BNL/AGS RSVP Upgrades Project WBS 1. 4 Rare Symmetry Violating Processes Preliminary Baseline Review Brookhaven National Laboratory 6 -8 April 2005 Phil Pile
BNL/AGS RSVP Upgrades Project Outline • AGS Complex • RSVP AGS Project o Technical Specifications o Work planned and approach • • • 2 P. Pile Construction costs and labor estimates Operations costs Project management RHIC related issues Final comments RSVP Preliminary Baseline Review April 6 -8, 2005
AGS/RHIC Accelerator Complex 12: 00 o’clock PHOBOS 10: 00 o’clock RHIC PHENIX (p) 8: 00 o’clock High Intensity Source 4: 00 o’clock STAR (p) 6: 00 o’clock U-line NSRL (NASA) BRAHMS & PP 2 PP (p) 2: 00 o’clock m g-2 Fast extraction RSVP (NSF) LINAC Pol. Proton Source BOOSTER AGS: • Intensity: 7 1013 protons/pulse • Injector to RHIC: < 1 hour about every 4 hours Slow extraction TANDEMS 3 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS Experimental Area The Plan • D-Line Decommissioned • Switchyard simplified V 1, p m Beam Line • A, B, C Lines run as “OR’s” FY 2006+ Experiments V-Target U Line RHIC Transfer Line * D-Target NASA Radiobiology D-Line: Decommission FY 2006 P. Pile * B-Target C-Target 4 A 3 – RSVP, MECO E 940, m N® e. N * ** A-Target B’ -Target * B 5 – RSVP, K 0 PI 0 E 926, KL 0 ® p 0 nn RHIC e. Cooling Test Facility (under construction) RSVP Preliminary Baseline Review April 6 -8, 2005
AGS Beam Specifications • K 0 PI 0 AGS Beam Specifications: – Momentum = 25. 5 Ge. V/c – Spill length = 4. 9 sec • actual spill length will be determined once rates are known and experiment optimization is complete – – Rep rate (AGS cycle time)= 7. 2 sec Intensity = 100 TP/spill Time between bunches = 40 nsec Beam bunch width = • 200 psec RMS (baseline) • 260 psec RMS (without 100 MHz cavity) – Extinction between bunches = 1 x 10 -3 – Beam size on target (95%) • 2 mm full width vertical, • ~ 4 mm horizontal – Beam hours: • engineering run = 800 hours • requested physics run – 12000 hours at 100 TP/spill (see Littenberg talk) • total integrated protons for physics run = 6. 0 x 1020 (with 4. 9 sec spill length) 5 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS Beam Specifications • MECO AGS Beam Specifications: – – Momentum = 7. 5 Ge. V/c Spill length = 0. 5 sec Rep rate (AGS cycle time) = 1. 0 sec Intensity • Experiment goal = Two bunches/AGS cycle 20 TP/bunch • AGS base-line (achievable) = 20 TP/sec – – – Time between bunches = 1350 nsec Beam bunch width < 50 nsec full width Extinction between bunches = 1 x 10 -9 Beam size on target = 1 mm RMS (radius) Beam hours: • engineering run = 800 hours • physics run – 2800 hours at 40 TP/spill (stretch goal) – 5600 hours at 20 TP/spill (base plan) • total integrated protons for physics run = 4. 0 x 1020 • Run time will depend on achievable muon flux, actual background rates etc. . 6 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS Complex NSRL to RHIC K 0 PI 0 Linac MECO Booster AGS HITL 7 P. Pile RSVP Preliminary Baseline Review C-AD Admin April 6 -8, 2005
Booster Modifications NSRL (NASA) Booster injection carbon blocks to protect C 5 & C 7 p Injection – Other: BLM, PFN and RF upgrade, new cables, tray, dipole coils and controls Environmental CAP for Booster C 3 HI inflector at risk with high intensity p, active protection planned Only one spare F 6, need another before resumption of high intensity p operation HI Injection LTB collimator – protects C 5 & C 7 8 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS Modifications. New H 20 electrostatic Septum (at I 20) Reliability&Aperture 100 MHz Cavity 25 MHz Cavity BTA Upgrade (CFI) A 5 upgrade New A 10 modules Other: BLM, PFN and RF upgrade, new cables, tray, dipole & sextupole coils and controls Environmental CAP for AGS New F 5, F 10 & PS’s Reliability & Aperture improvement 9 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Switchyard and Primary Beams (present) MECO Switchyard – rebuild/simplify New proton beam transports 10 P. Pile RSVP Preliminary Baseline Review K 0 PI 0 April 6 -8, 2005
Booster and AGS Modifications Why make modifications to the Booster and AGS 1. To meet the RSVP experimental specifications 2. To resume operations with high intensity 3. To ensure compliance with laboratory environmental protection guidelines. RHIC Consideration: To ensure that RSVP operations do not compromise the operation of RHIC 11 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RSVP ESHQ Requirements • QA – – – – • QA Plan Procurement and Specification Reviews Action Tracking System Management, EMS and OSH Assessments Operations Procedure Reviews Configuration Management Records Management NEPA – Baseline groundwater monitoring (~3 wells added) – Baseline external radiation monitoring – Environmental Assessment and FONSI • Covered by AGS EA #0909 – Air and water related permits • Commissioning/Operations – – – 12 Unreviewed Safety Issues for Radiation, Vacuum Vessel and Cryogenic Issues (DOE) Accelerator Safety Envelope (DOE) Environmental Process Evaluation Facility Risk Assessments Job Risk Assessments Accelerator Readiness Review (DOE) P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Electrical Safety / Fire Safety / Cryogenic Safety / Equipment Handling Issues and Requirements • Damaged/aging AGS Ring and Booster components: – Magnets, cables and breakers need to be repaired, replaced • Experimental safety reviews required, for example: – Equipment must meet UL or equivalent – Experimental layout must be OSHA compliant • Electrical safety reviews required – Quench protection and power supplies • Cryogenic reviews required – ODH, controls and pressure vessels • Critical lift reviews 13 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RSVP construction during RHIC operations • Present situation – during RHIC injection o o Switchyard not accessible with beam in AGS K 0 PI 0 primary cave (B-line) accessible MECO primary cave probably ok, fault study needed Almost decoupled from RHIC operations • Plans o AGS extraction beam plug Ø Will allow access in switchyard and elsewhere in AGS SEB area o New A-line (MECO) elevated beam transport Ø Will allow beam in any other beam line Ø Will allow work on MECO primary beam from RF Kicker on o New B-line (K 0 PI 0) beam plug Ø Will allow beam in any other beam line Ø Will allow work on K 0 PI 0 primary beam outside of switchyard o This decouples RSVP construction from RHIC operations o AGS/Booster work must, of course, be scheduled during normal RHIC shutdown periods. 14 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS/Booster – WBS 1. 4. 1 ($18. 2 M + 25% cont) • Four parts to this – AGS/Booster legacy repairs and high intensity upgrades (9. 8 M + 22% cont) • Result of internal analysis since the Jan 04 DOE Review • Environmental requirement - Radiation Caps (rain barriers) on AGS and Booster is largest piece ($3. 1 M + 22% cont) – MECO Specific Modifications ($1. 9 M + 27% cont) • Beam inter-bunch extinction hardware – K 0 PI 0 Specific Modifications ($5. 7 M + 31% cont - NSF) • Beam bunching RF cavities • Booster-AGS upgrade (for intensity) • Off-project CFI contribution ~$7. 2 Canadian $’s – AGS/Booster project support ($0. 9 M + 20% cont) 15 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Switchyard – WBS 1. 4. 2 ($2. 9 M + 21% cont) • Existing switchyard not in condition to support high intensity operation for RSVP experiments • Simplification/Modernization planned – – Beam plugs to decouple construction work from beam development Replace obsolete equipment Minimize beam loss Achromatic beam tunes to target stations • No beam servoing • No ramped magnets – No beam splitters • No beam sharing • No Lambertson magnets – Less instrumentation needed – Less maintenance • NASA AGS facility relocation (A 3 to Switchyard) 16 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
K 0 PI 0 – WBS 1. 4. 3 ($8. 0 M + 27% cont) • Primary Beam up to and including target station Neutral Beam • Experimental area • Project support and integration 17 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
KOPIO Neutral Beam D 4 Sweeping Magnet Neutral beam collimator system Proton Beam Dump 18 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
MECO – WBS 1. 4. 4 ($7. 9 M + 23% cont) • Primary Beam up to and including target station • Superconducting Solenoid and refrigeration infrastructure (support role – see WBS 1. 5) • Experimental area • Project support and integration 19 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
MECO Final Installation Compressors RF Modulated Magnet (RFMM) A-Line Primary Proton Beam MECO Detectors (Removed from DS) Electronics Hut P. Pile Transport Solenoids (TSu & TSd) Refrigerator Counting House Valve Box Lambertson Magnets Beamline Power Supplies 20 Solenoid Power Supplies Detector Solenoid (DS) RSVP Preliminary Baseline Review Production Solenoid (PS) & Proton Target Beam Stop Proton Target Cooling System April 6 -8, 2005
AGS Project Office – WBS 1. 4. 5 ($2. 3 M + 20% cont) • • 21 Overall schedule and integration Fiscal ES&H and QA Reporting P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Basis of cost estimates • Level 3 sub-system managers are responsible for cost estimates and schedules for their work • Bottoms-up approach to cost and scheduling – The physicist or engineer responsible for the work estimated the cost and developed the schedule – this individual holds the Cost Book and Project file – WBS 1. 4 has 10 cost books and 40 individual project files – Schedules were developed consistent with target milestones determined by experiment needs (tempered with reality) – Contingency was estimated using the “Lockheed” formalism (levels and weights) – Costs were scrubbed at least once by peer group C-AD engineers/physicists – Individual fully-loaded project files are linked to a Master Project file. Costs, schedule and personnel requirements etc presented at this review came from this file. 22 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 AGS Upgrades Cost Summary FY 05 $’s (1/2) 23 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 AGS Upgrades Cost Summary (2/2) 24 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 costs (FY 05) 25 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS/Booster CAPS 26 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 costs 27 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 Work 40 FTE’s per year 28 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 Work 40 FTE’s per year 29 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Personnel Issue Impact of RSVP on RHIC • Past experience has taught us: Ø We can augment our C-AD work groups up to ~10% to support other activities with little disruption to RHIC support. The additional personnel are either used to back-fill RHIC work or to work directly for the other activity with supervision coming from permanent C-AD personnel. 30 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 Work 10% of C-AD work-force 31 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RSVP Operations Cost RSVP Specific Considerations – Cost basis • Since the RHIC program does not support any manpower for AGS experiments all experimental area manpower support will be billed to the NSF consisting of: Ø a base manpower level that supports the extraction system, switchyard transport, primary proton transport and the primary target area (common to both RSVP experiments) Ø Incremental manpower for each experiment 32 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RSVP Support Personnel The supplemental base manpower estimate is comprised of the following: • • • Physicist Engineering (mechanical, electrical) Controls Instrumentation Vacuum systems Magnet systems Power supplies Utilities (power, water, AC) Extraction systems ES&H, QA, Admin, training (org. burden) Shift operations Total FTE 1 1 0. 5 1. 5 2 1 0 2 12 K 0 PI 0 specific manpower support • • Physicist, engineering RF systems (microbunch) Technicians (inst. , vacuum, magnet etc. ) 1 1 2 Total 4 Physicist, engineering Cryogenic engineering, technicians Technicians (insert. , vacuum, magnet etc. ) Total 1 3 2 6 MECO specific manpower support • • 33 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Operations Cost Basis RSVP Specific Considerations • RSVP manpower is matrixed into the Collider-Accelerator Department staff Ø Main control room operations is sufficient to cover SEB operations during RHIC collision operations except for an incremental effort to support the SEB extraction system Ø RSVP support personnel will come from the present C-AD staff together with new hires Ø C-AD RSVP support personnel will retain RHIC responsibilities at a reduced level Ø When a conflict between RHIC and RSVP support arises, RHIC support will win in all cases that could impact RHIC operations Ø Material costs are based on actual costs of AGS operations in support of HEP and NP fixed target experiments (late 1990’s). Full costs are recovered if running outside RHIC operations, otherwise the costs are incremental to RHIC operations. Ø Pre-Operations are similarly handled but with reduced costs due to reduced indirect charges (part of construction project) and limited operation (equipment development/testing). 34 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
NSF Indirect Charges • • • Salary Consultants DTS MSTC Subcontracts(>$25 K) Subcontracts (>$600 K) Pre-Ops 39. 7% 17. 5% 12. 0% 25. 7% 13. 7% Ops* 98. 3% 46. 3% 38. 2% 56. 0% 21. 5% 20. 8% (only applies to first $600 K) * Includes 3% full cost recovery 35 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Guidelines/assumptions for Example RSVP Operations (1) AGS not available for RSVP during 1 st 7 weeks of RHIC operations and for 4 weeks/additional beam during a given year (2) Last week of RHIC operations is considered running outside RHIC operations since this is cryo warm-up week (injectors not running) (3) AGS is available for RSVP the balance of the time after reserving 15 weeks for shutdown work (4) 80 full intensity hours/week are available for RSVP experiments during RHIC Operations (5) 120 full intensity hours/week are available for RSVP experiments outside RHIC Operations (6) 20 TP/sec available for MECO at 7. 5 Ge. V/c, linear ramp-up from 10 -17. 5 TP in FY 12, 17. 5 -20 in FY 14 (7) 100 TP/4. 9 sec spill every 7. 2 seconds available for K 0 PI 0, linear ramp-up from 30 -75 TP in FY 11, 75 -100 in FY 13 (8) RHIC Cryo Operations based on "Constant Effort" budget - 27 weeks per year (9) Assumes K 0 PI 0 construction ends in FY 2010 followed by 8 week engineering run in FY 2011 followed by physics run (10) Assumes MECO construction ends in FY 2011 followed by 8 week engineering run in FY 2012 followed by physics run 36 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Example Operations Plan 37 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RSVP Project Organization (Partial) RSVP PROJECT DIRECTOR and DEPUTY W. Willis, J. Kotcher KOPIO WBS 1. 2 M. Marx C-AD Accelerator Div. Head T. Roser AGS WBS 1. 4 P. Pile/ A. Pendzick MECO WBS 1. 3 M. Hebert 1. 4. 1 AGS Booster K. Brown 1. 4. 4 MECO D. Phillips 1. 4. 2 Switchyard A. Pendzick MECO Magnet WBS 1. 5 B. Smith 1. 4. 5 Project Office 1. 4. 3 K 0 PI 0 C. Pearson 38 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Some Management Milestones • AGS Upgrades Project, some milestones – AGS/Booster • Ready for high intensity – 12/1/2009 – AGS MECO Specific • AC Dipole and strip-line kickers ready for commissioning – 11/1/07 – AGS K 0 PI 0 Specific • • A 10 Kicker delivered to BNL – 4/1/08 25 MHz cavity – Ready for tests in AGS – 10/1/09 • 100 MHz cavity – Implementation decision – 10/1/07 – Ready for tests in AGS – 12/3/10 39 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Some Management Milestones • AGS Upgrades Project, some milestones – Switchyard • AGS/Switchyard radiation areas separated – 9/4/06 • Beam plugs installed – 11/1/06 • Complete – 12/3/07 – K 0 PI 0 • • • Detector Pit Complete: 8/20/07 Proton Beam Line Complete: 10/1/08 Neutral Beam Line Complete: 12/1/08 Electronics Hut Ready: 5/1/09 D 4 Sweeper Ready: 6/1/09 (Ready for Beam) – MECO • • 40 P. Pile A-Line Ready for Beam Tests: 10/1/07 A-Line Ready for Solenoid Installation: 4/1/08 Design Review Complete for A-Target: 1/15/09 A-Line Ready for Beam to MECO target: 6/1/11 RSVP Preliminary Baseline Review April 6 -8, 2005
Experiment construction milestones RSVP Beam Development Possible K 0 PI 0 Engr/Physics Run 41 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Machine construction milestones RSVP Beam Development Possible K 0 PI 0 Engr/Physics Run 42 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 Milestones Page 43 of 60 43 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Management during construction • Work is defined by yearly MOU’s between the AGS project, RSVP Project office and experiments. • Matrix RHIC personnel and new hires to support RSVP construction • RHIC priority will be maintained – Conflicts will be handled with goal to not seriously impact established RSVP milestones – overtime, second shift…etc. 44 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Management during construction • Cost Risk – C-AD work is not out of the ordinary so the risk of cost overruns is not so large. – Changing experiment requirements present cost risks and close liaison with experiments is essential – Cost risks will be mitigated through use of contingency 45 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Management during construction • Schedule Risk – K 0 PI 0 – 25 MHz cavity delivery from Triumf is a possible risk • Must be installed during summer 2009 to be ready for development run in 2010 and physics run in 2011 • Present delivery date (1 March 2009) is preliminary estimate from Triumf – must have by 1 July to commission with beam in 2010 four months float. • Close coordination between C-AD and Triumf is planned and is a must – MECO – Critical path is superconducting magnet installation • 1 June 2011 is present date for completion with engr/physics run in 2012 • Leaves ~ 6 month of schedule float to 1 Jan 2012 enrg/physics run – Will mitigate with overtime/second shift (contingency) if possible – Close liaison with experiments is critical to all our efforts 46 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Management during construction • Schedule Risk (cont) – RHIC Programmatic needs will take priority over RSVP construction and could lead to RSVP schedule risk. • Mitigated by careful planning, integration of RSVP into day-to-day C-AD activities and use of overtime, second shift etc when called for. 47 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Management during construction (and operation) RSVP Specific Communications Meetings: • • RSVP will be integrated into our normal management meetings that are relevant to the project, such as the work planning meetings of the Experiment and Facilities support division and the Accelerator Division. • 48 Plan to continue weekly RSVP specific meetings (these began in July 2004), including relevant Department personnel and representatives from the experiments, to discuss management issues, technical progress, schedule and cost issues throughout the life of the project. Other invitees include representatives from the RSVP Project Office and the DOE Brookhaven Area Office. This will integrate key RSVP personnel into RHIC planning so they become a participant in the scheduling and priority setting process P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RSVP Operations Support • C-AD operational crews (CAS Watch) are maintained on a 24 hr basis, 7 days a week during RHIC operations and shutdowns to provide: o Safety surveillance of C-AD experimental areas and equipment o General support for experiment and accelerator operations o This crew, appropriately augmented, will provide operations support for RHIC and RSVP 49 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
RHIC and RSVP • Programmatic risk for RHIC – Low risk – RHIC priority will be maintained – High intensity operation of Booster/AGS could lead to component failure and impact RHIC operations • Mitigated by pre-emptive component replacement and staying within acceptable RSVP operations parameters. • The Jan 2004 “DOE Review of RSVP Activities at BNL” had as a principal charge “ to review impact of RSVP work on RHIC operations” – Quote from findings: “In summary, the Committee concluded that the RSVP experiments will have minimal impact on the Nuclear Physics program at BNL. Plausible solutions exist for potential higher failure rates or longer repair times. The overall management structure of the project was found to be in the initial stages of development. ” 50 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Final Comments • C-AD has had ~50 years of experience with management, construction and operation of fixed target experiments • RSVP construction and operations will take full advantage of this previous experience. • RSVP construction is not out of the ordinary. 51 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Supplemental Material 52 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
AGS RSVP Project Office AGS Office P. Pile, Project Manager A. Pendzick, Deputy Project Manager WBS 1. 4 Fiscal D. Sappo QA D. Passarello ES&H E. Lessard Mechanical Engineering J. Tuozzolo Electrical Engineering J. Sandberg AGS/Booster K. Brown WBS 1. 4. 1 53 P. Pile Switchyard A. Pendzick WBS 1. 4. 2 K 0 PI 0 C. Pearson WBS 1. 4. 3 RSVP Preliminary Baseline Review MECO D. Phillips WBS 1. 4. 4 Project Office P. Pile WBS 1. 4. 5 April 6 -8, 2005
54 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
Basis of cost estimates • We have a total of 10 cost books. • 1) RF Systems 2) Mechanical 3) Switchyard 4) KOPIO 5) KOPIO Electrical 6) Security 7) Instrumentation 8) Electrical 9) Controls 10) MECO 55 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
WBS 1. 4 Materials & Labor 56 P. Pile RSVP Preliminary Baseline Review April 6 -8, 2005
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