 5 E+13 0. 9 1. 07 120 7. 5 E+13 1. 20 • Lifespan Component Cycle Life Minimum Time (yrs) Support Module >1, 000, 000 30 Stripline Block >200, 000 4 Target Utility Block >200, 000 4 Utility / Instrumentation Lines >100, 000 2 • Functionality - Allow module, target, conductor bus (stripline) shield block de-coupling. - Allow for one-time SLB(+TUB) re-use after decoupling expired adjacent or integrated component. - Allow for water cooling, gas cooling, purge gas, etc… 17 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Requirement Tracking / Tracing • High level project requirements are kept in CERN EDMS. • Beamline specific requirements with tracebacks to adjoining systems & high level requirements are kept in Beamline Share. Point site. 18 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Requirement Tracking / Tracing 19 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Integration Efforts / Design Tracking • Dedicated bi-weekly meeting held with RAL target group for Horn. Target-Module interface issues. Separate bi-weekly meeting held with Module & Chase team for internal interface issues. • Additional communication to adjacent systems occurs as-needed. • Important notes are documented for future reference & task assignments. - Module Notes: DUNE-doc-17289 - RAL Notes: DUNE-doc author list & Indico event. 20 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Module Design – Electrical Considerations EE Credit: Ken Quinn Max V @PS Max Allow. E Field Max Isolator Path Length Potential Horn A ΔV Horn B V Horn C V ~4. 5 k. V+ 25 V/. 001” ~1. 5 k. V ~3 k. V ~4. 5 k. V 21 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
ESH&Q • ESH&Q requirements identical to all critical beamline components. - Pressurization aspects for utility lines (RAW & purge gas piping). - Mixed waste (keep beryllium, silver, cadmium, etc… content low). - Disposal (remove RAW from utility lines / contain contamination). - Assembly (specialized tools, fixtures, rigging, procedures). • Quality aspect is most applicable to Stripline feedthrough & Mainframe. • Technically demanding assembly that takes years to build. • Performance or Q/A issues have major ramifications for programmatic goals. - Material certification records. - Vendor prequalification testing. - Component inspection, X-ray, CT scan, & signoff records. - Fabrication, assembly, and installation procedures. 22 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
FESHM / Engineering Design Manual • Engineering Risk Assessment Reviewed. • Final engineering documentation loaded to DUNE-doc-DB. • Assembly procedure generation & recordkeeping retained in Target Systems Department for design & fabrication continuity. • Two applicable codes for all of Horns WBS. - ASME B 31. 3: Process Piping. - ASME B 30. 20: Under the Hook Lifting Fixture Design. • Water systems operate at 40 PSI, greater than 15 PSI threshold, so industry standard tubes/pipes/fittings/weld preps required. • All welding done on site. All welders are ASME / AWS certified. • Lifting fixtures required for Module mainframe & Stripline Blocks. Fixtures, which are handled by Remote Hnadling WBS, must meet ASME code. Our “workpieces” will be designed to code as well. 23 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Engineering Risk Assessment 24 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Engineering Risk Assessment 25 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Module Schedule Overview • Final Design Review(s) start ~May 2022. • First build starts ~April 2024 (Funding constrained). • First Module / Horn integration activity occurs March 2027 - Verify water flow rates, voltage isolation, module connections, stripline block connections & remote clamp, utility block line changeouts, drive system operation, stripline flex, lifting fixtures, etc… • Module builds require the Target System Integration Building (TSIB) for floor space, crane capacity, hook height, & storage concerns. • Module fabrication occurs concurrently at times, so multiple assembly stands are required. • Substantial testing on target retraction while mated to Horn A & Module assembly, with RAL provided targets & exchangers, is accounted for. 26 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Integrated Schedule • Integration activities continue after March 2027 when the SLB + TUB are available. - Install helium lines & line supports. - Test complete assembly with dummy line connections for flexibility range, remote handling, chain clamp seal operation, etc. . . • Retest modules and entire mated assemblies in THC work cell. • Commissioning scheduled for 2028. 27 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
System Risks / Opportunities • One direct risk for modules: 131 -BEAM-153. - Horn A Prototyping leads to redesign of support systems. 5% Probability. • Risks to modules generally flows through Horns & target, which carry most of the WBS risk. - Integration difficulties / exchange system difficulties. - Voltage issues. • Module risk can retire after production Horn A is successfully mated and tested on module with integrated target. • General project schedule, resource, & accident type risks remain: - Production timelines / insufficient resources. - Component damage. • Available opportunity: 131 -Beam-064 - Non-DOE partner for fabrication. 28 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Cost Overview • Modules & ancillary equipment have remaining budget of ~7. 56 M. • Module & SLB fabrication is cost driver for Horns WBS primarily due to Component size + complexity. • M&S cost. - Machined end-wall plates. - Gun-drilled holes through end-walls. - Stripline block fabrication & ceramics package. • Labor. - ~22, 587 k hours remaining to reach installed modules milestone & commissioning date. 29 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
Summary • The technically demanding Module interfaces are the integrated horn & target, stripline blocks, and the connection to the power supply. • Module preliminary design is derived from FNAL design experience on Nu. MI / NOv. A module production and operations. • Design elements that have not historically lent themselves to long-term reliability in highly radioactive environments have been revised. • The requirements are clearly defined, and engineering parameters & specifications continue to be defined as we approach final design. • Module cost estimates continue to be updated. Some prior vendors have gone out of business. New vendor estimates are available. • Review material is available for all major design aspects of the modules. • Questions? 30 8. 13. 20 Cory Crowley | General Overview: Parameters, Interfaces, Requirements LBNF
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