EDM Fast Start Presentation WBS 11 – Assembly and Commissioning

1. EDM Fast Start PresentationWBS 11 – Assembly and Commissioning Vince Cianciolo, Paul Huffman May 23, 2006

2. Schedule Overview • Fully tested B-shield • Fully tested CV/liquifier and coil pkg. • Fully tested insert • Fully tested 3He system • Assemble/commission B shield • Assemble/commission coil package into CV • Assemble/commission insert in CV • Assemble/commission 3He system in CV • Re-install B shield upper half • Mate neutronics • Commissioning run • CD4/data collection :-) EDM Fast Start, WBS11

3. Significant Planning Assumptions • Internal cryostat components arrive fully tested at cryostat assembly site • Measurement cell insert • 3He injection and purification system • Coil package • All related DAQ components • This is hugely important. The full apparatus will require 6-8 weeks for a cooldown cycle and this dominates cost and schedule. As much as possible testing must be done prior to assembly, in parallel and in smaller cryogenic vessels. • Require ability to test 3He transport w/o external shield • Otherwise grossly inflates cooldown/warmup cycle time, and mandates lots of handling for delicate shield pieces. • M&S costs included in estimates for various subsystems (not in this WBS) • Rails and other infrastructure equipment • Helium • Tools • NCSU is the cryostat assembly site • Cost totally dominated by technician support (nearly 4 FTE years) • >$300k labor savings if done at NCSU • Balances against shipping, disassembly, re-assembly, extra infrastructure • Assembly requires continuous presence and expertise of the cryostat team for ~ 2 years • Probably significantly longer if apparatus and team not geographically close EDM Fast Start, WBS11

4. Gantt Chart Duration – 38 months Test coil pkg in CV (NCSU) Test insert in CV (NCSU) Test 3He system in CV (NCSU) Schedule dominated by repeated cooldown/testing cycles B-shield installation (FNPB) Test entire apparatus at FNPB EDM Fast Start, WBS11

5. Milestones Assembly and commissioning deliverables EDM Fast Start, WBS11 Subsystem inputs

6. Critical Path • Cryostat vessel • Whichever subsystem will be the first to install • Seemingly the coil package • Not the B-shield, which is only needed more than two years after the start of coil package assembly into the cryostat. EDM Fast Start, WBS11

7. Schedule Risks/Uncertainties • Cost and schedule is totally dominated by the number of cooldown cycles required for successful commissioning: • 3 for coil package • 4 for insert • 3 for 3He components • 3 for integrated tests • 2 for commissioning run w/ beam, B-shield • These estimates (sorry!) really are WAGs because it is impossible to know how long it is going to take to diagnose a problem. EDM Fast Start, WBS11

8. Areas of Interface - Everything • DAQ • Neutronics and Shielding • Cryostat • Insert • 3He Components • Coil package and shielding • Infrastructure EDM Fast Start, WBS11

9. Technical (Scope) Issues • Is your scope well defined (yes/no)? Is it documented? Yes and no. • We have carefully constructed this WBS so that it only involves assembly and commissioning of fully-tested parts. • Important that this is understood and agreed to by other subsystems. • Also, our model currently assumes that external subsystem labor is free or costed by the corresponding subsystem. • If this is not correct it needs to be fixed. EDM Fast Start, WBS11

10. Cost Estimates • Work package spreadsheets not complete. • Cost estimate is entirely labor. • Dominated by NCSU and ORNL technician time: • ORNL – ~2 FTE-years = $400k • NCSU - ~4 FTE-years = $450k • Shipping - $36k • Pre-contingency estimates. • These estimates (sorry!) really are WAGs because it is impossible to know how long it is going to take to diagnose a problem. EDM Fast Start, WBS11

11. Staffing Plans • NCSU (from D. Haase talk) • People - 5 NC State physics faculty, TUNL technical support (Engineers and electronics techs) • Key skills - cryogenics design, implementation and testing • Recruitments - need 1 postdoc and 2 cryo technicians • Issue - funding for recruitments • ORNL • Technicians w/ cryogenic expertise needed • Issue: not currently on staff • Issue: Need to come to grips with operational model for the experiment, i.e., will ORNL assume general responsibility w/ relatively little involvement by collaborating scientists (“J-Lab model”) or will there be substantial, on-site presence of collaborating scientists (“RHIC model”). EDM Fast Start, WBS11

12. Procurement Planning • We have structured this WBS element so that there are no material purchases. EDM Fast Start, WBS11

13. Issues • The “62% Rule” is not always applicable: • Hourly rate for NCSU technicians assumes 52*40 hours/year (unlike ORNL, and presumably LANL) in which vacation time is built into overhead. • To correctly cost things they should be entered as 71.4% or their hourly rate should be upped. • Another example is an intermittent resource, like a couple of electricians who work for a couple of weeks on the project. • ORNL, NCSU technician/engineer burdened rates in the spreadsheets are not correct. • I started this WBS in a fresh file. I didn’t realize it was using a 5-day calendar (apparently now the MSP default). So fractions are not currently consistent with 62% rule. EDM Fast Start, WBS11