wbs 6.2.1 stave cores · us staves to be delivered to cern 206 us staves to be assembled at bnl 206...

WBS 6.2.1 Stave Cores

Jeffery AshenfelterLevel-3 Manager & CAM

Yale University

U.S. ATLAS HL-LHC Upgrade Project Scrubbing Meeting Brookhaven National Laboratory

Upton, NYMarch 10-11, 2019

Outline

• Technical Details▪ Deliverable Overview, institutional responsibilities

▪ R&D Status and Plans

▪ Technical Progress in FY18

▪ Pending Issues

▪ Plans for pre-production

▪ Plans for production

• Schedule and Cost▪ How has the schedule changed since CD-1?

▪ How as cost changed since CD-1

• Risk and Uncertainty

• Closing Remarks

J. Ashenfelter ATLAS HL-LHC Upgrade Project Scrub, BNL, March 11-12, 2019 2

Technical Details

Stave Core

• A stave core is a plank, that provides a mechanical support structure, cooling, and electrical services for the modules

• Assembled by laminating foam, honeycomb, c-channel, and a titanium cooling pipe in-between two co-cured facings


Stave Core Assembly


Honeycomb First Facing Second Facing Side Closeouts PEEK End Closouts

Carbon Foam Ends Locking Points

Carbon Foam StraightsPEEK End Closeout (@z=0)

Titanium tubing/isolator/fitting subassy

Stave Core Assembly

US UK

• US & UK will each build 227 cores, for a total of 454. The US provides tapes, honeycomb, and foam. The UK cooling pipes, closeouts, and locking points.

From the WBS Dictionary

The USA will supply 50% of the barrel stave cores installed in the detector (the rest will be fabricated in the UK) totaling 196 units.

The tasks include:

• LBNL (6.2.1.2.1): procurement and inspection of the tapes, fabrication, test, and inspection of the facing

• Yale (6.2.1.5.2): preparation and procurement of the internal components, the lamination of the cores

• UMass Amherst (6.2.1.10.1): inspection of facings

• Iowa State (6.2.1.6.3): test and inspection of cores

The completed stave cores are sent to BNL where they are used in stave electrical assembly (WBS 6.2.5).


Quantities: Tapes, Facings, Cores

ITEM Quantity Yield Factor

US Staves in ATLAS 196 1.05

US Staves to be delivered to CERN 206

US Staves to be assembled at BNL 206 1.10

Core to be assembled at Yale 227

Facings supplied to Yale (cores x 2) 454 1.08

Bus tapes needed at LBNL 491

Bus tapes needed for production (US & UK) 982

Total bus tapes to order 982


Progress since CD-1: LBNL

▪ Purchased, received, inspected (50) 14-module prototype bus tapes

▪ Coordinated co-cure procedure in with Oxford (GB)


Progress since CD-1: UMass

• Automated electrical QA/QC of all tapes‣ Based on design of Oxford BTR

‣ Measure resistance between all connected pads

‣ Check insulation between neighboring lines

‣ HVIR (High Voltage Insulation Resistance) between

HV lines

‣ Designed to test a tape in less than 1 hour

Oxford BTR

• Status of UMass BTR‣ Primary components received at UMass (table; x, y

and z stages; drives; cameras): Dec. 2018

‣ Precision alignment of x-stages on table (±25μm):

Jan. 2019

‣ Machining of cross plates for y-stages: Feb. 2019

‣ Testing control and motion of x-stages: Feb. 2019

‣ Machining of custom pieces for probe stations (camera

holders, probe holders): Feb.-Mar. 2019

‣ Parts received for and construction of measurement

rack (DVM, HVPS, NI modules): Feb.-Mar. 2019

UMass BTR

Progress since CD-1: ISU

▪ Completed thermal QA tests—slow cycling, fast cycling (400 times)

▪ Constructing FEA—EOS region


Progress since CD-1: Yale

• Fabricated tube/foam jig

• Completing QA/QC stations


Pending Technical/Supply Issues

• Cooling tube (UK deliverable)—2 threats▪ Thin wall titanium tube welds

▪ Insulators (Ceramaseal)

▪ Temporary fittings

▪ QA/QC technique

• Delamination detection▪ Disagreement over technique

o Pressure—damage concerns (UK refuses)

o Tap—manual, instrument ($12K)

o Ultrasound—instrument ($45K)

• Bus Tapes—2 threats▪ Sole source vendor


Prototype, Pre-Pro and Production

• PDR: bus tapes (Apr ‘18), cores (Oct ‘18)▪ Prototype phase

• FDR: bus tapes (Jun ‘19), cores (Oct ‘19)▪ Pre-production phase

• PRR: bus tapes (Jun ‘20), cores (Aug ‘20)▪ Production

• Production completed: bus tapes (Mar ‘22), cores (Nov ‘23)

• External dependencies▪ Tooling designs (Feb ’19—milestone)

▪ Titanium cooling tube assembly

▪ Locking points, closeouts


Schedule and Cost

Schedule

• Prototype ▪ Purchase/fabricate one set of assembly tooling

▪ Commission QA/QC systemso thermal, flatness, delamination, electrical

▪ Purchase and inspect 50 tapes, co-cure 15 facings

▪ Build and test 6 cores

• Pre-production ▪ Purchase/fabricate 1-2 sets of assembly tooling

▪ Finalize multiple co-cure technique

▪ Purchase and inspect 64 tapes, co-cure 32 facing

▪ Build and test 10 cores, maximize efficiency of assembly

• Production▪ 982 tapes, 491 facings, 227 cores—deliver 206 to BNL


Milestones


WBS Milestone Date

SC200340EX Cores PDR 10/1/18

SC500727EX Updated tooling design (Oxford) 2/5/19

SC200382EX Tapes FDR 6/13/19

SC500555EX Cores FDR 10/29/19

SC200440EX PRR 8/19/20

SC201470 Delivery of All Facings 3/7/22

SC502230 Delivery of all Stave Cores 11/1/23

Prototype Materials & Labor Estimates


Table 3: Prototype Core Material Costs

Table 4: Tooling and Testing System Costs

Table 5: Labor Estimate for Tooling and Testing Systems Table 6: Labor Hours for Core Assembly

Pre-production Materials & Labor Estimates


Table 7: Pre-Production Core Material Costs

Table 8: Labor Estimates for Co-cure

Table 9: Fixture/Tooling Costs

Table 10: Pre-Production Labor Hours Summary—Core Assembly at Yale

Production Materials


Table 11: Production M&S Costs

Production Labor


0

50

100

150

PR PP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Lab

or

Ho

urs

/Co

re

Batch

Co-cure & Assembly Labor

Tapes Core

Table 12: Labor Hours Summary—Inspection and Co-Cure at LBNL Table 13: Labor Hours for Core Assembly

• Day 1: receipt, inspection, and preparation

o foam, c-channels, and honeycomb components

o locking points and inserts

o pipe assemblies

o facings (tape testing robot)

• Day 2: glue tube/foam subassembly

• Day 3: glue tube/foam subassembly, c-channel, locking point inserts, end closeouts to facing

• Day 4: glue honeycomb core

• Day 5: machine the partially built core and glue on the top facing

• Day 6: testing

o facings (tape testing robot)

o thermal

• Day 7: Glue locking points

• Day 8: Flatness testing

CD-3a: Stave Cores


Institution Item Task ID Date Materials K$ Explanation

Yale Bus Tapes SC200474M 08/19/2020 32.7 50 tapes

Yale Bus Tapes SC200475M 08/20/2020 444.7 680 tapes

LBNL CF Pre-preg SC200510M 09/08/2020 49.1 75 cores

LBNL CF Pre-preg SC200720M 12/21/2020 52.2 75 cores

Yale Tooling SC500890M 11/11/2019 76.4 1-2 sets

Yale Honeycomb SC501204M 02/06/2020 162.8 150 cores

Yale Foam SC501210M 02/21/2020 54.4 150 cores

BCP: DOE-002 Justification

• Cost estimate included in FY18 budget was $96,000

• Provided by Oxford University (UK), the designer of the tester

• Quotations from US vendors totaled $126,000

• Increase of $30,000 due almost entirely to X & Y linear drive motors and controllers

• Single source vendor (Parker) to match equipment at Oxford


BCP: DOE-004Change Justification

• One Oxford Tape Robot will be used at Yale for bus tape QC• Equipment cost of Oxford Tape Robot is in the project• Expectation was that construction and commissioning of the robot

was a “turnkey” task that could be accomplished by (uncosted) graduate student effort + faculty supervision

• Due diligence revealed during Oxford site visits in Jan/2018 aspects that will require expert technical/engineering effort▪ Electrical services▪ Complexity▪ Safety

• Proposing assembly and commissioning of Tape Robot at UMass, then installed at Yale

• Take advantage of recent expansion of UMass engineering personnel and new dedicated ATLAS lab infrastructure

• New costed tasks added to FY19 budget: $56,675 labor + $2,800 parts

ATLAS HL-LHC Upgrade Project Scrub, BNL, March 11-12, 2019 23J. Ashenfelter

BCP: DOE-005Stave Cores Cost Variance

WBS FY18-25 After ($)

FY18-25 Before($)

FY18-25 Delta($)

Delta(%)

6.02.01 Stave Cores 5,173,788 5,100,933 72,856 1.4

6.02.01.02 LBNL 937,998 962,195 (24,197) (2.5)

6.02.01.05 Yale 3,964,719 3,896,853 67,866 1.7

6.02.01.06 Iowa St 27,830 59,310 (31,480) (53.0)

6.02.01.10 UMass 75,408 60,415 14,993 24.8

6.02.01.90 PM 167,834 122,160 45,674 37.4

• LBNL: Cost reduction due to shortening bus tape co-cure period by 5 months

• Yale: Cost increase due to labor cost escalations

• Iowa State: Cost reduction due to reduced need for QA/QC technical support

• UMass Amherst: Cost increase due to labor cost adjustment

• PM: Cost increase due to additional year of core production oversight


Expected/Actual FY18

• Expected to be building 14-module tooling and cores▪ Built 2 more 13-module cores (#8 & 9)

▪ Adjusted co-cure procedure (consensus with UK)

▪ Constructed thermal imaging and flatness measuring stations

• Expected to transfer QA/QC technology from ISU to Yale▪ Substantially completed

• Expected to purchase all parts needed for tape testing robot▪ Substantially completed (BCP)


Risk and Uncertainty

Risk and Uncertainty


RISK RANKING (Probability vs Impact)

Threat

Low

Impact Medium Impact

High Impact

2 3 7

Technical Impact Slightly

Sub-standard Moderately

Sub-standard

Significantly Sub-standard or KPP in jeopardy

Cost Impact < 100 k$ (100-250) k$ > 250 k$

Schedule Impact < 2 months (2 – 6) months > 6 months

Pro

bab

ility

Very High 65 – 100% 50 100 150 350

High 40 – 64% 40 80 120 280

Moderate 20 – 39% 30 60 90 210

Low 10 – 19% 20 40 60 140

Very Low 0 – 9% 10 20 30 70

• High Rank (red) risks could lead to failure to complete a major deliverable within cost, schedule,

or quality constraints and may jeopardize the project’s KPPs. Well-developed mitigation and

response plans are required for High rank risks.

• Medium Rank (yellow) risks could have significant impact on the deliverable cost, schedule, or

quality, but are not expected to impact project KPPs. Mitigation and response plans must be

prepared for Medium rank risks.

• Low Rank (green) risks can lead to modest technical, cost, or schedule impact, but will have no

effect on the project’s KPPs. Mitigation and response strategies for these risks are not required

to be as detailed as those for Medium and High ranked risks.

Closing Remarks

• Group is steadily progressing toward production▪ Co-curing and testing tapes

▪ QC testing systems are coming together

▪ QA tests have all been positive

▪ Experience building 13-module cores

• Reliant on UK▪ Schedule impact due to delays in design

▪ Supply chain issue due to availability of cooling tube


BACKUP

Jeff Ashenfelter

• Associate Director for Operations, Wright Lab @ Yale ▪ Oversee laboratory operations and technical staff

▪ Responsible for EH&S (Safety Officer)

▪ Support 15 Principle Investigators

• ATLAS upgrade project▪ US L3 Manager—Stave Cores

▪ CERN Activity Coordinator—Local Support Cores

• Other projects▪ PROSPECT

• Past experiences▪ Director, Accelerator Operations, WNSL, Yale

▪ Supervisor, Reactor Plant, USS Kamehameha, US Navy


Institute Capabilities

• Facilities available▪ LBNL: laboratory space, clean room, machine shops

▪ Yale: laboratory space, clean rooms, machine shops

▪ ISU: laboratory space, machine shop

▪ UMass: laboratory space, machine shop


BCP: DOE-002Cost and Schedule Report

• Cobra report: Before and After Delta = $30,900

• P6 Schedule Impact: linked to original material purchase, caused 5 days delay for ATLAS FDR

• UMass BCP will link between material purchase and FDR

• ATLAS FDR will be moved to July 2019 due to CERN re-baseline


Strips Total Before and After Delta

Cost Set BCWS

Sum of Total Column Labels

FY17 FY18 FY19 FY20 FY21 FY22 FY23 FY24 FY25 Grand Total

Row Labels TOTAL COST TOTAL COST TOTAL COST TOTAL COST TOTAL COST TOTAL COST TOTAL COST TOTAL COST TOTAL COST

After 273,292.59 3,742,380.44 6,152,409.97 7,121,008.86 5,770,741.40 5,043,695.24 4,160,556.20 2,889,467.22 789,225.27 35,942,777.20

Before 273,292.59 3,711,480.44 6,152,409.97 7,121,008.86 5,770,741.40 5,043,695.24 4,160,556.20 2,889,467.22 789,225.27 35,911,877.20

DELTA - 30,900.00 - - - - - - - 30,900.00

BCP:DOE-004Cobra Delta Report

• Cobra report: Before and after Delta = $59,475 in FY2019


BCP: DOE-004P6 Delta Report

• P6 Schedule Impact: This is a new labor task in parallel with tasks already in P6

• Requires strict beginning and ending dates

• Proper linkages cannot be implemented until Yale Stave core task list is updated


Thermal Imaging set-up

• IR camera: FLIR A655sc w/ 80° wide-angle lens

• Cooling System▪ Recirculating Chiller: Sp Scientific RC211B0

T Range (-80 °C → +50 °C)

▪ Booster pump for higher pressure(> 250 psi @ -60 °C)

▪ Coolant: 3M Novec HFE 7100

▪ Computer controlled actuator valves w/ bypass (Allows for thermal shocking)

• Low humidity enclosure

J. Ashenfelter 35ATLAS HL-LHC Upgrade Project Scrub, BNL, March 11-12, 2019

Laser Scanning set-up

• Vere optical bench• 1.5 m linear stage• 2M pixel camera with 660 nm filter• Each side of stave is scanned at 5PSI and 0PSI pressure

(multiple times). Facing-to-honeycomb defects are apparent in the difference between scans.


Original “Slow” Thermal Cycling

• 100 cycles were done on US core 2R▪ Program waits for avg. stave

temp. to get to ~-37 C and ~20 C respectively. It waits for stabilization before moving onto the next cycle

▪ For cooling |dT/dt| was ~0.04 C/sec taking about 20 minutes to reach the cutoff

• Shown are last 10 cycles • No new defects or changes in

existing defects were found


“Fast” Thermal Cycling

• Cycled US core 6 with chiller temp set to -55 C and a flow rate through the core of ~1l/min cycling 400 times as follows:▪ Wait in bypass mode: (Stave core returns to

11C over 18 min)▪ Wait in stave mode: (Stave core drops to ~-37

and holds it for around 12 min)▪ Tests found that we could achieve a max

|dT/dt| of ~13 C/sec on the cooling part

• Second set of 10 cycles: average temperature across the stave core from thermal image


Thermal Shock Tests

• Average stave temp extracted from stave core images taken during the cycling▪ Inlet Temp is an average from

Line 2

• Tests found that we could achieve a max |dT/dt| of ~13 C/sec by having the actuators in bypass mode then switching the actuators to stave mode


wbs 6.2.1 stave cores · us staves to be delivered to cern 206 us staves to be assembled at bnl 206...

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