accelerator systems

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Systems

Ferdinand WillekeDirector, NSLS-II Accelerator Systems

NSLS-II PAC MeetingNovember 20, 2007


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


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


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


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


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


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.


Large Procurements


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


Estimated Cost Profile

More detailed information in accelerator breakout

These are burdened and escalated numbers


Accelerator Cost

Accelerator Systems,

Accelerator Systems R&D,

Accelerator Systems Pre-Ops

~ 250 WBS items level 3-6

1200 scheduled activities


Detailed Cost Information

LEVEL 3

LEVEL 4

LEVEL 5

Activities

LEVEL 2


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


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


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


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


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.


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


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


Staffing Plans and Group StructureMechanical Engineering

Electrical Engineering

Functional Core Groups defined for all accelerator groups by concentrating functions in M & E Groups


Accelerator Systems Division Organization

Line Management Structure



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

X X X X X X

X X X

X X X X X X X

X X X X X X X

X X X

X X X X

X X X X X X X

X X X X X

X X X X X X X X



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

X X X X X X X X

X X X X X X X

X X X X X X

X X X X X X X

X X X X X X X X

X X X X

X X X X X X X Insertion Device Integration nn


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

accelerator systems

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