Operation phase technical requirements, testing plan, resources and cost estimates

2. Operation phase technical requirements, testing plan, resources and cost estimates P. Schnizer on behalf of FAIR project team members L. Serio on behalf of bldg. 180 test facility project team members (TE and EN departments)

3. Outline • Introduction • Technical Requirements • Testing Plan • Baseline • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

4. Introduction According to the last collaboration meeting we have proceeded with the review, optimisation and minimization of the test program and overall test plan in order to fit within the allocated 3 years for the testing phase. Several meetings have taken place between CERN and FAIR personnel leading to the baseline scenario, the minimized plan and alternative reduced scope proposal. A preliminary resources and cost estimate has been prepared together with the main competences (field of expertise required). L. Serio, P. Schnizer et al.

5. Outline • Introduction • Technical Requirements • Testing Plan • Baseline • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

6. Technical requirements • A magnetic measurement request template has been prepared by CERN to provide the detailed requirements of the tests to be performed at ambient temperature and cold conditions • This database is being populated by FAIR • A preliminary review of the requirements and optimisation (reduction) of tests in order to reduce the cold testing to 13 days; main points: • Measure of field maps and harmonics only for dipoles and for each prototype only • No warm up before processing of the data and assessment; preliminary assessment after one week; this requires an on-site assessment team to take on-line decision on acceptance of tests and warm up • Can use the same fluxmeter for all dipole magnets with 3 segments • Absolute field integral measured with 5 *10^-4 accuracy • All the same hysteresis cycle but no demagnetisation cycle required • Longitudinal magnetic centre to be measured (exact center of the magnet) • After prototype detailed measurement only need magnet to magnet relative measurement; thus expected tp go from 12 down to only 4 points current level testing • Measure magnets reproducibility (harmonics) instead of individually map the field; • Proposal to reduce the number of current level for everything else than main dipole and quadrupole • High voltage tests only between neighbouring magnets and ground • Testing of voltage taps and DAQ preparation in parallel • Increase cool-down / warm-up speed from 1 K/h up to about 2 K/h (maximum cryogenics capabilities, to be checked on prototypes) • Installation, preparation and dismantling activities streamlined L. Serio, P. Schnizer et al.

7. Outline • Introduction • Technical Requirements • Testing Plan • Baseline and minimised • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

8. TestingProgram Evaluation • Test Program • Industry Tests • Tests on Test Benches • Preparation Tests • Cold Tests • Final Tests • Tests during Installation and Commissioning L. Serio, P. Schnizer et al.

9. TestingProgram Evaluation: Industry Test I/II selected Tests: • Material Tests • Conductor: critical current, n-Value, geometry, CuSc ratio, RRR • Yoke material: BH – curve, Hc value (for each roll) • Cryostat / cold mass components: certificates, approved welding etc. • Magnets • Magnet geometry: • punch die, • lamination geometry, • magnet geometry, • magnet pole assembly geometry • coil geometry • Magnet weight • High voltage Tests • Polarity Tests L. Serio, P. Schnizer et al.

10. TestingProgram Evaluation: Industry Test II/II selected Tests: • Magnet Assembly: • Geometrical tests of magnet column (multiplett) • Fiducalisation / transfer: • magnet column • cold mass vessel • cryostat fiducials • Sensor Tests • Continuity Tests • High Voltage Tests • Pressure Vessel Tests • compliance with European rules • in particular “TÜV” • acceptance as pressure vessel L. Serio, P. Schnizer et al.

11. TestingProgram Evaluation: Reception Tests • Proper Transportation • Shock Sensors • Visual Inspection • Papers delivered • “Worth to put on bench” • Test Sensors functional • High voltage tests L. Serio, P. Schnizer et al.

12. TestingProgram Evaluation: On Bench at Warm • On bench • test equipment preparation • sensor tests • high voltage tests • continuity tests • During cool down • leak test monitoring • sensor tests • Cool down finished • sensor tests (all active) • high voltage tests L. Serio, P. Schnizer et al.

13. TestingProgram Evaluation: Test At Cold • Power tests • Voltage taps tests • Quench Detection System check • Ramp up to 110% of nominal • Ramp of all Magnets up and down (three times) • Magnetic Measurement • Measurement of integral strength and axis (SSW) • Information to GSI • Measurement of field quality • Agreement with GSI on warm up • Comments: Reduced current levels in series: magnet to magnet comparison, adjustment in series • Test of Stationary Loss • boil off during weekend L. Serio, P. Schnizer et al.

14. TestingProgram Evaluation: Finalisation • Test after Warmup • Test of Sensors • High voltage Tests L. Serio, P. Schnizer et al.

15. TestingProgram Evaluation: Commissioning I/II • Commissioning Tests • Repetition of: • Transport Checks • Visual Inspections • Documentation Checks • High voltage Tests • Instrumentation Tests • Leak Tightness Tests • Electrical Parameters (inductance, resistance) • Connection • Electrical • Cryogenic • Tests • High voltage tests • tightness of process lines • polarity • sensors / instrumentation L. Serio, P. Schnizer et al.

16. TestingProgram Evaluation: Commissioning II/II • Cool down • check of sensors during cool down • vacuum / leak tightness • temperatures • At cold: • High voltage tests • Continuity Tests / Voltage Taps Tests • Magnet Powering: • Polarity tests (assymmetric voltage taps) • Magnet Protection System • Magnet Powering to Nominal • Ramping individual magnet assemblies to nominal • Ramping all magnets to nominal L. Serio, P. Schnizer et al.

17. Outline • Introduction • Technical Requirements • Testing Plan • Baseline and minimised • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

18. Reviewed test program and time L. Serio, P. Schnizer et al.

19. Test sequencing optimization L. Serio, P. Schnizer et al.

20. Optimal overall duration L. Serio, P. Schnizer et al.

21. Outline • Introduction • Technical Requirements • Testing Plan • Baseline and minimised • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

22. Tests duration comparison • Request → investigatenumberoftestbenches • originally • 4 benchestomatch FAIR masterscheduledemanded • 3 testbenches: maximumfeasible: • space • precoolers • coolingcapacity • → bestuseofinfrastructure • 2 testbenches: • reducemeasurementprogram • increaseoverallproject time line • outlined on thenextslides L. Serio, P. Schnizer et al.

23. Tests duration comparison • 3 benches • 15 daysofcoldtest: solid testprogram • 13 daysofcoldtest: testprogram, nomargins, noslips • 2 benches • extendscheduleto 6 years (2023) • ornomagneticmeasurement (spectrometer!) • not included (furtherextend): Panda • mappingofdipoleswith „branchexit“: currentlyassumedtobemappedwithinthe 2 weeksofmagneticmeasurement • TB ... testbench • PC ... precooler L. Serio, P. Schnizer et al.

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

25. Alternative scenarios (2TB-2PC with a later upgrade to 3TB-2PC) LS2 Nota: a. Delayed decision / financing b. Increased overall cost c. Reduced testing capabilities and time for prototypes L. Serio

26. Outline • Introduction • Technical Requirements • Testing Plan • Baseline • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

27. Resources and cost estimate(core operation team not inclusive of GSI acceptance team and CERN on-call support for troubleshooting) L. Serio, P. Schnizer et al.

28. Resources and cost estimate L. Serio, P. Schnizer et al.

29. Outline • Introduction • Technical Requirements • Testing Plan • Baseline • Alternatives • Reduced number of benches • Resources and cost estimates • Conclusions L. Serio, P. Schnizer et al.

30. Conclusions 1/2 • The test requirements, program and duration have been reviewed and optimized • A parametric study of various alternatives and configuration has been performed • The baseline test program of 15 days at cold requires an overall testing time of almost 4 years • If the test programm is reduced to 13 days the cool down and warm up speed of 1K/h are the limiting path and the total test time will take less than 3.5 years • The minimum overall test duration is reached with 10 days at cold and reduced cool-down/warm up and/or installation/dismantling (2.5 years) • There is no contingengy, margins or time to repeat tests or perform adjustments • Short multiplets will be tested first in order to have some margins (time) during the start of series testing operation • It is not possible to postpone the decision of the second pre-cooler • thus financing is required now • It would be possible to delay the decision on the financing of the 3rd test bench later during the prototype tests but the overall program will be delayed by about 9 months, the cost will be significantly higher and start of the test facility will run in parallel with the preparation of LS2 L. Serio, P. Schnizer et al.

31. Conclusions 2/2 • The required material cost and resources during a 4 years operation period corresponding to the baseline (0.5 years prototypes and 3.5 years series testing) have been estimated: • material cost (inclusive of electricity): 4.4 MCHF (1.1 MCHF/year) • material cost (w/o electricity): 3 MCHF (0.75 kCHF/year) • resources: 12 FTE-y ENG (3 ENG); 14 FTE-y technicians (3.5 TECH-ENG) • A preliminary inventory of competences has been made • a part time cryogenic supervisor engineer and one operation team leader technical engineer + operators • a magnetic measurements and analysis engineer + support technicians/operators • a test facility test coordination and operation engineer • two test facility electromechanical technicians • a part time survey technicians • a part time data acquisition and industrial control engineer • These resources, if made available in the next 6 months, can provide part of the missing construction support and be trained for the future operation of the facility L. Serio, P. Schnizer et al.