1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Ferdinand Willeke Director, NSLS-II Accelerator Systems NSLS-II PAC Meeting November 20, 2007

2 BROOKHAVEN SCIENCE ASSOCIATES 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

3 BROOKHAVEN SCIENCE ASSOCIATES Scope R & D Program design, procure, 200 MeV LINAC design, procure, 3GeV booster design, build, assemble, 300MeV, 3GeV beamlines Install injector design, procure/build, assemble, test injection straights Design procure, assemble, test ~ 1000 magnets on 150girders Design, build, procure, assemble, test 185 beam pipes incl P+I Specify, design, procure, assemble 360kW 500 MHz trans., 500MHz SCC+ 900 W Cryo Plant Design, procure, assemble 6 front-ends Design, 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

4 BROOKHAVEN SCIENCE ASSOCIATES Design Goal / Baseline / CD4 ParameterDesign GoalBaseline Configuration CD-4 Criteria Beam Energy [GeV] 333 Beam Current [mA] Beam Emittance [nm] Active Beam Lines >5862 Number of RF Cavities 421 Number of RF Stations 411 Number of DW procured 833 Number of DW installed 830 Radiation Sources 5862 Number of ID TPW62

5 BROOKHAVEN SCIENCE ASSOCIATES Status of the NSLS-II Accelerator Systems Design Booster and LINAC: preliminary design almost completed, alternative designs and procurement paths being developed Next 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 progress Next Steps: Evaluate prototypes, complete R&D, complete design S.R. Vacuum System : preliminary design far advanced, test extrusions underway Next Steps: Evaluate test extrusions, work on shielded bellow design, complete design S.R. PS System : preliminary design in progress, R&D program underway Next Steps: perform R&D, complete conceptual design, complete design S.R. Diagnostic System : specifications well advanced, preliminary design in progress, R&D program underw Next 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

6 BROOKHAVEN SCIENCE ASSOCIATES Major Design Issues Injector Re-design based on compact booster concept performed Route: semi turn-key procurement Concern: high cost and single vendor Action: explore alternative vendors Reducing Lattice Complexity in order to reduce cost and free up space Present Status: 2 chromatic sextupole families, triplet focusing for matching the ID straights Action: 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 changes Present Status: Existence proof of (a) further studies planned

7 BROOKHAVEN SCIENCE ASSOCIATES 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.

8 BROOKHAVEN SCIENCE ASSOCIATES Large Procurements

9 BROOKHAVEN SCIENCE ASSOCIATES Scope Contingency Omitted Cost ItemScope ReductionCost ReductionLatest Decision Date (1- 4) 3.5m long Damping Wigglers  x =1.1 nm   x =1.3 nm 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 SpareAvailability risk2.4 M$October 30, 2009

10 BROOKHAVEN SCIENCE ASSOCIATES Estimated Cost Profile More detailed information in accelerator breakout These are burdened and escalated numbers

11 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Cost Accelerator Systems, Accelerator Systems R&D, Accelerator Systems Pre-Ops ~ 250 WBS items level scheduled activities

12 BROOKHAVEN SCIENCE ASSOCIATES Detailed Cost Information LEVEL 3 LEVEL 4 LEVEL 5 Activities LEVEL 2

13 BROOKHAVEN SCIENCE ASSOCIATES 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

14 BROOKHAVEN SCIENCE ASSOCIATES 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 FTEsLabor Non-Labor (Mtrl, Trvl, Act) %$ Value 1.03 Accelerator Systems ,991136, , ,315315, Accelerator Systems Management 28.42, , Accelerator Physics63.2 6, ,477445,91119, Injection System ,699 26,575 36, ,331 46, Storage Ring ,72082, , , , Controls Systems ,6564,421 18,668224,01622, Accelerator Safety Systems ,2334,230341,4195, Insertion Devices18.71,48416,51522, ,58036, Accelerator Fabrication Facilities 16.51,1582,2594,585291,3225,907 *) *) margin taken into account in cost estimate

15 BROOKHAVEN SCIENCE ASSOCIATES 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

16 BROOKHAVEN SCIENCE ASSOCIATES 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

17 BROOKHAVEN SCIENCE ASSOCIATES 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.

18 BROOKHAVEN SCIENCE ASSOCIATES 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

19 BROOKHAVEN SCIENCE ASSOCIATES Labor Type Staffing Profile Total 575 FTE includes & Smooth labor profile Assume transition to operations Mech. Designers move to EF in FY11 20 FTE temp. M/E Techs in FY 12

20 BROOKHAVEN SCIENCE ASSOCIATES Staffing Plans and Group Structure Mechanical Engineering Electrical Engineering Functional Core Groups defined for all accelerator groups by concentrating functions in M & E Groups

21 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Division Organization Line Management Structure

22 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Division Organization WBS  Worked performed in WBS  Worked performed in Accelerator Physics Storage Ring Safety Systems Insertion devices Controls Accelerator R&D Acc. Fabrication Fac … Integr.Testing Comissioning Injector XXXXXX XXX XXXXXXX XXXXXXX XXX XXXX XXXXXXX XXXXX XXXXXXXX

23 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Division Organization Task Forces  Coordinate work performed in 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 XXXXXXXX XXXXXXXX XXXXXXX XXXXXX XXXXXXX XXXXXXXX XXXX XXXXXXX Insertion Device Integration nn

24 BROOKHAVEN SCIENCE ASSOCIATES 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 ready to move to detailed engineering phase ready to move to detailed engineering phase