Thermal Control System TCS status report

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Thermal Control System (TCS)status report

• Joseph Burger (MIT)
• Christian Vettore, Massimiliano Olivier, Marco
  Molina (CGS)

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Topics

• Main radiators
• Crates/xPD/MLI bonding
• Heater architecture design and wiring
• CAB TCS status
• MLI status and next steps
• CRYO TCS status

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CRATES/XPDs bonding issue

• Bonding issue was brought-up at the last TIM.
  Taking advantage of having the crates / jigs
  installed on the USS, it was agreed that with
  the obstructions posed by additional hardware and
  cabling, the bonding strap fixation would result
  quite difficult.  Getting access for the tools to
  torque the fasteners would be the most difficult
  part.
• Because of this, the grounding philosophy has
  been revisited all over these three months thru a
  discussion involving JS/AMS Collaboration people
  and CGS.

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AS IT WAS
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BONDING REQUIREMENT CONSOLIDATION

• Bonding class
• Class H (0.1 ohm for powered electronics) / Class
  S (1.0 ohm for dumb metal / blankets) are the
  only safety requirements imposed by NASA and they
  can be easily met with wire.
• Class R (RF bonding). Shortest possible (aspect
  ratio 5/1), fat braid to earth (chassis, etc) on
  each subsystem reducing the probability of a
  subsystem acting like an antenna. The DC portion
  of the Class R (2.5 mOhm). The RF bonding is a
  mission assurance EMI requirement.
• Number of bonding (number of straps per crate)
  and class type
• CRATES/xPDs do not need QTY 2 class R (RF) bonds.
  They need to respect safety req. (class H) and a
  as close as possible to RF bond for EMI reasons.
• For class H it was decided to rely on the
  conduction of the alodined links to make the
  crate assy one entity electrically . This means
  the crate assembly is one large, electrically
  conductive structural piece.
• For class R dedicated short flat braids were
  defined.
• RESULT All interior - hard to reach - ground
  straps can and have been removed. The external,
  reachable straps are the RF straps.
• The Class H requirement is met by electrical
  conduction provided by links

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Crates/XPD RF bonding strap

• Flat copper braid Nickel plated
• Copper nickel-plated terminals
• Aspect ratio 51
• STRAPS HAVE BEEN ORDERED

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SHV BONDING REQUIREMENTS

• SHV has no links that connect the box to the
  other structures. We have ONLY ONE bonding pad on
  the SHV. That was aligned with the original
  request.
• This has been OK, after meeting between Tim Urban
  and EMEP representative (16thJune) a single
  (one) Class R is OK for these boxes. Or as near
  to R as possible. No need for a second bond.
• The use of a bonding wire (AWG16-12 with 2
  eyelet) meets Class H, which is the absolutely
  mandatory safety requirement.  However, it is
  very strongly preferred that a single Class R
  bond should be used for EMI reduction. 

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• PICTURE WITH THE BONDING PAD

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What makes SHV discussion different ?

• The SHV1 (RAM) and SHV0 (WAKE) have been 180deg
  rotated wrt. its original position. In turns the
  bonding insert should have been moved but this
  would have caused a delay in the panel
  manufacturing. In order to cope with that it was
  decided to replace the bonding strap with a
  bonding wire (AWG16-12 with 2 eyelet).
• In any case none of the foreseen bonding inserts
  on the radiator is used for bonding (neither for
  lower not for upper-rotated SHVs). Same issue
  previously mentioned about reaching the straps
  once the radiator is mounted.
• In taking decisions for the bonding it shall be
  considered that once the radiator jig is removed
  the SHV boxes have to be kept in place someway

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TSPD-main wall left
GP_SHV1
GP1
GP6
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UPD0
TSPD1
GP4
GP_SHV0
SHV-0
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Galvanic corrosion prevention

• Any bond location, even if it does not involve
  dissimilar metals (i.e. alodined Al to alodined
  Al at links) needs to have Super Koropan applied
  along the edge to prevent corrosion in moist
  atmosphere on ground.  The fact that it is an
  electrical bond implies some small current, which
  creates the same galvanic corrosion cause by
  dissimilar metals.  This must be done for
• links (when crates laid out flat)
• exterior straps
• blanket terminals
• The SuperK is applied around the periphery of
  the joint - after assembly, and it is not inside
  or between layers of the joint.

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Main Radiator heater architecture and wiring

• All the RAM/WAKE Electrical and Thermal H/W to
  complete the heater bus installation is in our
  hands
• RAM Heater connector bracket and Terminal blocks
  H/W clamps manufacturing started at CERN.
• Paper documentation (i.e. wiring table ,
  procedures) are in progress.
• Crimping test to qualify the process is on-going
  and it will be finished by the arrival of the
  main RAM and WAKE radiators

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MAIN RADIATOR INTEGRATION FLOW NOTE
CGS THERMAL HARDWARE INSTALLATION ON PANEL
RAM PANEL INSTALLATION ON GEMINI
RAM PANEL _at_CERN
RAM PANEL STORAGE
CGS THERMAL HARDWARE INSTALLATION ON PANEL
WAKE PANEL _at_CERN
WAKE PANEL STORAGE
CAB LHP INSTALLATION ON WAKE RADIATOR
CAB REINSTALL AND LHP CONNECTION TO CAB
WAKE PANELCAB LHP INSTALLATION ON GEMINI
WAKE PANELCAB LHP STORAGE
CAB REMOVAL
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SCHEDULE

• MAIN RADIATORS (CGS) THERMAL H/W INSTALLATION
  not later than October 23th 2008
• AVAILABILITY IN CERN CLEAN ROOM OF MAIN
  RADIATORS AND SUITABLE HANDLING JIG NOT LATER
  THAN September 23th 2008

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• CAB TCS status

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CAB TCS parts
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CAB TCS update

• CAB LHP Design consolidation
• Routing finalized (two minor modifications
  introduced)
• Flexibility test performed
• USS heat pipes design consolidation
• Manufacturing and procurement status

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CAB LHP design update 1\

• The saddle design has been modified and the long
  saddles have been replaced by shorter pieces to
  meet the required planarity.

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CAB TCS design update 1\

• SAMPLES OF SADDLES HAVE BEEN MANUFACTURED.
  TESTING IS IN PROGRESS TO VERIFY FINAL PLANARITY
  OF SADDLES WHEN LHP TUBES ARE SOLDERED.

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CAB LHP design update 2\

• The compensation chamber size has been modified
  and the current compensation chamber is 12mm
  longer.

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CAB LHP design update 2\
Being the external envelope not affected by the
change , the verification of the integration
sequence doesnt need to be repeated
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USS heat pipes
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CAB LHP flexibility

• At the last TIM the CAB LHP system was considered
  suitable for manufacturing authorization but a
  minimum flexibility was required. A flexibility
  of 12deg/-1 is required between the evaporator
  and the condenser to allow the CAB LHP/WAKE rad
  insertion
• Two options
• Add pig-tails to match the requested/needed
  flexibility in the plumbing
• Make a test of the plumbing w/o pig-tails

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CAB LHP flexibility
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CAB TCS LINES FLEXIBILITY TEST SAMPLE
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CAB TCS LINES FLEXIBILITY TEST RESULTS
NO PLASTIC DEFORMATION FOR ANGLES lt 14deg, MINOR
YELDING UP TO 20 deg
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CAB TCS (LHP excluded) parts procurement and
manufacturing status

• Heaters Ordered.
• Circular connector delivered.
• Circular connector bracket under manufacturing.
• Silver Teflon Tape delivered.
• Thermostats delivered.
• MLI on zenith and nadir faces of the CAB to be
  designed and produced.
• Choterm for LHP evaporator interface USS
  interface CAB heat pipes interface to be
  ordered.
• CAB /USS heat pipes ordered.
• Glue for the fixation of the heat pipes ton the
  USS ordered.
• USS heat pipes Clamps under manufacturing.
• Fasteners for thermostats, connectors, heat
  pipes , brackets - ordered

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LHP Manufacturing status

• CAB valve assembly complete
• CAB evaporator saddle complete
• CAB transport line bending tools under
• production

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CAB TCS schedule

• CAB LHP Delivery at CERN December 19th 2008
• Other CAB TCS H/W Installation on CAB FM not
  later than September 25th 2008

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• MLI status

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MLI design and manufacturing process

• A discussion took place on Monday this week
  between CGS/AMS Coll representative/NASA to
  review all the MLI design and installation
  process.
• The complete MLI production schedule, proposed by
  CGS, has been presented
• The main conclusions of the meeting have been
• NASA has asked to improve the MLI design approval
  process suggesting to have at the beginning of
  the design phase concept design sketch to
  immediately get an idea how the blanket is
  conceived. No details, just hardware sections
  with envelope lines and attachment methods.
• This conceptual design shall be reviewed in a few
  days by NASA and shall be the starting point for
  the blanket detail design that shall be anyway at
  the end reviewed by NASA and authorized for
  production.
• Tight blankets shall be avoided. MLI blankets
  shall be fluffy. Build bigger blankets. This
  under the assumption that the final fine
  tailoring of the blankets to fit late hardware
  features not foreseen shall be done on-site by
  NASA personnel.

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MLI production plan

• After the review of the plan, most blankets CGS
  proposed delivery dates and fit-check are
  adequate for AMS integration planning considering
  also availability of NASA personnel for late
  modifications where needed.
• For some blankets different dates considering
  the general integration flow are needed. They
  seem to fit with the supplier MLI manufacturing
  capability CGS shall check and confirm asap.

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MLI next steps

• Since last April TIM an MLI integration slot has
  been planned for 04-08 August 2008
• (11) blankets manufactured and delivered to CERN
  (XPD-crates INTERNAL MLI).
• (12) After April fit-check RICH SYS blankets have
  been authorized and are under manufacturing
• (4) RICH LATERAL MLI - delivery_at_CERN 12/09/08
• (4) LTOF MLI - delivery_at_CERN 12/09/08
• (4) ECAL CORNER ZN MLI - delivery_at_CERN 12/09/08
• (TBD gt20) blankets design in-progress (XPD-crates
  EXTERNAL MLI)

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These 12 blankets are under manufacturing

• LTOF MLI fit-check (4 blankets)

• RICH LAT MLI fit-check (4 blankets)

• ECAL CORNER (ZN) MLI fit-check (4 blankets)

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MLI next steps

• A further Integration slot had been planned for
  September 08 at CERN for dedicate second
  fit-check of support rings blanket with MAGNET
  H/W or suitable mock-ups.
• CGS is evaluating the possibility of removing
  this second fit-check delivering larger blankets
  to be tailored in place by NASA to compress
  delivery schedule.

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XPD-crates INTERNAL MLI Ram side (6) blankets
Internal blankets
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XPD-crates INTERNAL MLI ram side grounding
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TSPD-main wall left
GP_SHV1
GP1
GP6
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XPD-crates INTERNAL MLI wake side (5) blankets
Internal blankets
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XPD-crates INTERNAL MLI wake side grounding
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XPD-crates IN-EXTERNAL MLI side fixation method
on XPD
Velcro for IF with INTERNAL blanket
Velcro for blanket fixation on the unit
INTERNAL blanket
XPD
cables
radiator
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XPD-crates IN-EXTERNAL MLI side fixation method
on crates
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MLI PLANNING 04/08-08/08 activities
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04/08-08/08 INTEGRATION SEQUENCE for XPD-crates
INTERNAL MLI

• Bonding of MLI attachments (Velcros, Tie mounts)
  according to the standard procedure in
  QSTD-MPRC-3054-AAE. Positions according bonding
  drawings included in the ADP.
• After the 24hr of curing time the adhesive is
  dry for a careful usage of the MLI attachments.
• 2) Integrate the FM MLI blankets according to
  paragraph 8 of QSTD-MPRC-3054-AAE and the
  assembly sketch in the ADP
• Routing of structural bonding leads - fixation by
  Kapton tape.
• Connect the grounding wires according to
  paragraph 8 QSTD-MPRC-3054-AAE. And record the
  hardware used to fasten the wire, the torque
  wrench calibration data, the torque applied to
  the screws
• Measure with a calibrated Ohmmeter (attach the
  calibration data sheet to this ATS) the total
  resistance and record the values in the ADP
  section

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Up-coming integration steps Internal/External
MLI

• Jig Horizontal
• 1\ install SHV MLI SHV bond strap (SHV side -
   this is shared with one of the two  MLI grounds)
  covered by MLI ATS
• 2\ install internal MLI blankets and
  corresponding bonding point to crate/xPD side
  covered by MLI ATS
• 3\Install straps as soon as we can even if they
  are the exterior ones
• 4\ Install if really needed the internal
  straps that might be difficult later
• Jig Vertical
• 5\ install external blankets when the radiator
  jig is vertical . The MLI bond at the radiator
  side (where applicable) remains floating till the
  radiator comes. Crates bonds need to be done
  later when radiator is in position. Only the
  crate side of the bond might be fixed. Fix it! In
  any case the blankets shall not prevent crates
  from running.
• 5\A Another possibility is to install external
  blankets while the USS is in the PSS with the
  Jigs on. Waiting for the magnet.

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21-24 April 2008 MLI Integration slot
VC Upper Skirt MLI
USR MLI
LSR MLI