From Here to Construction

1
From Here to Construction

• Michael Hebert
• UC Irvine
• January 20, 2003
• NSF RSVP Review

2
Outline

• For each Level 2 WBS
• Remaining RD tasks
• Additional resources needed, if any, including
  what is and what is not included in the pending
  RD proposal
• Schedule to complete all tasks and baseline the
  subsystem
• Revised Construction Cost Estimate
• The impact of delaying a start until FY05 or FY06

3
Notes

• We have deferred many tasks for lack of funds,
  however we need to define the interfaces to the
  solenoids now. The following schedule assumes
  that additional money is available
• Proposed 3.1M RD grant begins on 4/7/03
• 20 supplemental funds on the existing grants are
  available on 2/28/03
• Delays in either push the schedule out, i.e.
  funded tasks are on the critical path
• The pending RD proposal was limited to 3M, not
  because we cannot gainfully spend more, but
  because we thought it unlikely that we could get
  more. We will note for each task what is in the
  request and what goes beyond it.
• Comments about the MS project file you have on
  the CD-ROM
• Allows you to investigate directly the impact of
  delayed funding
• Tasks in it are for the most part NOT
  effort-driven, e.g. resources indicate
  responsible people, but anticipated fraction of
  effort is only included for Engineering and Design

4
WBS 1.1 AGS Mods RD Schedule

• We need to study, bunch intensity limits, 8 GeV
  bunched beam extraction, and the extent to which
  we can tune to reach 10-9 level of extinction.
• Estimated 627k cost precluded this effort from
  the RD proposal
• In addition to the substantial funds, we need for
  Mike Brennan to have some time to work on MECO

Subsystem Baselined 1/2/04
5
WBS 1.2 Proton Beam Tasks

• In the pending proposal 291k
• Shielding design
• A portion of instrumentation controls design
• RF Modulated Magnet conceptual design, but no
  prototype
• Additional resources required for these tasks
• We need for Kevin Brown to have some time to work
  on MECO
• Additional tasks to baseline
• Prototype module of RF magnet
• Engineering (9 weeks) and Design (10 weeks) time
  for developing preliminary designs and detailed
  costs for all beamline components
• Additional resources required for these tasks
• 293k

6
WBS 1.2 Proton Beam Line Schedule 1
7
WBS 1.2 Proton Beam Line Schedule 2
First need for additional funds
Subsystem Baselined 2/13/04
8
WBS 1.3 Target Shield Tasks

• In the pending proposal 87k
• Further stress analyses of radiation cooled
  target
• Heat and Radiation Shield conceptual design
• Target handling, mounting, and cooling system
  design
• Additional resources required for these tasks
• Identify a full-time Target Subsystem Manager
• Additional tasks to baseline None

9
WBS 1.3 Target Shield Schedule 1
Target Design Approved
10
WBS 1.3 Target Shield Schedule 2
First need for additional funds
Subsystem Baselined 7/30/04
11
WBS 1.4 Solenoids

• In the pending proposal 368k
• Tolerance Studies
• Magnetic Verification System conceptual design
• PS and DS return yoke designs
• Additional resources required for these tasks
• No additional funds are required, however a
  portion of these funds are needed very soon (the
  schedule assumption is 250k by March 1)
• Additional tasks to baseline None

12
WBS 1.4 Solenoids Schedule 1
13
WBS 1.4 Solenoids Schedule 2
14
WBS 1.4 Solenoids Schedule 3
First need for additional funds
15
WBS 1.4 Solenoids Schedule 4
Draft RFP Released 7/2/03
16
WBS 1.4 Solenoids Schedule 5
Subsystem Baselined 11/6/03
Final RFP Released 12/11/03
Engineering Design Commences 7/1/04
17
Muon Beamline Studies

• In the pending proposal 260k
• Collimator, Beam Stop, Proton Absorber, and
  Detector Shield designs
• Detector supports and installation procedure
• Vacuum system design
• Measurements of neutron and proton spectra from
  nuclear de-excitation using stopped muon beam at
  TRIUMF (existing funds)
• Additional resources required for these tasks
• We need to expand simulation efforts at the Lab
• Additional tasks to baseline None

18
WBS 1.5 Muon Beamline 1
First need for additional funds
19
WBS 1.5 Muon Beamline 2
20
WBS 1.5 Muon Beamline 3
Subsystem Baselined 8/6/04
21
Tracker RD Plan

• In the pending proposal - 840k
• Complete assembly of the full-length vane
  prototype
• Mechanical and electrical tests with prototype
• Revise the BaBar Elefant chip for MECO use a
  joint venture between Houston and LBNL
• Prototype boards to use the Elefant chip
• Full-time mechanical engineering support
• Design and prototype a low mass manifold
• Osaka development of 3 m seamless straws (more
  details next)
• Additional resources required for these tasks
  None
• Additional tasks to baseline
• Pending the decision on the geometry we will
  either need to pursue a second full-length vane
  prototype or pursue 15 mm thick straws
• Additional resources required for these tasks
• 54k

22
Seamless Straw RD Plan

• Production
• Length is limited by the size of oven in which
  the Polyamide is polymerized
• Single straw cost is high due to the number of
  production processes
• High-Rate Tolerance requires distributing
  charge to the cathode faster than the resistive
  straw can supply it.
• Strategy
• Manufacture the a 3 m oven and study the
  mass-production techniques
• Find another material such as PEEK Carbon that
  can be extruded
• Much better for mass-production with lower unit
  cost
• Straightness might be an issue
• Build and beam test a 2nd generation prototype in
  a high-rate environment
• PEEKCarbon or much longer PolyamideCarbon
• Tube grounding
• Improved readout electronics

23
WBS 1.6 Tracker Schedule 1
24
WBS 1.6 Tracker Schedule 2
Geometry Decision
Mutually Exclusive
Readout Architecture Decision
Subsystem Baselined 11/12/04
25
Calorimeter RD Program For This Year

• Single Channel Tests
• Use chiller (0.01 deg C, 150 watts _at_ -20 deg
  C) to continue tests with better temperature
  control
• Add and study new low noise fast charge
  sensitive preamp
• Vacuum (10-4 10-6 torr) to investigate
  associated special problems
• APD voltage (2 kV) control and stability
  against breakdown
• Heat transfer in vacuum for electronics
  cooling and crystal temperature stability
• Nine Channel Tests
• Cosmic ray studies
• Vacuum chamber and chiller will accommodate
  
  8 x 8 crystal array
• Add fast trigger sum to shaper circuitry
• Beam tests
• Study again all of above
• Study nuclear counter effect
• Study rate effects to settle on preamp/shaper
  parameters
• Sixty-four channel system assembly and tests

26
Calorimeter Support

• In the pending proposal - 490k
• Beam testing of the prototype 3 x 3 arrays
• Funds for construction of an 8 x 8 prototype
  crystal array including photodetectors, cooling,
  calibration, and readout electronics
• Note if we go with PbWO4 instead of BGO, the
  costs decrease somewhat
• An electrical engineer for readout electronics
  development and a technician to assist in crystal
  and readout prototype construction
• Additional resources required for these tasks
  None
• Additional tasks to baseline None

27
WBS 1.7 Calorimeter Schedule
Crystal Material Determined
Subsystem Baselined 12/7/04
28
WBS 1.8 Cosmic Ray Shield Tasks

• No support in the pending proposal. Costs are
  covered with existing funding support.
• Complete tests with new four quadrant PMT with
  existing scintillators
• Extrusion of full-length samples this summer at
  FNAL facility
• Additional resources required for these tasks
  None
• Additional tasks to baseline
• Engineering (2 weeks) and Design (2 weeks) time
  for developing preliminary designs of counter
  support system
• Additional resources required for these tasks
• 26k

29
WBS 1.8 Cosmic Ray Shield Schedule
Subsystem Baselined 10/7/03
30
WBS 1.9 DAQ Trigger

• In the pending proposal - 241k
• Support for BUs Electronics Design Facility
• Components, prototype boards, test equipment
• Additional resources required for these tasks
  None
• Additional tasks to baseline None

Subsystem Baselined 3/30/04
31
WBS 1.10 Infrastructure Tasks Schedule

• In the pending proposal
• AGS Liaison Engineer and MDMG support is covered
  in 1.11
• Additional resources required for these tasks
  None
• Additional tasks to baseline None

Subsystem Baselined 10/13/03
32
WBS 1.11 Project Management Tasks

• In the pending proposal 315k
• AGS Liaison Physicist and Liaison Engineer
  support
• BNL MDMG and Contracting Officer support
• Primavera cost and schedule software system
  licenses, install, training
• Support for additional internal reviews
• Additional resources required for these tasks
  None
• Additional tasks to baseline
• Support for Cost and Schedule Manager I would
  like to get this individual on board prior to
  baselining for obvious reasons
• Additional resources required for these tasks
• 122k

33
WBS 1.11 Project Management Schedule
Subsystem Baselined 12/5/03
MECO Baselined 12/7/04 (Pearl Harbor Day)
34
Proposal Budget 1
35
Proposal Budget 2
36
Additional Pre-Construction Costs
37
High Level Milestone Summary
Milestone Date
Tracker Geometry Decision 5/03
Draft Solenoid System RFP Released 7/03
Tracker Readout Architecture Decision 9/03
Cosmic Ray Shield Baselined 10/03
Solenoids Baselined 11/03
Calorimeter Crystal Decision 11/03
Infrastructure Baselined 11/03
Final Solenoid System RFP Released 12/03
Project Management Baselined 12/03
AGS Mods Baselined 1/04
Proton Beamline Baselined 2/04
Target Design Approved 2/04
DAQ Trigger Baselined 3/04
Solenoid Engineering Design Commences 7/04
Target Shield Baselined 7/04
Muon Beamline Baselined 8/04
Tracker Baselined 11/04
Calorimeter Baselined 12/04
MECO Baselined 12/04
38
Changes Affecting Construction Costs

• Increased BNL labor rates and overhead adds 1.3M
  
• Increased material costs by 4 for inflation from
  FY02 estimate.
• The MIT construction cost estimate is
  significantly higher than NHMFLs
• Design costs are similar
• Refrigerator cost is simply scaled from 1.5kW to
  1.0kW we will have new data on this shortly
• Fabrication and installation costs are higher.
  These costs are being scrubbed by MIT, a cost
  driver is being studied by General Atomics, and
  we are getting an independent cost estimate.
• Oversight is higher since three FTE for MECO
  oversight of the construction vendor are assumed
  rather than the two originally budgeted.
• Added a full-time QA person to Project Office per
  earlier review recommendations

39
Revised Construction Cost for FY04 Start
WBS Task 6/01 Cost (M) 1/03 Cost (M)
1 MECO 65.5 74.8
1.01 AGS Modifications 2.1 2.2
1.02 Proton Beamline 6.4 7.0
1.03 Production Target Shield 1.7 2.4
1.04 Superconducting Solenoids 30.3 36.4
1.05 Muon Beamline 2.5 2.6
1.06 Straw Tracking Chamber 3.7 3.7
1.07 Electron Calorimeter 6.2 6.4
1.08 Cosmic Ray Shield 3.4 3.6
1.09 Data Acquisition and Trigger 2.7 2.7
1.10 Infrastructure 0.8 0.8
1.11 Project Management 5.7 7.0
40
Implications of Delayed Construction Start

• The short answer is that I have not calculated a
  number for this, although it will have to include
  at least six months of the following standing
  army costs
• Project Manager
• Solenoid Subsystem Manager
• Any other hires (UCI, NYU engineers)
• Interim Base Support (?)
• Of course this begs the question, will there be a
  collaboration left at that point?