Download - Accelerator Systems
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Accelerator Systems
Ferdinand WillekeDirector, NSLS-II Accelerator Systems
NSLS-II PAC MeetingNovember 20, 2007
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Outline
• NSLS-II Accelerator Systems Design Status• NSLS-II Accelerator Systems Major Design
Achievements and remaining Issues• NSLS-II Accelerator-Cost• NSLS-II Accelerator-Schedule• NSLS-II Accelerator-Staffing• NSLS-II Accelerator-Organization
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Scope
R & D Program
design, procure, 200 MeV LINACdesign, procure, 3GeV boosterdesign, build, assemble, 300MeV, 3GeV beamlinesInstall injector
design, procure/build, assemble, test injection straightsDesign procure, assemble, test ~ 1000 magnets on 150girdersDesign, build, procure, assemble, test 185 beam pipes incl P+ISpecify, design, procure, assemble 360kW 500 MHz trans., 500MHz SCC+ 900 W Cryo PlantDesign, procure, assemble 6 front-endsDesign, procure, assemble, test utilities (8MW cooling water)Install storage ring system
Design, procure, assemble, test 6 3.5m DW, 3EPU, 2 IVU, install 2 ID
Vacuum assembly, girder assembly, survey, ID testing, RF testing, Kicker testing labs
Integrated testing and commissioning
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Design Goal / Baseline / CD4
Parameter Design Goal Baseline Configuration
CD-4 Criteria
Beam Energy [GeV] 3 3 3Beam Current [mA] 500 300 25Beam Emittance [nm] 0.6 1.1 2Active Beam Lines >58 6 2Number of RF Cavities 4 2 1Number of RF Stations 4 1 1Number of DW procured 8 3 3Number of DW installed 8 3 0Radiation Sources 58 6 2Number of ID 28 +15TPW 6 2
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Status of the NSLS-II Accelerator Systems DesignBooster and LINAC: preliminary design almost completed, alternative designs and procurement paths being developedNext Steps: complete preliminary design, validate alternative vendors, prepare for procurement
S.R. Magnet System: Preliminary design completed, prototypes underway
Next Steps: Evaluate prototypes, refine and complete design
S.R. Girder System: Preliminary design completed, prototypes underway, R&D in progressNext Steps: Evaluate prototypes, complete R&D, complete design
S.R. Vacuum System: preliminary design far advanced , test extrusions underwayNext Steps: Evaluate test extrusions , work on shielded bellow design, complete design
S.R. PS System: preliminary design in progress , R&D program underwayNext Steps: perform R&D, complete conceptual design, complete design
S.R. Diagnostic System: specifications well advanced, preliminary design in progress , R&D program underwNext Steps: perform R&D, complete preliminary design
Utilities (Electrical,Cooling) : specifications well advanced, preliminary design in progress , Next Steps: complete design
Controls: Specifications well advanced, preliminary design in progress , Next Steps: complete design
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Major Design Issues
Injector Re-design based on compact booster concept performedRoute: semi turn-key procurementConcern: high cost and single vendorAction: explore alternative vendors
Reducing Lattice Complexity in order to reduce cost and free up spacePresent Status: 2 chromatic sextupole families, triplet focusing for matching the ID straightsAction: perform comprehensive simulation study, keep reserve to introduce more sextupoles
or other multipoles
Design Magnet Support System: (a) align magnets to < 30 m (b) suppresses girder amplification of vibrations < 50Hz
(c) insensitive to temperature changesPresent Status: Existence proof of (a) further studies planned
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Stretched Wire Test Measurements
High precision magnet alignment procedure using a vibrating wire technique
• Existence proof for 30micron alignment tolerances achieved with this method at Cornell
• Magnet alignment precision of < 10 m demonstrated recently at BNL
See Satoshi Ozaki’s presentation in acc. b.o.
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Large Procurements
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Scope Contingency
Omitted Cost Item Scope Reduction Cost Reduction Latest Decision Date
(1- 4) 3.5m longDamping Wigglers
x =1.1 nm x=1.3 nm - 2.2 nm
(1.2 – 5) M$ Oct 24, 2011
Reduce Number of PS General Performance Reduction
Up to 5 M$Oct 22, 2010
Omit S.C. Cavity Spare Availability risk 2.4 M$ October 30, 2009
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Estimated Cost Profile
More detailed information in accelerator breakout
These are burdened and escalated numbers
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Accelerator Cost
Accelerator Systems,
Accelerator Systems R&D,
Accelerator Systems Pre-Ops
~ 250 WBS items level 3-6
1200 scheduled activities
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Detailed Cost Information
LEVEL 3
LEVEL 4
LEVEL 5
Activities
LEVEL 2
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Areas of Risk
• Cost Risks: - Turn key procurements of LINAC, RF Cavities, RF transmitter are subject to currency exchange
rate changes, partially only single vendors - Procurement of high quality permanent magnet material in view of recent large price increases)
Mitigation: allocation of contingency• Schedule and Cost Risk Only one, at most 2 vendors for SC cavities, LINAC Mitigation: Efforts to validate more vendors
• Schedule, Cost Risk, Technical Risk - Copy of existing Landau cavity design, need complicated collaboration Mitigation: In-house development under consideration - Low beam lifetime due to low D.A. Mitigation: Landau Cavity provides margin, additional sextupole circuits require contingency
• Technical & Schedule Risk: Meeting requirements in Beam Stability, high precision alignment Mitigation: Mitigation: problems addressed in R&D program
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WBS Dictionary: Design and develop the NSLS-II accelerator systems: storage ring, injector complex, insertion devices, and accelerator infrastructure, including controls. Additional activities include the detailed design of corresponding components and subsystems; their procurement, testing, and assembly; and, finally, installation of the entire accelerator complex for NSLS-II.
Total Estimated Cost and Bottoms –Up Contingency Assessment
WBS Description
Direct k$Total
Burdened &
Escalated
Bottoms up Contingency
Total with Contingency
FTEs Labor Non-Labor(Mtrl, Trvl, Act) % $ Value
1.03 Accelerator Systems 527.3 41,991 136,545 240,174 31 75,315 315,4891.03.01 Accelerator Systems Management 28.4 2,107 865 5,251 0 0 5,251
1.03.02 Accelerator Physics 63.2 6,332 709 13,477 44 5,911 19,3881.03.03 Injection System 34.5 2,699 26,575 36,083 29 10,331 46,415 1.03.04 Storage Ring 277.2 20,720 82,968 135,174 29 38,735 173,910 1.03.05 Controls Systems 77.9 6,656 4,421 18,668 22 4,016 22,6841.03.06 Accelerator Safety Systems 10.9 835 2,233 4,230 34 1,419 5,649
1.03.07 Insertion Devices 18.7 1,484 16,515 22,706 60 13,580 36,2871.03.08 Accelerator Fabrication Facilities 16.5 1,158 2,259 4,585 29 1,322 5,907
*)
*) margin taken into account in cost estimate
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Scheduling • Weekly meetings Febr.-March 07 of technical staff with project support team to: Agree on global schedule strategy, Define milestones, Acknowledge constraints, Envision build-in float Introduce integrated testing at the end of the installation Acknowledge installation as the most complicated schedule activity, generate very detailed installation work break-down and sequencing Agree on pentant-wise staged installation while the building is being completed Generate a logical network which link the schedule activities
• Detailed assessment of labor work out duration of activities as part of the cost estimate in July 07, consolidation in August 07
• Generating a schedule using the available float to support procurement strategies and to match the funding profile, very close and intense collaboration between technical staff and project support team in September 07 Reiterate schedule to optimize TPC, staffing profile, procurement strategies
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Accelerator Systems Schedule
Booster on the critical path
Reason:
• Injector Turn-key procurements delayed to preserve option for alternative vendor development of change of procurement plan as part of the injector risk mitigation strategy
• It also helps to match the time phased cost estimate with the funding profile
After May 2013: Accelerator and ID commissioning
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Critical Path
| FY09 | FY10 | FY11 | FY12 | FY13 | FY14 | FY15 |Booster on the critical path
April 09 – May 2013
Reason:
Injector Turn-key procurements delayed to preserve option for alternative vendor development of change of procurement plan as part of the injector risk mitigation strategy
It also helps to match the time phased cost estimate with the funding profile
After May 2013: Accelerator commissioning and ID comm.
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Estimated Labor
Accelerator Systems Staffing•Planned labor will allow for a smooth staffing plan.
•Detailed Staffing plans have been developed based on estimated labor effort
•Peak work loads in FY12 need temporary labor
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Labor Type Staffing Profile
0
20
40
60
80
100
120
FY08 FY09 FY10 FY11 FY12 FY13 FY14
ScientistVacuum TechnicianManagementRF TechnicianRF EngineerMechanical TechnicianMechanical DesignerMechanical EngineerElectronics TechnicianElectrical DesignerElectrical EngineerAdministrative
Total
575 FTE
includes
1.03
1.02.01 & 1.06.02
Smooth labor profile
Assume transition to operations
Mech. Designers move to EF in FY11
20 FTE temp. M/E Techs in FY 12
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Staffing Plans and Group StructureMechanical Engineering
Electrical Engineering
Functional Core Groups defined for all accelerator groups by concentrating functions in M & E Groups
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Accelerator Systems Division Organization
Line Management Structure
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Accelerator Systems Division Organization
WBS
Worked performed in
1.03.02 Accelerator Physics
1.03.04 Storage Ring
1.03.06 Safety Systems
1.03.07 Insertion devices
1.03.05 Controls
1.02.01 Accelerator R&D
1.03.08 Acc. Fabrication Fac.
1.06… Integr.Testing Comissioning
1.03.03 Injector
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Accelerator Systems Division Organization
Task Forces
Coordinate work performed in
Storage Ring Coordination F. Willeke
Injector Ring Coordination T. Shaftan
Integrated Testing nn
Fast Orbit Feedback nn
Commissioning nn
Girder Integration and Alignment nn
Global Integr. and Interfaces E. Johnson X X X X X X X X
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X X X X X X X Insertion Device Integration nn
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Summary
• Design of Accelerator Systems has advanced well, in some area’s design is close to be completed, in other areas design process is stretched out in time to optimize cost distribution
• A detailed and thorough cost estimate has been produced for NSLS-II accelerator systems which is based on fairly detailed design
• The schedule has been generated based on detailed planning which involved the entire high level technical staff of the division and based on the detailed cost estimate
• Based on time phased cost estimate a firm staffing plan has been developed so that hirings can start now to assure execution of the project as planned
• Major risks have been identified and mitigation plans have been developed
• All these constitute a reliable base for the project baseline
• An organizational structure is envisioned which consists of a stable line management structure and dynamic task forces which will address special project needs
NSLS-II Accelerator Systems NSLS-II Accelerator Systems ready to move to detailed engineering phaseready to move to detailed engineering phase