HL-LHC Accelerator Upgrade Project PMG #20 Giorgio Apollinari/Ruben Carcagno Project & Deputy Project Manager logo area Fermilab July 23rd, 2019 Plans for Today Project Status Financial Situation Project Cost and Schedule Performance QA/QC Issues June Change Control Board Meeting ICB-A Saga Revised Impact of CERN Cryostat Tooling Delay MQXF International Review @ CERN Future PMG/RMB/TB/CCB
BNL Reports Technical Status of 302.2.05 and 302.4.01 logo area PMG Meeting 7/23/19 2 Financials (Jun Report) FY Obligations by Lab (updated Jun 2019): Through FY19 (updated Jun 2019): logo area PMG Meeting 7/23/19 3 Cost Performance Report (End of June 2019 Report) Compared to last month, SPI up from 0.97, CPI up from 1.04 June 2019 Status:
SPI = 0.97 (up from 0.96), CPI = 1.05 (up from 1.04) Total Project Cost (TPC): $242.7M Estimate at Completion (EAC): $181.1M ETC (EAC-ACWP): $144.0M Contingency (TPC EAC): $61.6M % Complete (Planned): 21.5% Contingency as % work-to-go: 42.8% logo area PMG Meeting 7/23/19 4 Cost Performance Trends AUP SPI and CPI Trend 1.10 1.05 1.00 0.95 0.90
Jan-19 Feb-19 Mar-19 Apr-19 May-19 Jun-19 SPI by CA BNL Faster on Ship. Tooling SPI CPI CPI by CA BNL Ship. Tooling under budget LBNL Slower on Magnets logo area PMG Meeting 7/23/19 5 AUP QA/QC Issues QA Issues raised/encountered at BNL: Issue Loss of Coil 205/Total Loss of Cable for 205 Short Coil-to-Ground in MQXFAP1b Test*
Coil 208 L1/L2 lead conductor damaged during curing Status BNL NCR completed. NCR submitted to CERN, and it is under review. Discussions are ongoing with BNL regarding off-normal work planning and control. Discovered at BNL, issue with LBNL Assembly Process. Investigation underway at BNL QA Issues at FNAL: Issue During assembly of MQXFA03 at LBNL, coil 109 developed a short to ground Status Coil has been replaced with #205. Investigation is underway at FNAL. *QA Issues at LBNL: Issue Short Coil-to-Ground in MQXFAP1b Test* logo area Status Traces used starting in coils 107 and 205 was modified to prevent this problem, caused by single wire leaving trace
and pinched by assembly bolt. Magnet assembly procedure was modified to look for, and prevent, pinched wires during the axial end load process. This is in place for assembly of MQXFA03. PMG Meeting 7/23/19 6 June Change Control Board (#12) Management Reserve (MR) Before June BCRs: +950 k$ Approved June BCRs: BCR084: Additional Plasma Coating for CERN BCR083: Cryostat Tooling Platform Delay (same period app.) BCR081: BAC Corrections for 302.2.06 BCR079: Horizontal Test Stand Interconnect Design Mod. BCR077: Magnetic Field Measurements at BNL BCR070: Cable Qual. & Coil Heat Treatment Validation tests BCR059: Replan of RFD CC Schedule June BCRs Total: 560 k$
MR (After June BCRs): +950 k$ (before June) 560 k$ (June BCRs) = 390 k$ July BCRs: Change Control Board Meeting (CCB #13) scheduled for 7/26/19 logo area PMG Meeting 7/23/19 7 ICB-A Occupancy Occupancy of ICB-A delayed at least to Aug. 21st 2019 (from ~May 19) Necessity to integrate fire alarms from 3 connected buildings without fire-retardant boundaries: ICB-, ICB-A and IB-3 Issue known since beginning of ICB-A project, but funds made available only in March 19. Round of bids and vendor response pushed delivery date to Aug. 21 st known to FESS but APS-TD only notified in July. Needed for storage of Cold Mass parts arriving from CERN (30 tons, 36 x 5 SS Plates) logo area 8
Plans for Today Project Status Financial Situation Project Cost and Schedule Performance QA/QC Issues June Change Control Board Meeting ICB-A Saga Revised Impact of CERN Cryostat Tooling Delay MQXF International Review @ CERN Future PMG/RMB/TB/CCB BNL Reports Technical Status of 302.2.05 and 302.4.01 logo area PMG Meeting 7/23/19 9 CERN Cryostat Assembly Tooling Delay CD-2 baseline specified CERN cryostat tooling delivery in August 2019 (approved by CERN on EDMS No 1825173) Operational tooling needed by February 2020 to cryostat the AUP prototype cold mass On 6/10/19, the CERN WP Leader (Ezio Todesco) communicated to AUP Project Office that the new likely vendor delivery date for this tooling is now September 2020.
A delay of 13 months compared to the CD-2 baseline Reason: contracted vendor default (financial difficulties). CERN contracted a new vendor (Applus) CERN Cryostat logo area AUP Cold Mass PMG Meeting 7/23/19 10 Interactions on Tooling Delivery Analysis presented at June PMG#19 was discussed with CERN. CA#1: CA#2: .. CA#10 Delivered by Jul 22
Delivered by Oct 22 (Jul 21 in Baseline) (Nov 21 in baseline) Delivered by Mar 25 (Oct 24 in Baseline) In late June 2019, CERN expressed concern about the viability of String Test at CERN in CY23, and committed to: Anticipate delivery of CryoAssembly Tooling to July 20 Insure mechanical calculation availability from manufacturing Company to allow expeditious commissioning at FNAL New schedule and cost analysis performed. logo area PMG Meeting 7/23/19 11 Interactions on Tooling Delivery (cont.)
~8 months delay in CA#1 & #2 Minor delay in CA#10 Cost Difference: +511 k$ Communicated to CERN Management BCR addressed in one of the future CCBs. logo area 12 MQXFA International Review Charges Magnet requirements and final design status, including cold mass with its interfaces (cryostats, electrical, hydraulic, mechanical, vacuum) and integration issues (cold mass and integration will be assessed at the level of preliminary design stage) Have major design alternatives been considered? Status of program Results of model magnets and status of prototype magnets
Conductor performance, procurement status and plans Status of Production Tooling, finalization of design and procurement; Components procurement, status and plans Test plan, QA/QC, and safety aspects Risk registry and mitigation measures Status of the US-CERN Collaboration Strategy for magnet construction and/or procurement and overall schedule 10 presentations from HL-LHC AUP (out of 25) logo area PMG Meeting 7/23/19
MQXFB04 MQXFB05 MQXFB06 MQXFB07 MQXFB08 MQXFB09 MQXFB10 C C C C C C C March 18 (C&S3) MCBXFBP 1 - proto 1 MCBXFBP 2 - proto 2 MCBXFB01 - series 1 MCBXFB02 - series 2 MCBXFB03 - series 3 MCBXFB04 - series 4 MCBXFB05 - series 5 MCBXFB06 - series 6 MCBXFB07 - series 7 MCBXFB08 - series 8
MCBXFB09 - spare 1 MCBXFB10 - spare 2 MCBXFB11 - spare 3 MCBXFB12 - spare 4 C F C C C S C C C C C C F C C F C
T C F C C F C 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024
2025 July 19 (C&S3) Q2 Schedule not yet infringing on present LS3 schedule (CY24-mid CY26) PIT Conductor for Q2 (2 CAs) not conforming on rolled Ic test and rejected by CERN logo area PMG Meeting 7/23/19 14 Sample of AUP Slides L. Cooley on Conductor/Cables logo area R. Carcagno on Production 5% higher yield on Cable 4.5% lower yield on Coils G. Ambrosio on NC Experience PMG Meeting 7/23/19 15
Sample of AUP Slides (cont.) S. Feher on VT and CM logo area J. Blowers on QA/QC 16 MQXFA International Review Close-out Major Comments or Recommendations: We expect that the new full-scale pre-series magnets will demonstrate that all performance requirements can be met. The committee does not see sufficient evidence to change the baseline design for the Quench Heater at present, but investigation of alternatives would be reasonable. REC: We recommend that all CERN MQXFB magnets be fabricated using RRP strand to maintain both schedule and performance (irrespective of the results of contractual discussions between CERN and the PIT vendor) Experience with the 11 T dipole project and a mid-2020 contracting date would suggest achieving full MQXFB production sometime in 2021 Total production rate is limited by the reaction furnace cycle. Additional furnace capacity could have significant impact on the CERN critical path Careful consideration of the integration and training schedule for an external fabrication team is critical REC: Reassess the construction schedule including:
The external team ramp-up Possible addition of reaction furnace capacity at CERN logo area PMG Meeting 7/23/19 17 MQXFA International Review Close-out (cont.) Comments or Recommendations relevant to HL-LHC AUP: The AUP plan is well thought out. Obtaining pre-series test data is the top priority REC: Reconsider whether plasma-coated end parts are a technical necessity Some issues need to be resolved on the US side before CD3, for example: Number of pre-series magnets Acceptance Criteria REC: We recommend that no magnets be rejected if they achieve nominal field + margin (% TBD), but not ultimate field logo area PMG Meeting 7/23/19 18
Future PMG/TB/RMB/CCB/POG July CCB#13 on Friday, July 26th Management Reserve will need to be replenished, especially after CERN Cryostat Tooling Delay is processed Propose to cancel August PO meetings September PO Meetings PMG: TB/RMB: CCB: logo area Sep 17th (3rd Tuesday) Sep. 11th (2nd Wednesday) Sep 18th (3rd Wednesday) PMG Meeting 7/23/19 19 Summary Contingency on work-to-go remains healthy (42.8%), and SPI/CPI trends are reasonable A sizable withdrawal from contingency funds ($0.5M) in the near future is anticipated to absorb the CERN cryostat
tooling delivery delay This delay produced a revision of the AUP early/late cryoassemblies delivery dates agreement with CERN. Such revision has already been communicated to CERN Management. MR will need a replenishment after BCR is processed Positive outcome of MQXF International review at CERN. Acceptance Criteria on Ultimate Current and number of preseries elements. logo area PMG Meeting 7/23/19 20 Support Slides logo area 21 June Change Control Board #12 (cont) BCR084: Additional Plasma Coating for CERN CERN requested additional Coil parts plasma coating. This is a direct cost of $18,400 which will be invoiced at FNAL in October 2019. This amount will be reduced from the CERN exchange activity. BCR083: Cryostat Tooling Platform Delay (same period app.)
In June, 2019 CERN informed AUP that a new vendor had been selected to fabricate the cryostat tooling to be used at Fermilab and that the delivery of the cryostat tooling would be delayed by 13 months. The tooling design from the new vendor will not be complete for another 3-6 months. The project schedule currently has an activity to place a concrete platform to support the tooling, as designed by the previous vendor, in July, 2019. Due to the selection of the new vendor and possible design changes to the tooling, it is not prudent to place the concrete platform in July as scheduled. This activity will be pushed out until January of 2020 to allow the new vendor time to complete the design and notify AUP of any changes needed to support the tooling. BCR081: BAC Corrections for 302.2.06 At the time of creating a baseline, the costs for material received for the Additional Tooling at BNL (CTC 302.206M7002), Additional Coil Shipping Fixtures (CTC 302.206M7003) and Additional Magnet Shipping Fixtures (CTC 302.206M7004) were added as actual costs prior to February 1 but not reduced in the budgeted activities after February 1. This has resulted in the budget for this control account to be erroneously increased by $217k. This BCR will add activities to decrease the budget under the 3 chargeable task codes by the appropriate amount, bringing the budget for the control account to a more realistic total. logo area PMG Meeting 7/23/19 22 June Change Control Board #12 (cont) BCR079: Horizontal Test Stand Interconnect Design Mod. There are 3 items that require modification to the Cryo-mechanical Horizontal Test Stand activities: 1) Risk RT-302-4-04-008, Test stand mechanical and thermal interface
compatibility issues, materialized. The recent cryo-assembly design changes triggered this risk. New estimates include the following upgrades: The existing Lead end mechanical interface will not match the interconnect design for the CERN provided cryo-assembly. Design and fabrication of the interconnect sleeve and new lambda plug is required. The adapter box piping and anchor system design must be modified to meet high-pressure test requirements. The existing Return End Box and thermal shield will not match the interconnect design and thermal shield configuration for the CERN provided cryo-assembly. Design and fabrication of the return box vacuum shell and thermal shield is required. Estimated cost impact is 2190 hours of Labor and 57 k$ of M&S. 2) High pressure helium supply line, as well as Feed box and cryo-assembly relief lines will be fabricated and installed through the fixed price contract. Estimated impact: M&S is increased by 55 k$, and labor is reduced by 360 hours. 3) Q1/Q3 cryoassemblies will be protected using CERN provided heater firing units (HFU) that are identical to the ones that will be used during LHC operation. CERN HFUs must be upgraded to make it compatible with the horizontal test facility and the quench protection system at Fermilab. Estimated impact is 476 hours of labor and 21 k$ M&S logo area PMG Meeting 7/23/19 23 June Change Control Board #12 (cont) BCR077: Magnetic Field Measurements at BNL .. . It will allow us to study field harmonics and its relationship to the cable pitch length in more detail. Once the two new probes are ready, they will be shipped to BNL for further assembly and calibration, for planned magnetic field measurements as part of the vertical magnet testing at BNL.
BCR070: Cable Qual. & Coil HT Validation tests As a follow-up on a recommendation from the cable PRR, in order to fast track the quality assessment of the Rutherford cables without having to wait for the coil heat treatment to be completed, the project is changing the current test plan. See attached file "AUP BCR070 Summary - June 2019_Rev2.pdf" for the complete description of this change. BCR059: Replan of RFD CC Schedule This baseline change is necessary in order to meet the early delivery dates agreed with CERN, while taking into account 2 planned failures among the total of 12 cavities. This is achieved by consolidating activities such as the Bare cavity supplier fabricating the braze joints and the raw niobium supplier performing also the UT Inspections. However, consolidating the work still does not meet the dates. POs for magnetic shields for the preseries cavities must be placed in the first half of FY21. This is approximately $41k. The failures will be planned so that the 1st failure is at the bare cavity processing and the other is during the dressed cavity processing. The bare cavity that will fail or not meet all requirements will not be dressed, resulting in only 11 dressed cavities. logo area PMG Meeting 7/23/19 24
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