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  1. BTeV Spools (WBS 2.1.2.3) Thomas Page Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004

  2. Topics • Scope of work • Spool design parameters • Spool conceptual design • Cost and schedule • Key milestones • Critical path analysis • Risk analysis • Summary Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  3. Organization (or “You are here”) 2.1.3 Project Management WBS 2.1 Magnet Fabrication & Test 2.1.1Q1 to Q5 Quadrupoles 2.1.2 New Spools 2.1.1.1Cold Mass 2.1.1.2Cryostat 2.1.1.3 MTF Test Stand 2.1.1.4 Q1 to Q5 Fabrication 2.1.2.1 HTS Leads 2.1.2.2Corrector Magnets 2.1.2.3Spool Assembly Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  4. Scope of Work • Design and oversee production of two sets of spools plus one spare set. • Each set consists of 5 spools (X1H, X1V, (2) X2, X3) for a total of 13 spools. • The current plan is to have an outside company fabricate and build the spool assemblies based on our design. • The major components would be supplied to the vendor. • HTS Leads, correctors, other leads, bus work, etc. • The completed spools will be tested at FNAL. Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  5. Initial Design Criteria • Designed in accordance with ASME Boiler and Pressure Vessel Code • Design pressure, MAWP*: • Single phase: 200 psig • Two phase: 50 psig • LN2 system: 100 psig • Heat load to 4K: 5 W per device (spool, quad, etc.) • Corrector envelopes: • X1 spools: 250 mm OD x 1200 mm long • X2 spools: 250 mm OD x 550 mm long • X3 spools: 250 mm OD x 800 mm long • BPM length: 10 inches * MAWP is Maximum Allowable Working Pressure Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  6. Q3 L L Q1 X3 L Q2 BPM C0 C0 C0 C0 X2 X2 X2 X2 … … … … … … … … Q4 Q5 Q5 Q4 L L L L L L L L L L L L L L L L L L L L * * * * C0 * IP IP IP IP IP … … C-sector C-sector B-sector B-sector Spool Pieces • Spools are located between other components, either new quads or existing Tev equipment (not shown here) • X1 (not shown) variations driven by H/V Dipole corrector requirement Q1—Q2—X3—Q3 (mirror image about IP not shown for space) Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  7. Spool Internal Components • Spool component list: • Corrector magnets • Power leads: • 10 kA HTS leads, 2 per power spool (1 pair) • Corrector leads • 200A leads • Instrumentation leads • Beam position monitors • Relief valves: 3 per spool • Cryogenic pipe interfaces as needed • Through bus as needed • Quench stoppers • Vacuum Break Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  8. Slot * VD HD SQ Sx Q HTS Spool Location BPM Other Leads Length, 2 T. m T. m T.m/m T.m/m T.m/m Leads m X1V packb43 1.83 0.48 450 25 4x100A+SL X1H packb44 1.83 0.48 450 25 4x100A X2 packb47 1.43 0.48 0.48 V&H 2x10kA 2x100A+SL X2 pac kb48 1.43 0.48 0.48 V&H 2x10kA 2 x100A X3 packc0u 1.43 0.48 0.48 7.5 V&H 2x10kA 3x100A+200A X3 packc0d 1.43 0.48 0.48 7.5 V&H 2x10kA 3x100A+200A X2 packc12 1.43 0.48 0.48 V&H 2x10kA 2x100A X2 packc13 1.43 0.48 0.48 V&H 2x10kA 2x100A+SL X1V p ackc16 1.83 0.48 450 25 4x100A X1H packc17 1.83 0.48 450 25 4x100A+ SL Spool Information (Details) (Interfaces) Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  9. X2 Spool Conceptual Design Corrector leads Relief valves HTS Leads Suspension ports Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  10. X2 Spool Cross Section HTS Leads Liquid Nitrogen volume 2-phase heat exchanger Vacuum break BPM Helium vessel Corrector Vacuum vessel Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  11. Spool Cost and Schedule Summary Engineering and design manpower: • Engineers: 1.5 FTEs (FY05 & FY06) • Designer/drafters: 2 FTEs (FY05 & FY06) • 1.5 years of detailed design: October 2005 – March 2006 • Bidding, fabrication, assembly and test: • March 2006 – October 2009 • Production oversight: 1 FTE Summary of spool cost: (Based on LHC DFBX and preliminary fabrication study) Base cost: $5.038M (Material: $3.448M, Labor: $1.590M) (Does not include spares.) Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  12. Spool Schedule Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  13. Spool Cost Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  14. Spool Labor Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  15. Key Milestones • Start of detailed design – October, 2004 (FY05) • Bidding process: March, 2006 • 1st Spool fabrication begins: October, 2006 • Series production begins: November, 2007 • Production and test complete: November, 2008 Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  16. Critical Path Analysis • Design of internal components: • The Corrector and BPM designs need to be complete in time so that integration into the spool can begin. • Detailed design complete: • The spool detail design needs to be completed in time so that the bidding process may start. • Vendor production schedule: • Timely delivery of components to vendor. • Production oversight is critical to keep the vendor on schedule. Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  17. Risk Analysis Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  18. Summary • The conceptual design is based on the stated corrector envelopes, BPM length and (2) HTS leads per power spool. • The remaining components are well understood and the conceptual design is under way. • Cost estimates for assembly by an outside vendor are based on the LHC DFBX (feedbox) which is similar is size and function to the new spools and a preliminary fabrication study that was completed in August, 2004 by potential vendors. • The cost to design and build the new spools: $5.038M Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page