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PROJECT OVERVIEW. Peter Wanderer APUL Project Manager APUL CD-1 DOE Review January 20-21, 20010. OUTLINE. Scope, WBS, Concept, Deliverables Project Team, Prior Experience, Organization Charts Schedule with Critical Path, Long Lead Procurements, Milestones Cost, Funding Profiles

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Project overview

PROJECT OVERVIEW

Peter Wanderer

APUL Project Manager

APUL CD-1 DOE Review

January 20-21, 20010


Outline

OUTLINE

  • Scope, WBS, Concept, Deliverables

  • Project Team, Prior Experience, Organization Charts

  • Schedule with Critical Path, Long Lead Procurements, Milestones

  • Cost, Funding Profiles

  • Risks, Cost Contingency

  • Value Management

  • ESH, QA, Hazard Analysis, Security

  • Configuration Management, CERN-U.S. Documents

  • Approval requested from this review: CD-1 + LLP

  • APUL Supporting Documents

  • Summary

P. Wanderer - Project Overview


Lhc large hadron collider

Large Hadron Collider

Lake of Geneva

CMS

LHCb

Airport

ALICE

ATLAS

LHC: Large Hadron Collider

P. Wanderer - Project Overview


Ir layouts present upgrade

IR LAYOUTS – PRESENT, UPGRADE

P. Wanderer - Project Overview


Lhc phase i ir upgrade scope

LHC PHASE I IR UPGRADEscope

  • Scope: Upgrade LHC Insertion Regions 1 and 5 (ATLAS, CMS)

    • IR = insertion region = LHC near beam collision point

    • Upgrade Goal: increase luminosity (collision rate) a factor of 2-3 by replacing IR components with superconducting magnets having larger aperture and a more serviceable interface to the power supplies.

      • D1 superconducting dipole magnets (BNL)

      • Cold Powering (Fermilab)

      • quadrupole and corrector magnets, service module, etc. (CERN)

P. Wanderer - Project Overview


Project overview

APUL Project WBS

WBS - 1

Project Management

WBS - 2

D1 magnets

WBS - 3

Cold Powering

WBS - 2.1

D1 Design/Engineering

WBS - 3.1

DFX

WBS - 2.2

Tooling, D1 Magnet

WBS - 3.2

Current Leads

WBS - 2.3

Prototype, D1 Magnet

WBS - 3.3

Sc Link

WBS - 2.4

D1 Magnet Cold Mass Production

WBS - 3.4

DFX, Lead, and Link Test

WBS - 2.5

Testing

P. Wanderer - Project Overview


Subproject comparison

SUBPROJECT COMPARISON

  • Similarities in Cold Power and D1 dipole tasks:

    • Build, test prototypes of each deliverable, then build four production units

  • Difference: level of design

    • Cold Power:

      • Conceptual designs are based on similar items previously built and tested

      • Engineering design underway

    • D1 dipole:

      • Minimal modifications to previously-built magnets (RHIC - DX)

      • Engineering design (needed in a few areas) underway

P. Wanderer - Project Overview


Concept division of labor based on previous experience of cern fermi bnl

CONCEPT: division of labor based on previous experience of CERN, Fermi, BNL

APUL – yellow; CERN – remainder

P. Wanderer - Project Overview


Concept cold powering

CONCEPT: COLD POWERING

THREE MAJOR COMPONENTS - for each, prototype + four

  • DFX Distribution Feed box

    • More serviceable than present feed box

    • Connects warm bus and cold bus (superconducting link)

  • Superconducting link

    • Links 50 to 90 m long, with complex and unique routing

    • Link includes NbTi bus for all IR magnets, helium cooling, vacuum, quench-protection instrumentation

  • Current leads

    • Cooled by helium vapor

    • Four different currents

  • Prototypes used in system test at Fermilab, CERN, and as spares

P. Wanderer - Project Overview


Concept d1 dipoles

CONCEPT: D1 DIPOLES

  • Replace resistive D1 dipoles with much larger aperture superconducting dipoles

  • RHIC DX dipole inner diameter = 180 mm ok (>> 120 mm quad aperture)

    • Modify cold mass outer radius to fit into LHC cryostat

      • Similar to work on BNL dipoles now in LHC

    • Two modified DX cold masses in one cryostat = one D1

    • Modify DX cold mass only as necessary

    • Use RHIC tooling, set up in new location.

  • Build 5 (prototype+4 production) D1 combined cold masses

    • CERN will install D1 combined cold masses into cryostats  D1 magnet

    • CERN to test the D1 magnets at cryogenic temps

    • Install two around ATLAS, two around CMS, use prototype for string test & spare

P. Wanderer - Project Overview


Deliverables scope contingency

DELIVERABLES & SCOPE CONTINGENCY

  • Deliverables (from the two previous slides)

    • D1 dipoles: 1 prototype, 4 production combined cold masses (magnets)

    • Cold Powering: 1 prototype, 4 production of:

      • DFX distribution feed boxes

      • Current Leads

      • Superconducting Links

  • Scope Contingency

    • Previous scope reduction: CERN took over tasks of installing combined cold masses into cryostats, cryogenic testing of D1 magnets. This task is similar to work CERN will perform for the quadrupole magnets made at CERN.

    • There is now no scope contingency

P. Wanderer - Project Overview


Project office

PROJECT OFFICE

  • Peter Wanderer, Project Manager – superconducting magnets for SSC, RHIC, US-LHC Project

  • Sandor Feher, Deputy Project Manager – superconducting magnets, current leads, magnet testing for Tevatron, at CERN, US-LHC Project

  • Marc Kaducak, Project Engineer – Pierre Auger

  • Ronald Prwivo, Project Controls Specialist – US-LHC Project

  • Karen Prosapio, Project Budget Specialist – Fermilab staff (retired  part-time telecommuting)

P. Wanderer - Project Overview


Subproject leaders

SUBPROJECT LEADERS

  • Cold Power - Sandor Feher

  • D1 dipole - Michael Anerella – head of BNL Superconducting Magnet Division Mechanical Engineering Section

P. Wanderer - Project Overview


Cern team

CERN TEAM

  • Ranko Ostojic head of LHC IR Upgrade Project, principal contact for US-LHC Project

    • CERN engineer for Cold Powering: Amalia Ballarino

    • CERN engineer for D1 dipoles: Herve Prin

  • All have prior experience in US-LHC Project

P. Wanderer - Project Overview


Prior experience 1

PRIOR EXPERIENCE (1)

  • Much of the APUL scope is similar to work done previously by the current APUL staff

    • “US-LHC” = accelerator-related deliverables from the US now installed in the LHC

    • distribution feed boxes

    • superconducting dipoles for other insertion regions

  • Remainder of scope similar to recent work:

    • cost of superconducting link based on CERN link

    • cost based on current leads built at Fermilab

P. Wanderer - Project Overview


Prior experience 2

PRIOR EXPERIENCE (2)

  • Prior experience (US-LHC Project) 

    • Models for APUL-CERN interface, both technical (e.g., interface specification) and administrative (e.g., QA). This has saved a lot of effort.

    • Limited interface to LHC hardware – present scope close to “stand alone”

P. Wanderer - Project Overview


Doe and apul

DOE and APUL

P. Wanderer - Project Overview


Functional org chart

Functional Org Chart

P. Wanderer - Project Overview


Lhc ir upgrade schedule

LHC IR UPGRADE SCHEDULE

  • Above-ground string test – install first of each type of component in January 2013

  • Tunnel: ready to install in LHC in 2014  delivery complete fall 2013  little flexibility in CD-4

    • CERN may choose to install at a later date, but plans to keep the present date for “ready to install.”

P. Wanderer - Project Overview


Project overview

Design

APUL Summary Schedule

Procurements

28-Dec-2009

Fabrication

FY2009

FY2010

FY2011

FY2012

FY2013

FY2014

Testing

Q1

Critical Path

Q2

Q3

Q4

Q1

Q1

Q1

Q1

Q1

Q2

Q3

Q4

Q2

Q3

Q4

Q2

Q3

Q4

Q2

Q3

Q4

Q2

CD-0

CD-1

CD-2/3

CD-4b

Project Management (1.0)

1st Set of APUL Deliverables

Due at CERN 31-Dec-12

All APUL Deliverables Due at CERN 01-Sep-2013

Beam Separation Dipole Magnets (2.0)

Conceptual and Preliminary Design

01-Apr-09

21-Jul-10

Prototype Parts Procurement

02-Nov-09

01-Sep-10

Prototype Fab., Assembly, Testing

12-Aug-10

15-Apr-11

15-Feb-10 – Order placed for SC Cable

Production SC Cable Procurement

18-Aug-09

14-Jun-11

Production Parts Procurement

18-Jan-11

10-Oct-11

Production Fab., Assembly, Testing

14-Apr-11

19-Nov-12

Ship last Magnet to CERN

23-Nov-12

25-Jan-13

Cold Powering (3.0)

Conceptual and Prototype Design

19-Mar-09

02-Sep-10

Prototype Procurement

03-Sep-10

31-Aug-11

Prototype Testing

01-Sep-11

13-Jan-12

Production Units Procurement

29-Feb-12

01-Feb-13

04-Feb-13

02-Apr-13

Shipment to CERN


Project overview

APUL L1 and L2 Milestones

29-Dec-2009

FY2009

FY2010

FY2011

FY2012

FY2013

FY2014

Q1

Q2

Q3

Q4

Q1

Q1

Q1

Q1

Q1

Q2

Q3

Q4

Q2

Q3

Q4

Q2

Q3

Q4

Q2

Q3

Q4

Q2

CERN Delivery Dates

1st Set of APUL Deliverables

Due at CERN Dec-2012

All APUL Deliverables Due at CERN Sep-2013

Project Management (1.0)

Critical Decisions (L1 Milestones)

CD-0

01-Dec-2008

CD-1

18-Mar-10

CD2/3

05-Nov-10

CD-4A

16-Dec-13

L2 MILESTONES

Beam Separation Dipole Magnets (2.0)

CD-4B

01-Apr-14

SC Cable Order Placed (2.4.1.1)

15-Apr-10

Coil, CM Prelim. Design Complete (2.1.1.1)

25-Jun-10

Proto. Magnet Leaves BNL (2.3.3.6)

20-Jun-11

Coil, CM Final Design Complete (2.1.2.1)

30-Aug-11

Proto. Magnet Arrives CERN (2.3.3.6)

03-Oct-11

Production Coils Complete (2.4.2.5.20)

09-Jan-12

D1 Magnet #3 Leaves BNL (2.4.3.10)

11-Jul-12

D1 Magnet #5 Leaves BNL (2.4.3.15)

23-Jan-13

All D1 Magnets @ CERN (2.4.3.15)

06-Jun-13

Cold Powering (3.0)

Current Lead Proto. Design Complete (3.2.2.1)

08-Sep-10

SC Link Proto. Design Complete (3.3.3.1)

19-Oct-10

DFX Proto. Design Complete (3.1.2.1)

02-Nov-10

Place Order for DFXs (3.1.2.2)

03-Feb-11

First DFX at FNAL (3.1.2.4)

31-Oct-11

Proto. Testing Complete (3.4.2)

13-Mar-12

Prototype Cold Powering at CERN

31-Dec-12

Production DFX Fab Complete (3.1.3.2)

04-Apr-13

02-Sep-13

Final DFX Units at CERN


Schedule contingency

SCHEDULE CONTINGENCY

  • Level 2 milestones include 2 mo. float

  • Baseline schedule for delivery of final components to CERN is April 2013

    • 5 mo. ahead of CERN Upgrade Project schedule.

    • 8 mo. ahead of CD-4a (CERN initial acceptance, based on incoming inspection)

    • 11.5 mo. ahead of CD-4b (CERN final acceptance, following cold test)

APUL Cost Slides

M. Kaducak


Funding

FUNDING

  • DOE OHEP funding cap:

    • Presented at November Director’s Follow-Up Review: TPC = $29.0M with 30% contingency

    • Recommendation of Nov. review: strengthen Project Management – accepted – TPC increase $0.4M  contingency for $29M TPC reduced to 28%.

    • OHEP advice: present 30% contingency, $29.4M budget at DOE CD-1 review

APUL Cost Slides

M. Kaducak


Apul cost summary

APUL Cost Summary

APUL Cost Slides

M. Kaducak


Funding obligation cost table

Funding, Obligation, Cost Table

APUL Cost Slides

M. Kaducak


Funding obligations

Funding, Obligations

APUL Cost Slides

M. Kaducak


D1 long lead procurements

D1 LONG-LEAD PROCUREMENTS

  • The procurements of several materials for the D1 magnets have long lead times. For the production run of four magnets, APUL requests permission to purchase these items following CD-1 approval:

    • NbTi superconductor, baseline cost $635k

    • Yoke laminations, $212k

    • Collar laminations, $508k

    • Stainless steel half cylinders for helium containment, $200k

  • The most time-critical material is the NbTi superconductor, for which we have one qualified, interested vendor, a good price, and a 120 day period to accept the price, ending Feb. 28, 2010.

  • Details in talks by M. Anerella

APUL Cost Slides

M. Kaducak


Apul ftes

APUL FTEs

APUL Cost Slides

M. Kaducak


Risk management

RISK MANAGEMENT

  • Risk management follows standard “integrated” process:

    • Identify risk (registry) … analyze (risk matrix) … plan abatement … carry out plan … check result of plan. (APUL docs #2, #49)

  • Technical risk control via design reviews, procedures, QA

    • Magnets: cold test magnet cold masses before shipment to CERN

    • Cold Powering: test 1st system (one of each component) at Fermilab

  • Cost risk

    • Cold powering: fixed price contracts

    • Magnets: maintain cryo test facility, track labor closely

  • Schedule risk:

    • Magnets: testing at each stage of production, assembly

    • Cold Powering: Track progress at vendor, subcontractor as needed.

P. Wanderer - Project Overview


Risk impact probability classification

RISK IMPACT, PROBABILITY CLASSIFICATION

P. Wanderer - Project Overview


Project overview

Risk

WBS 1 — Project Management

Probability = Probability of Event; Cost = Current Cost Impact Estimates (Use $K); Schedule = Schedule Impact (Use time in months); Technical = Technical Impact (Use performance degradation in %);

O = Optimistic; ML = Most Likely; P = Pessimistic;

P. Wanderer - Project Overview


Cost contingency 1

COST CONTINGENCY (1)

Followed dictionary used in recent particle physics experiments:

  • 10% Vendor Quote in $

  • 15% Previously Built (several times in house)

  • 20% Previously Built (factory)

  • 30% Previously Built (one-time) -- much of Cold Powering

  • 35% Technical Design (Engineer's estimate)

  • 40% Conceptual Design (Engineer's estimate)

  • 50% Conceptual Design (Physicist's estimate)

  • 100% Early R&D

P. Wanderer - Project Overview


Cost contingency 2

COST CONTINGENCY (2)

  • Bottoms-up contingency (from previous slide) is 30%

    • Experience of Project Team important in estimating

  • “Top Down” contingencies from Risk Registry, using Most Likely probabilities:

    • Project Management $45k/1.3 mo., D1 dipoles $312k/6 mo., Cold Powering $171k/5.3 mo., total $528k/7-12 mo.

  • Opinions of colleagues with significant experience in similar projects: experienced staff, similar to items built before  30% is reasonable

P. Wanderer - Project Overview


Cern us scope of work

CERN-US SCOPE OF WORK

  • CERN-U.S. government: Protocol options

    • New Accelerator Protocol (9 months to approve)

    • ATLAS/CMS Protocols

  • CERN-DOE Labs: Implementing Arrangement

    • Sets detailed scope for APUL

    • draft by APUL under review at CERN

    • similar to US-LHC document – contains WBS – each page initialed by CERN, US Project Managers

    • no significant issues expected

P. Wanderer - Project Overview


Cdr specs for upgrade

CDR, SPECS FOR UPGRADE

  • Phase I Upgrade CDR Dec. 2008

    • http://slhc-irp1.web.cern.ch/SLHC-IRP1/

    • Weekly meetings of Technical Design Group, with APUL attendance via Webex (slides, phone)

  • Functional specifications (CERN documents)

    • D1 dipole completed (posted at CERN; APUL doc # 134)

    • Cold Powering draft available Nov. 2009; finalized January 2010

  • Interface specifications (APUL document)

    • Fewer than for US-LHC project (“stand alone”)

    • Under development

  • Technical Design Report (APUL doc): for CD-2

P. Wanderer - Project Overview


Configuration mgmt

CONFIGURATION MGMT

  • Mechanical and electrical design drawings showing the specifications for the equipment and subcomponents

    • Controlled as part of standard engineering procedure

  • Requirements and Specification Documents

    • Controlled via interface to CERN, standard Project practice

  • Interface Control Documents, Technical Design Reports

    • Controlled via interface to CERN

  • Management documents such as the Baseline Schedule, PMP, MOU’s, and SOW’s.

    • Controlled via interface with DOE, Fermi Office of Pgm Mgmt Oversight

P. Wanderer - Project Overview


Value mgmt engineering

VALUE MGMT/ENGINEERING

  • Budget cap  minimize cost while maintaining scope and schedule

  • D1 dipoles – examples

    • Use alternate material for collars

    • Use of existing tooling, cryo test facility

    • Use previously-developed methods for achieving desired field quality with construction of just one prototype

  • Cold Powering - examples

    • Competitive bidding / fixed price contracts

    • Phased contract: build prototype, test prototype, build remainder

    • Conductor donated by CERN

P. Wanderer - Project Overview


Es h qa

ES&H, QA

  • Overall: Follow plan for US-LHC work, updating documents as needed

  • Environment: NEPA “categorical exclusion” granted by DOE Brookhaven Office (BHSO) in May.

  • Safety and Health: MOU with CERN in draft status

    • Kaducak et al. discussed with CERN during September visit

    • Generic superconducting object testing issues,

    • Added issue: weld needed to close D1 dipole helium vessel, which has a non-circular shape. As far as R. Ostojic knows, US-LHC approach is ok.

  • QA: Separate BNL and Fermilab plans, as last time

    • Fermilab -APUL doc #54; BNL – APUL doc # TBD

P. Wanderer - Project Overview


Hazard analysis

HAZARD ANALYSIS

  • Hazards are basically the same as those encountered in much of the work in the Fermilab Technical Division and in the BNL Superconducting Magnet Division. APUL work will be carried out by staff familiar with these hazards.

  • “The conclusion of the APUL project management is that all major hazards have been identified and can be addressed by the means discussed here and in the references.” – joint Fermilab, BNL Preliminary Hazard Analysis for APUL (APUL doc # 146)

P. Wanderer - Project Overview


Security

SECURITY

  • Security Vulnerability Assessment Report (SVAR)

  • BNL: Memo, J. Amabile (Manager, BNL Lab Protection Division) to P. Wanderer, Dec. 23, 2009:

    • Report On An Assessment of Security Risks at the Brookhaven National Laboratory and the Accelerator Project Upgrade of LHC-APUL

    • “The Accelerator Project Upgrade of LHC-APUL, within the Superconducting Magnet Division, does not result in any changes to the current [BNL lab-wide security] document.”

P. Wanderer - Project Overview


Requested from this review

REQUESTED FROM THIS REVIEW

  • Approve CD-1:

    • selection of alternatives for deliverables

    • cost range, contingency

  • Approve Long-Lead Procurements

    • Listed earlier in talk; details in M. Anerella talks

P. Wanderer - Project Overview


Supporting documents

SUPPORTING DOCUMENTS

  • Conceptual Design Report, APUL-doc-6

  • Value Management, APUL-doc-44

  • FNAL QA Plan, APUL-doc-54

  • Risk Management Plan, APUL-doc-2

  • Risk Registry, APUL-doc-49

  • Preliminary Hazard Analysis, APUL-doc-53

  • Configuration Management Program, APUL-doc-3

  • Key Assumption Document, APUL-doc-56

  • WBS Dictionary, APUL-doc-60

  • NEPA Categorical Exclusion, APUL-doc-50

  • Preliminary Project Management Plan, APUL-doc-1

  • Preliminary Project Execution Plan, APUL-doc-58

  • Acquisition Strategy, APUL-doc-62

P. Wanderer - Project Overview


Summary

SUMMARY

  • APUL leverages US capabilities to made a high-impact contribution (factor of 2-3 increase in luminosity) to LHC.

  • Scope well-defined

    • Close to scope of previous work

    • Need to be careful with the details

  • Delivery dates firm, float adequate, no scope contingency

  • Experienced team in place

  • Budget is tight  contingency level important

     schedule risk, especially from CR

P. Wanderer - Project Overview


Backup

BACKUP

P. Wanderer - Project Overview


Funding obligation cost chart

Funding, Obligation, Cost Chart

P. Wanderer - Project Overview


Critical decision process 1

CRITICAL DECISION PROCESS (1)

Critical Decision (CD) 0: establish “Mission need”

Signed Oct. 30, 2008 by Ray Orbach

CD 1:

Internal reviews for Cold Powering (May 6), D1 dipole (May 15), cost scrub/value engineering (June 19)

Fermilab CD-1 Director’s Review (July)

Fermilab CD-1 Director’s Follow-up Review (this one)

DOE CD-1 review – first week of Dec.

Will request “tailoring” to allow long-lead procurements (LLP), as follows -

D1 production cold masses: superconductor (Jan. 2010), iron, stainless steel laminations, etc. (Spring 2010)

[delayed schedule – order coil parts, but not cold mass parts]

Cold Powering: Prototype DFX (Summer 2010)

DOE CD-1 approval (~ 1 month after CD-1 review)

46

P. Wanderer - Project Overview


Critical decision process 2

CRITICAL DECISION PROCESS (2)

  • CD-2/3a/3b  establish project baseline, order any remaining LLPs, start production

    • DOE CD2/3a review ~ Summer 2010

    • D1 dipole coil production starts Nov. 2010  tailoring for CD3b

    • DOE CD 3b full review ~ Dec. 2010/Jan. 2011

  • CD-4 (3/31/2014)

    • CERN shutdowns are most efficiently scheduled to start Jan. 1.

    • CERN date for beginning of assembly of string test components, and date for installing remaining components, sets the schedule. Also: LINAC4 completion in 2014.

P. Wanderer - Project Overview


To do

To do

  • Update DOE-APUL org chart (slide 15?)

  • BNL QA APRL doc #

  • DOE and Functional Org charts

P. Wanderer - Project Overview


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