january 4, 2007 rhic ii project internal cost review gary mcintyre rhic ring modifications january...
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January 4, 2007
RHIC II ProjectInternal Cost Review
Gary McIntyre
RHIC Ring Modifications
January 4, 2007
Project Overview
2
January 4, 2007
Scope
• Project Engineering and Design (PED) 1.2.10
Multiple In-Tunnel Efforts
3
January 4, 2007
Scope - PED
- D5I/O Warm-to-Cold Transitions (WtC)
– New Magnet Interconnects (8 types)
WtC Cross Section
Sector 2 WtC/VJR
RHIC Interconnect
4
January 4, 2007
Scope - PED
– New pressure/leak check fixtures
– New Quad-only Triplet vacuum vessel & support system Quads moved longitudinally & radially
– Four new dummy magnets (DU6) two with re-coolers
DU6 – “Dummy Magnet
End Volume with Expansion Joint
Bus-carrying process piping
Process piping DU6 Cross Section
Support Posts
Bus Support Structure
5
January 4, 2007
Scope - PED
– In-tunnel material handling device(s)
– Re-design of Q7 with GC lead changes Required for higher current
– Planning/layout of DX & D0 removal, relocation of Q1, Q2 & Q3
– Layout of new Sector 1, Sector 2 & 2:00 Interaction Point
Existing Q7 lead, Sector 2
Existing Sector 1 Triplet / DXDX – to be removed
D0- to be removed
Q3 Q2 Q1
6
January 4, 2007
Scope (cont’d)
• Construction 1.3.10
– Removal of 4 WtCs at Q4, refurbish Q4 to replace Q6 (2)
– Remove and transport Q7 (2) to SMD for new power leads
– Building of new DU6s (2) with re-coolers (internal heat exchanger) to replace the Q6 re-coolers(Q4)
WtC in progress
RHIC sector 5
RHIC magnet
transport in progress
7
January 4, 2007
Scope - Construction
– Removal and /or relocation of RHIC magnets Q4 thru DU7 Sectors 1 and Sector 2 (opening of 32 interconnects)
– Survey of magnets, D5 thru Q7
– Interconnecting of magnet relocations Sector 1 and Sector 2
X = Interconnect opening required
8
January 4, 2007
Scope - Construction
– Removal of DXs (2)
– Disassembly and removal of Triplets (2)
– Removal & staging of Triplet quads Q1, Q2, Q3 (6) and D0 removal (2)
DX Assembly
(~ 20ft long X 4ft diameter)
Triplet Assembly
8 cold masses
(~60ft long X 4ft diameter)
9
January 4, 2007
Scope (cont’d)
• Installation 1.3.13.5
– Installation / Assembly of D5 O/I WtCs (4)
– Installation / Assembly of Quad only Triplets (2)
RHIC Triplet Assembly in progress
WtC Assembly in
progress
10
January 4, 2007
Costs by WBS
Direct Burdened Contingency TotalWBS Description FTEs Cost Cost 19.2%
1.2.10.1 Warm-to-Cold Transitions 1.05 111 131 17 148
1.2.10.2 Magnet Modifications and Relocation 2.35 254 300 29 329
1.2.10.3 RHIC Triplet DX Removal and Modifications 2.05 223 263 55 319
1.3.10.1 Warm to Cold Transitions 1.76 404 470 56 525
1.3.10.2 Magnet Modifications & Relocation 3.38 355 646 193 838
1.3.10.3 Triplet/DX Modifications & Relocation 10.83 2002 2311 352 2663
1.3.13.5 Installation of Ring Component Modifications 14.58 1801 2096 491 2587
0
0
Total 36.00 5151 6217 1193 7409
FY07 K$
11
January 4, 2007
Major Procurements (direct $)
• No single “big ticket items”
– WtC components total $1.17M
– Triplet components total $2.2M
Contingency & Risk
– Increases in raw materials required adjustments to the historical data used to develop Triplet and WtC parts estimates beyond “normal” inflation
12
January 4, 2007
Milestones
• Design complete– WtC at D5O/I– New Triplets– Interconnect – 8 types
• Purchase orders placed– In-house & offsite fabricators, Triplet & WtC parts– Pressure-balancing WtC bellows ordered & delivered– All parts received and inspected
• Installation– Triplets – Magnets relocated & interconnected– WtCs / VJRs interconnected – system pressure-tested
13
January 4, 2007
Assumptions
• RHIC In-Tunnel modifications confined to a single shutdown
– Minimal recycled components
• Funding is available as planned/needed
• Sufficient manpower to simultaneously begin work on
– Warm-to-Cold Transitions at Sector 1 and Sector 2
– Build-up Sector 1 and Sector 2 Triplets
– Magnet removal and relocation
– Equipment procured to sustain simultaneous efforts
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