March 23, 2009 H.J. Krebs 1

BaBar D&D Schedule & Budget Overview

H. James KrebsMarch 23, 2009

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Outline of Presentation

• Basis of estimates – both cost and schedule

• Overview of Project Schedule• Overview of Cost Estimate• Final comments

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BaBar Detector

‘Ideal’

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BaBar Detector

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BaBar Detector Disassembly• BaBar completed the IFR upgrade in Fall 2006. This

upgrade took place over three campaigns: IFR Forward Endcap Resistive Plate Chambers in 2002, 1st third of IFR Barrel Limited Streamer Tubes in 2004, balance of IFR Barrel sextants with LSTs in 2006.– Barrel upgrade required uncabling of forward end of SVT and

forward end of EMC, load transfer of EMC, removal of most of the corner blocks fore and aft, removal of flux bars, releasing some of the cryostat restraints, pulling forward doors to walls.

– Experience gained in these campaigns plus experience from the initial detector assembly provide excellent input for planning the detector disassembly schedule and estimating the required manpower (both labor and engineering), as well as M&S.

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Project Schedule• A Detailed BaBar D&D Project Schedule is provided on the web site (March

1, 2009)• 51 months duration• Project start date July 1, 2008• Five Project Phases (Subprojects)

– Project Management– Engineering and Tooling Refurbishment– Peripherals Disassembly– Core Disassembly– DIRC/EMC System Disassembly

• May not be needed if major components are reused in a Super B Factory

• Statused and updated weekly• Assumptions

– The sequence, estimated time durations and personnel assignments are based on experience from the original 1997 to 1999 installation and the three IFR Upgrade campaigns that occurred in 2002, 2004, and 2006

– The disassembly sequence is approximately a reversal of the original installation

– Reuse of the original installation tooling for the disassembly process– Use of personnel knowledgeable in the assembly of BaBar– Retrieval of subject matter experts as needed

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Project Schedule (Cont’d)• Assumptions (Cont’d)

– Major components are removed in two designated locations• Collision area – the present location of BaBar• Main disassembly area – 12.3 meters east of present

location– Requires detector roll-out

– Dismantling tasks performed sequentially• Tooling refurbishment performed in parallel at IR-12 and

B750• Can be optimized with additional work crews• Experienced supervision may not exist for multiple

crews– Ownership issues associated with detector components

and/or systems with potential reuse are settled no later than end of calendar year 2009

– Includes an educated fudge factor in the task durations associated with the new Work Planning and Control Program

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Project Schedule (Cont’d)• Potential Schedule Risks:

– Issues associated with the metals suspension• Controlled storage• Materials tracking database

– There are components that cannot be removed in a reverse process• Barrel IFR brass absorber plates

– Unanticipated events• Extended illnesses of key individuals• Non-SLAC related injuries• Lab closures• Power outages• Striking bargaining unit workforce (Existing contract ends September ’09)

– There is little design documentation that exists of the original installation• Rely heavily on institutional knowledge of key personnel

– Unanticipated and changing SLAC and/or DOE requirements– Ownership issues and the decision to build the Italian SuperB may not be

settled as scheduled (December ’09)– Indoor controlled storage space may not be available– Effects of Continuing Resolution and/or lower-than-expected budget profile

• The pre-disassembly phase is nearing completion:– Planning– Preliminary engineering– Tooling refurbishment– Minor peripherals disassembly, removal and cleanup from outside of the

shield wall

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Core Detector Disassembly Flow Chartand Performance Measurement Milestones

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Cost Estimating• Cost estimate spreadsheet is posted on

the web site• Costs include Direct plus Indirect• Contingency is managed by the Project

Manager• Labor Rates

– EDIA• Project Manager $22.92K/mo• Deputy Project Manager $22.92K/mo• Physicist $20.83K/mo• Safety Officer $16.67K/mo• Senior Engineer $20.83K/mo• Designer $16.67K/mo• S&E Associate $16.67K/mo

– Labor• Sr. Tech/Rigger/Electrician $14.17K/mo

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Cost Estimating• Costs are estimated at outline level 3

– 1.4 DETECTOR CORE DISASSEMBLY• 1.4.6 FWD EAST END DOOR

– EDIA» Safety Officer .1 man mo. = $1.67K» Senior Engineer 2 man mo. = $41.67K» S&E Associate 2 man mo. = $33.33K

– Labor» Sr. Tech/Rigger 6 man mo. = $85.00K

– M&S = $5.00K– Contingency @25% = $41.67K– Total 1.4.6 = $208.3K

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Phase ED&I ($K) M&S ($K) Labor ($K) Cont ($K) Total ($K)

Project Management 2384.38 550 0 646.10 3580.48

FY08 350       350

FY09 645.83 150   198.96 994.79

FY10 490.63 150   160.16 800.79

FY11 448.96 150   149.74 748.70

FY12 448.96 100   137.24 686.20

Engineering and Tooling Refurbishment 1872.49 505.50 1050.00 1020.90 4448.89

FY08   12.50 12.50   25.00

FY09 770.83 109.00 503.33 414.95 1798.11

FY10 420.83 84.00  220.00 217.45 942.28

FY11 680.83 300.00 314.17 388.50 1683.50

Peripherals Disassembly 362.71 29.50 548.96 282.35 1223.52

FY09 175.21 13.50 208.96 119.30 516.97

FY10 187.50  16.00 340.00 163.05 706.55

FY11 0 0 0 0 0

FY12 0 0 0 0 0

Core Disassembly 1105.84 92.50 1551.66 765.32 3515.32

FY08   12.50 12.50   25.00

FY09 232.92 17.00 262.08 145.27 657.27

FY10 597.92 43.00 1022.08 482.55 2145.55

FY11 275.00 20.00 255.00 137.50 687.50

DIRC/EMC System Disassembly 616.66 130.00 1064.16 543.25 2354.07

FY11 133.33 40.00 510.83 205.25 889.41

FY12 483.33 90.00 553.33 338.00 1464.66

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Budget Breakdown• Breakdown by Project Phase

– Project Planning & Management $3580K– Engineering and Tooling Refurbishment $4449K– Peripherals Disassembly $1223K– Core Disassembly $3515K– DIRC/EMC System Disassembly $2354K

• Breakdown by Fiscal Year– FY2008 $400K– FY2009 $3966K– FY2010 $4595K– FY2011 $4009K– FY2012 $2151K

• Project Total $15,121K– EDIA $6341K– M&S $1308K– Labor $4215K– Contingency $3257K (27.4%)

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Final Comments• We have developed a detailed project schedule with

performance measurement milestones to help us track progress and costs– Performance measurement milestones are based on Core

Detector Disassembly• Cost estimates include direct + indirect costs• Cost estimates do NOT include:

– Costs associated with disposal of materials• Removed materials are assumed to be placed in controlled storage

for future disposition– Costs associated with shipping materials off-site

• Configuration changes are not expected. However, such an occurrence will be settled thru concurrence of David MacFarlane, Bill Wisniewski, and Jim Krebs

• We are seeing a level of requirements (documentation, training, equipment certification, external review & oversight, etc.) on this project that we have not previously experienced. If this continues, or increases, it may challenge our contingency estimates and adversely affect our project schedule.