SST Final Design Review Beamline Infrastructure Chris Stebbins
SST Final Design Review- Beamline Infrastructure Chris Stebbins Project Engineer Photon Science Division February 15, 2017 1 BROOKHAVEN SCIENCE
Outline • Scope • Technical Team • First Optical Enclosure • Mechanical Utilities • Electrical Utilities • Personnel Protection System (PPS) • Equipment Protection System (EPS) • Conclusions 2 BROOKHAVEN SCIENCE
SST Beamline Infrastructure Scope • • WBS 7. 02. 04 - Beamline Infrastructure (C. Stebbins) • • • 7. 02. 04. 01 –Hutch (E. Haas) 7. 02. 04. 02 – Mechanical Utilities (J. Gosman) 7. 02. 04. 03 – Electrical Utilities (G. Ganetis) 7. 02. 04 – EPS (R. Kadyrov) 7. 02. 04. 05 – PPS (G. Fries) Same CAM structure is applied across other beamline projects at NSLS-II • • • Ensures coordination of resources and scheduling Streamlines communication and points of contact Better application of lessons learned 3 BROOKHAVEN SCIENCE
Beamline Infrastructure Technical Team • The infrastructure technical team will be supported by existing fully staffed groups • Matrixed Organization employed to execute scope: – NSLS-II staffing, including Engineers, Designers, and Technicians – Trades (Electricians, Plumbers, Riggers, etc) – Outside Contractors (LN 2 Piping, experimental exhaust) • Personnel already experienced with Beamline Common Systems (i. e. NSLS-II Project Beamlines, NEXT, ABBIX, and other NSLS-II Partners). • Able to leverage “standard” designs from existing beamline systems. • Able to value engineer existing systems. • Able to bundle procurements of common parts across projects to reduce costs. 4 BROOKHAVEN SCIENCE
SST Hutch Overview SST has a first optical enclosure (FOE): • Hutch design review was previously held in 2014. • • • Includes lead shielding. Labyrinths located overhead to accommodate utilities and cables. Labyrinths located on outboard hutch wall for PPS conduit and user needs, as well as hutch ventilation. Automated door actuation. Access/egress via stairs to storage ring mezzanine. Foot bridge installed for access/egress to adjacent 6 -BM-B hutch (BMM) Overhead mobile hutch crane with 1 ton capacity Was manufactured and installed by Caratelli in 2014, as part of NEXT lead hutch procurement. 5 All acceptance testing is completed BROOKHAVEN SCIENCE
SST Mechanical Utilities Overview Technical Scope • • Standard utilities installation scope that has been used at other NSLS-II beamlines, and tailored to needs at SST. • SST scope is larger than a typical beamline due to multiple end stations and number of critical safety components that require cooling. De-Ionized (DI) Water, from Accelerator for cooling beamline components on beamline. • 4 circuits for cooling PPS components • 13 circuits for cooling EPS components Process Chilled Water for cooling equipment racks and user / end station equipment. Compressed air for vacuum valves, shutters, etc. Dry Nitrogen gas for purging vacuum vessels and experimental requirements. All piping installed; final DI water integration to equipment expected in early summer. Final “as built” flow diagram released in December. 6 Mechanical Utilities Design Mechanical Utilities Installation in FO BROOKHAVEN SCIENCE
SST Mechanical Utilities Overview Technical Scope (continued) • 10 racks for controls, network, and vacuum • • • equipment • Procured and installed in 2016. 11 structural pylons used for utilities support downstream of the FOE. • All pylons are installed and have been reinforced with additional cross bracing Liquid nitrogen distribution system to the end station areas. • Installed in 2016 by Technifab Exhaust ducting for any gases or fumes needing to be removed from the end stations. • Installed in 2016 by Blake Sheet Metal. Equipment Rack 7 Utilities Pylon BROOKHAVEN SCIENCE
SST Electrical Utilities Overview Technical Scope and Status • Standard utilities installation scope that has been • • used at other NSLS-II beamlines, and tailored to needs at SST. • Scope is larger than a typical beamline due to multiple end stations and overall number of power circuits and hardware. AC power distribution from storage ring mezzanine outfitted to FOE and downstream along pylons. Uninterrupted power supply (UPS) for equipment racks. Electrical grounding provisions for all equipment. Released “as built” electrical diagram released in January. 8 Released “as built” electrical diagram BROOKHAVEN SCIENCE
SST Electrical Utilities Overview Technical Scope and Status • Includes cable tray provisions for controls, communication, and vacuum system cabling. • Cable tray requirements are developed jointly with the beamline staff, Controls Group, and Electrical Engineering Group. • Cable database is maintained by the Controls Group, and includes label IDs and operating voltage of each cable. • Cables with voltages above 50 V and below 600 V will be identified as electrical hazardous voltage. • Installation was completed in late 2016. 9 BROOKHAVEN SCIENCE
Personnel Protection System (PPS) Overview Beamline PPS Designed to Protect Against Synchrotron and Bremsstrahlung Radiation Technical Scope • Dual chain safety-rated PLC architecture (two manufacturers) • Status of PPS functions available on local HMI and EPICS • Redundant critical device configuration • Doors and labyrinths monitored by redundant and diverse switches • Interface to photon shutters & water flow circuits • Interior warning - revolving beacons and sirens 10 Bench assembled PPS pan BROOKHAVEN SCIENCE
Recent PPS Improvements PPS group has continued to develop and engineer improvements into existing architecture: • The mechanical door switches on the hutches will be replaced with magnetic coded switches. • Replace B chain magnetic reed switch with switch incorporated in magnetic lock assembly. • Where practical, field wires will be directly wired to I/O modules, eliminating intermediate terminal blocks and wires. • Using cable tray for cables instead of conduit Increased reliability and reduction 11 Existing reed switch New reed switch reduces installation cost and time BROOKHAVEN SCIENCE
SST PPS Installation Overall scope for SST is larger than typical beamlines at NSLS-II • Nine current photon shutters, plus cabling for tenth future shutter. • Ten pairs of vacuum switches for current pink beam transport pipes, DCM, PGM, and current end stations. • Four PPS DI water circuits to monitor photon shutters, WBS, DCM, PGM, and masks. • PPS conduit was installed in late 2016. • Cable pulling and termination is currently in process. • FOE control cabinet assembled; downstream box starting. • Component integration and system testing scheduled for this summer. • Certification by ES&H expected in September. 12 BROOKHAVEN SCIENCE
SST EPS Overview Protects equipment Beamline EPS Monitors the following: • Temperatures of white or pink beam components. • DI water flow rates through components; 13 circuits on SST. • Position of gate valves. • Over-travel limit switches on some critical components. • Vacuum pressures in each beamline vacuum section. • Smoke detectors in equipment racks Flags problems either: • As a warning (gives early indication of problems to the operators). • As a trip threshold – closes the front end shutter immediately upstream. 13 Water Leak Detection in FOE Rack Smoke Detector BROOKHAVEN SCIENCE
SST EPS Status through January 2017: • Gathering of EPS requirements and initial • • design work kicked off in November 2016. • Design of the PLC code and EPICS database will start in March. • IOC design is ~20% complete. Procurement of system components and hardware is mostly complete. Initial installation at the beamline has started • All of the EPS cables have been pulled; 75% have been terminated. • EPS enclosure is installed and wired at the box. • Remaining EPS integration will be done as beamline components and end stations are installed. System testing expected to start in late Spring. Completion of EPS expected in late summer, after all beamline systems are installed. 14 Main EPS panel wired on top of FOE BROOKHAVEN SCIENCE
Conclusions • SST Beamline Infrastructure scope well defined and understood. • Majority of work is already designed, procured and installed at the beamline. • Fully capitalizing and benefiting from engineering designs and experiences from NSLS-II Project/ABBIX/NEXT Beamlines • Value engineering and engineering improvements are already being pursued in many areas, particularly for Utilities and PPS. • Resources are fully planned to execute remaining work on schedule. 15 BROOKHAVEN SCIENCE
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