# Presentation: 828897

## Technical Division FY2006 Budget Review

**Bob Kephart/Victor Yarba**
**Oct 31, 2005**

- FY06 TD Budget presentation

- 10/31/05

## Outline

**Mission and Overview of the Technical Division ( Bob)**
**What we do **
**TD Organization and Personnel**
**FY05 Labor Plan vs. Reality**
**FY05 Closeout and Comments**
**FY06 Guidance (Victor starts here)**
**FY06 Labor Plan & SWF income from “outside” projects**
**FY06 SWF and M&S analysis for the Division **
**Overall Budget Analysis**
**Discussion of M&S **
**Conclusions**
**ILC/PD/SCRF Budget discussion (Bob)**
**TD LWWBS comparison FY05 vs FY06 if desired (Rich)**

- FY06 TD Budget presentation

- 10/31/05

##  Technical Division Mission

**  **
**   ****The research, development, design, fabrication or procurement, and testing of accelerator and detector components**
**The Technical Division provides labor, expertise, and facilities for a variety of activities related to this mission**
**Accelerator R&D activities: ILC, PD, and LHC**

- FY06 TD Budget presentation

- 10/31/05

## What we do

**Support the Accelerator Complex**
**Conduct Accelerator R&D**
**Support Projects**
- CMS muons, LHC Accelerator Project, Pierre Auger
**Provide Lab-wide Services**

- FY06 TD Budget presentation

- 10/31/05

## Support the Accelerator Complex

**Design & build accelerator magnets and components**
- Repair conventional and SC magnets for the entire accelerator complex
- Design/build new magnets and devices as required by AD
- Magnets for accelerator improvements (Booster: Orbump and new corrector package; MI: large aperture quads & Lambertsons; etc.)
- Electrostatic separators and reversing switches
- Kicker magnets (new) and other specialty magnets & devices
**Magnetic measurements**** **
- Operate Magnet Test Facility (MTF) including 1500W He refrigerator
- Design and build magnetic measurement equipment
- Measure both conventional and SC magnets on test stands
- Maintain historical database of magnetic measurements

- FY06 TD Budget presentation

- 10/31/05

## Support the Accelerator Complex

**	****In FY04 and FY05 TD took on a number of non-traditional responsibilities as part of the overall lab effort to help AD solve Run II problems**
**Run II **** (“extra”)**
- Studies of Tevatron magnets
**Measurements in MTF to understand persistent current phenomenon** (e.g.  Tune drifts, 150 GeV lifetime & losses... this has led to new Tevatron b2 unwind corrections and revised Tevatron operating procedures)
**Reshimmed additional dipoles to further reduce coupling in the machine, with work to be completed during the 2006 shutdown**
**Identified lug alignment errors on two quadrupoles, explaining observed coupling and specifying corrective rolls**
- Electron Cooling/ Recycler vacuum work
- Study and improve the AP2/debuncher apertures, etc....
**Provided lots of experienced technicians for shutdowns**

- FY06 TD Budget presentation

- 10/31/05

## The “level of effort” in TD to build magnets and other devices in FY06 is projected to be very similar to FY05  
Details later in the talk
However, with the completion of many of these  “extra” projects, the FY06 “extra” effort on Run II is planned to be < FY05 
These people are being redirected into ILC/PD/SCRF

- Details later in the talk
**However, with the completion of many of these  “extra” projects, the FY06 “extra” effort on Run II is planned to be < FY05 **
- These people are being redirected into ILC/PD/SCRF

- Support the Accelerator Complex

- FY06 TD Budget presentation

- 10/31/05

## Accelerator R&D and Services

**R&D  ****(Now a major part of the Division’s effort)**
- SC magnets for future accelerators: HFM, LARP
- International Linear Collider R&D
- Cavity & Cryo-module development and new assembly facility in MP9
- ILCTA, PDTA:  with AD developing facilities to test cavities and modules Several locations on site:   MDB, NML, IB1, etc
- SCRF:
-  3rd harmonic module for DESY (exchange for DESY TTF 1.3 GHz module)
- Lead a Collaborative SCRF materials program ( FNAL + UW + NW + Cornell + JLAB + MSU + etc...)
- SCRF linac based Proton Driver
**Labwide Services**
- Machine shops, welders
- Materials Development & Engineering Labs: materials expertise, testing facilities, electron microscope, etc.
- Material Control (QC, CMM’s, etc.  for entire lab)
**All these are supported by TD base funding**
- Except: Machine Shop operates with a charge-back system, and
- LARP which is direct funded from DOE

- FY06 TD Budget presentation

- 10/31/05

## Projects

**“****inside”   projects  = funded by TD base budget**
**“****outside” projects  = funded outside TD base budget **
**LHC** (IR Quads, management, accelerator science)
**LARP** ( new: LHC Accelerator Research Program = design 2nd generation LHC quads using Nb3Sn technology,commissioning, instrumentation)
**Pierre Auger** (engineering design/construction, project management)
**ILC:  (New) Funds will move to a project in Directorate**
**Some projects provide SWF income to TD, ****but not all**
**Funding:**** ****These projects represent a significant part of the TD’s effort and provide substantial SWF “income”**
**In FY05 we got ****$ 2,338 K**** in SWF income from these “outside” projects and “handled” their M&S funds**

- FY06 TD Budget presentation

- 10/31/05

## LHC Accelerator Project Status

**$200 M DOE funded Project **
- FNAL = Project Office
- Project Manager: J. Kerby
**Excellent Progress Continues**** **
**BNL: IR Dipoles and Cable Tests --****Complete**
- All production and testing complete
- 17 of 20 at CERN; 1 en route; last 2 await shipping container availability
**LBNL: DFBX and Absorbers –****Complete**
- DFBX (IR feedboxes) 8 of 8 items complete at Meyer Tool!
- Last 2 ship this week. Strong FNAL assist in engineering and production oversight.
- All IR Absorbers at CERN
**FNAL: IR Quadrupoles**
- 7 of 9 LQXB complete; 14 of 18 LQXA or C complete
- 14 of 27 magnets are at CERN, 3 more en route
**Project finishes in FY06**
- CD4A (98%) completed Sept 30, 2005; punch list items to finish
- CERN to start installation in early 2006

- FY06 TD Budget presentation

- 10/31/05

## LHC Project Endgame

**Laboratory Contribution increased in April 2005**
- Contingency analysis showed previous position was not sustainable
- DOE, FNAL, CERN, LBNL and BNL involved in negotiations
- All labs helped to control costs...
- FNAL Directorate agreed to pick up $400K of TD SWF associated w/ rebuilds on TD base budget in addition to previous FY05 agreement
- Project on tract to a “close”  but successful completion in March 06
**Also in FY05 CERN declined TD offer for additional work. Focus is on completion of original scope**
- No extension of SC cable testing @ BNL
- No additional spare collared coil assemblies
**Division SWF “income” from the LHC project is expected to be only     $ 238 K in FY06. (****ie down by $ 1,212K compared to FY05****)**

- FY05= complicated story
- More project $, but more OT
- BTEV, magnet problems  more
- effort from TD operating funds

- * Chose to include $ 175 K of material control here. $ 334 + 175 = 509K

- FY06 TD Budget presentation

- 10/31/05

## LARP

**Program was approved and is direct funded by DOE**
**The LARP program continues to ramp up in FY06**
-  BNL, LBNL, FNAL, SLAC collaboration
- Steve Peggs (BNL) = Program Leader
**AD collaborates on Accelerator Physics and Instrumentation**
**TD’s principal activity is collaborative development of  2****nd**** generation IR quads based on Nb****3****Sn **
- fits closely with baseline HFM plans, see next slide
**LARP funds people to help commission US built hardware @ CERN**
**All funds are in TD; AD charges against TD codes**
- M&S includes travel in both Divisions, expected to be > $ 120 K in FY06
**LARP TD budget guidance= ****$2, 922 K****  but using actual numbers from Steve Peggs we get a lower number**
**His total allocation to Fermilab in FY06  including G&A is = ****$3,207 K**

- FY06 TD Budget presentation

- 10/31/05

## LARP

**From the LARP work sheets here is how this breaks down**

- LARP TD SWF increase is
- $879 K vs 1212 K decrease in
- LHC Project  net outside
- magnet SWF income is down   $ 333K in FY06

**Note: AD showed $406 K SWF in budget presentation, but worksheets show $ 505 K**
- Assuming they do the work, AD’s salary burden is actually $ 99 K smaller vs presentation

- FY06 TD Budget presentation

- 10/31/05

## High Field Magnet Program

**Goal of this program is the development of high-field magnets based upon Nb****3****Sn superconductor**
- Materials and Conductor R&D
- Model Magnet program
**Technical Progress**
- FY02-03: model magnets did not achieve desired performance
- After lots of studies and design improvements, the problem was traced to Nb3Sn strand instabilities
- a theoretical model was developed
- series of experiments using strands, cables and simple model magnets were performed to verify the model predictions
-  FY04-05: two cos dipole magnets (accel quality field) were built with PIT conductor (stable) and achieved design field of 10 T and for the first time demonstrated the reproducibility of Nb3Sn technology (major technical success!)
**In the LARP proposal FNAL said we would maintain HFM funding at present levels if LARP was approved**
**HFM Program provides major infrastructure support for LARP**

- FY06 TD Budget presentation

- 10/31/05

## Auger: Status

***Surface Array Status***
**1001 (of 1600) surface detector stations deployed**
**854 surface detector stations have electronics and are operational **
***Fluorescence Detector Status****** ***
**Three (of four) fluorescence buildings complete with a total of 18 telescopes operational. **
***Taking Data!***
***Array should be complete in FY06***

*** ******First Spectrum (Preliminary)***

**Mendoza, Argentina**

**First data set (Jan04 – Jun05)**
**180,000 surface array events**
**18,000 hybrid events**

**Sky map of arrival directions – galactic coordinates**

- FY06 TD Budget presentation

- 10/31/05

## New Initiatives/Changing Priorities

**BTEV**
- The project was cancelled in FY05.  This was very disruptive but...
- It allowed us to move people to ILC, PD, and LARP effort
**In FY04 TD delivered on its NLC x-band commitments producing some of the best 11 GHz copper structures delivered to NLCTA**
- After the ILC technology choice in Aug 04 we stopped all x-band work
**In FY05 we began a major push to develop “world class” facilities and expertise in SCRF (for both ILC and PD)**
**SMTF Proposal for a “broad” DOE funded collaborative SCRF effort**
- Was not approved as proposed by lab & DOE (HEP/Nuclear/BES funds, ILC/PD/RIA/light sources)
- However, DOE was very supportive of FNAL’s plans for ILC/PD cavity development & test facilities
- SMTF  bilateral agreements to collaborate on SCRF
- MOU’s: ANL, JLAB, MSU, DESY, Cornell, etc
- SCRF test capability ( TD collaborates with AD on this)
- SMTF  ILCTA and PDTA
- Horizontal and vertical cavity test facilities ( IB1)

- FY06 TD Budget presentation

- 10/31/05

## ILC

**Overall objective is to provide FNAL with credentials such that it is the chosen international site to host the ILC**
**TD ILC R&D Program ****( Major Ramp up in Effort !)**
**ILC Cryo-module Development**
- Effort in progress to convert DESY type III+ drawings to US standards
- Collaborative design effort on the next generation ILC cryo-module (next slide)
- Cryo-module assembly area in MP9 (clean rooms, fixtures, etc) (expand into ICB)
- Assemble a “cryo-module kit” from DESY
- Purchase cavities and parts for the 1st US built Cryo-module
- Cavities: Accel(4), AES(4), KEK(4) as part of US-Japan agreement
**Cavity development**
- “tight loop” 1.3 GHz  cavity development to reliably achieve 35 MV/M
- Chemistry & EP ( collaboration with ANL, Cornell, JLAB, KEK, DESY etc)
- Vertical & Horizontal test capabilities: In design for MDL & IB1
- 3.9 GHz SCRF 3rd Harmonic
- Build a 4 cavity module  DESY TTF, they give us a 1.3 GHz module kit
- 3.9 GHz accelerating and “transverse kick” cavities for FNPL

- FY06 TD Budget presentation

- 10/31/05

## ILC

**TD ILC R&D Program (cont)**
**Initiated collaborative activity on various SCRF activities**
- Cryomodule: FNAL, Cornell, DESY, INFN, KEK, etc.
- Modulator: FNAL, SLAC
- Initiated an SCRF Materials program (led by TD Peoples Fellow Pierre Bauer, includes  NW, U of Wisc, Cornell, JLAB, etc)
**ILCTA **
- Cavity and cryo-module test facilities in MDL, NM, IB1
- Funded as “SCRF infrastructure”
**Industrialization** (with GDE)
- Forum, but no funds available for industrial studies in FY06
- Need to order cavities & components from industry in FY06 to get them up to speed
**Cost Reduction**
- May be crucial for ILC approval Need to mount an serious effort here
- No funds in FY06 (except what we can steal from elsewhere)
**Accelerator Physics Design ( in collaboration with AD and CD)**
- Main Linac Design
- Damping ring Design
**Misc**
- Piezo electric control of Lorentz detuning
- LLRF development (with AD, Penn, INFN, DESY)

- FY06 TD Budget presentation

- 10/31/05

## IB1 Magnet Test Facility (MTF)

**In FY06 test activities for Superconducting magnets will be significantly reduced (to ~40% of FY05)  ****Why****?**
**Cancellation of BTEV ( no IR quadrupole testing) **
**Completion of Tevatron Studies for Luminosity Improvements**
**Completion of LHC IR quadrupole testing by March 2006**
**MTF Infrastructure for SC Magnet Testing is ideally Suited to SCRF Testing (superfluid-ready cryoplant, trained test staff etc...) **
**Plans are under way for Horizontal & Vertical SCRF Test stands in IB1**

**Horizontal Cryostat**
**Design in progress**

- Footprint for Vertical Dewar and Horizontal Cave in IB1

**Vertical Dewar**

- FY06 TD Budget presentation

- 10/31/05

## Proton Driver

**8 Gev SCRF Linac******** MI ( 2******** 4 MW beam power)**
- Received a strong positive endorsement from the Fermilab Long Range Planning Committee
- PD also strongly recommended by recent APS Neutrino Study
- Ramped this effort up significantly in FY05
**Project Progress**
- Successful Directors Review of the project, Extensive Design Document ~completed in FY05
- CD-0 document in Ray Orbach’s Office, preparing for CD-1 review in Summer 06
**PD R&D program**
- Accelerator physics & the machine design
- Machine civil layout & cost estimate
- Preparations underway for Cavity RF and Front End tests at Meson Lab
- Test Cryostat commissioning ~January 2006
-  Modulator / 325 MHz Klystron commissioning ~March 2006
- SC spoke resonator design (in collaboration with ANL)
- Excellent progress on fast phase shifter R&D, with 2 versions successfully tested

- FY06 TD Budget presentation

- 10/31/05

## The ILC/PD “Opportunity”

**ITRP decision allows PD and ILC R&D efforts at Fermilab to be well aligned**
**This is an amazing opportunity for Fermilab!**
**However, to capitalize on it we will somehow have to commit 10’s of millions of dollars into R&D at a time when lab funding is very tight**
**We are very short on mechanical engineers, designers, and RF experts**
**Progress on both PD & ILC will be limited by:**
- Funding
- Our ability to assign good people to the effort, and
- Our ability to hire a small number of experts

- FY06 TD Budget presentation

- 10/31/05

##    Activity              FY06         FY07 and beyond    Comments
Run II               ~flat               flat?                   “Extras” will roll off
BTEV                ended                                       effort shifted to LARP,PD,ILC
LHC                  ends 	       		        $1450  238 K of SWF in 06
LARP                growth            flat                   $500K SWF in 05=>1379 in 06
HFM                 flat                   flat  	         part of LARP agreement
Auger                flat                   flat?                 (Auger North ?)
ILC/SCRF        growth             growth !
Proton Driver  growth             growth !

**Run II               ~flat               flat?                   “****Extras” will roll off**
**BTEV                ****ended****                                       ****effort shifted to LARP,PD,ILC**
**LHC                  ****ends**** ****	****       ****	****	****        ****$1450 ******** 238 K of SWF in 06**
**LARP                ****growth****            flat                   ****$500K SWF in 05=>1379 in 06**
**HFM                 flat                   flat  ****	****         ****part of LARP agreement**
**Auger                flat                   flat?                 ****(Auger North ?)**
**ILC/SCRF        ****growth****             ****growth !**
**Proton Driver  ****growth****             ****growth !**

- Summary: Future of TD Efforts

**Big Areas of growth are all in SCRF. The Division is making substantial changes to respond to changing priorities**

- } $$$$

- FY06 TD Budget presentation

- 10/31/05

## How is the Technical Division Organized ?

**Matrix management**
- Labor and physical resources are managed by Department Heads
- Large projects or activities have dedicated management but obtain the bulk of their resources from the Departments

- FY06 TD Budget presentation

- 10/31/05

## Technical Division: Matrix Management

- Numbers indicate people; FTE shown in brackets.
- 4 unpaid guests and 4 contract employees not shown.

- Snapshot Oct 1, 2005
- Used for this presentation

- FY06 TD Budget presentation

- 10/31/05

## Technical Division: Matrix Management

- New TD Org Chart
- Effective Dec 1, 2005

- Last reorganization ~10 yrs ago.           Goal = focus on new priorities

- FY06 TD Budget presentation

- 10/31/05

## TD Personnel (FTE)

- Size of TD permanent Staff ~flat vs time with ~2% decrease due to VSP in 05
- Admin staff is lean. Shift from Machinist/welders to Engineers/physicists

- * = two offers accepted but not yet arrived

- + 3 designer req’s

- Now replace people

- FY06 TD Budget presentation

- 10/31/05

## Technical Division Openings

| Opening # | Position | Purpose | Status | Assumed FTE |
| --- | --- | --- | --- | --- |
| 050018 | Engineering Physicist III (retitled) | SRF Test Facility (IB1) | Candidate identified | .75 |
| 050068 | Mechanical Engineer (internal) | ILC/PD Component Design | Candidate identified | .83 |
| 050069 | Mechanical 
Engineer (internal) | ILC/PD Component Design | Convert to external opening | .67 |
| 050079 | Mechanical Technician (cryo) | MTF Operations (replacement) | Interviewing candidates | .75 |
| 050080 | Electromechanical Technician | SRF Materials R&D | Interviewing candidates | .75 |
| 050096 | Sr. Mechanical Technician (internal) | IB2 Magnet Fabrication | Interviewing candidates | .9 |
| 050085 | Associate Scientist | SRF Materials R&D | Searching for candidates | .5 |
| 050093 | Software Developer | IB1 Data Handling (replacement) | Interviewing candidates | .75 |

- Assumed FTE Total =  5.9

- FY06 TD Budget presentation

- 10/31/05

## TD personnel

**These openings only replace average attrition, not those lost by the VSP **
- Replacements all pointed at ILC/PD and SCRF
- Know we need to fix some critical holes in the rest of the organization
**TD ( and lab in general) needs some freedom to hire the needed SCRF experts, RF engineers, and Accelerator Physicists for ILC/PD**
- This will have a big effect on how fast we can get up to speed on SCRF and the ILC/PD machine design
- RF tasks >> available workforce !

- FY06 TD Budget presentation

- 10/31/05

## ES&H

**Nevertheless, the Technical Division has an excellent safety record**

**End of FY05: TD worked 881 days without a DART case**
**September 27, 2005:- TD reached 1,000,000 hours worked mark without a DART case**
**This is largely a result of the work of a small, but well run TD ES&H organization headed by Romesh Sood, and a TD work force that has accepted that safety is a part of their job description and is in their own best interest**

- FY06 TD Budget presentation

- 10/31/05

## Electrical Safety

**In FY05 Director Mike Witherell requested that TD investigate the best available technologies to locate conduits in reinforced concrete slabs and make a recommendation to improve the lab’s capability **
**TD investigated the available technologies and provided a report to the Directorate. The report recommended purchase of a modern ****Ground Penetrating Radar**** (GPR) unit, training personnel to use it to provide an indoor conduit location service for the lab.**
**The director requested we include this in our FY06  TD budget request.  ****The estimate is $ 75 K**

- FY06 TD Budget presentation

- 10/31/05

## FY05 Closeout 

**FY05 was another “tight” year for TD Departments**
- Dept M&S budgets were flat at ~FY01 levels
- Limited purchases of desktop computing, some license fees & maintenance costs increased, etc.
**Nevertheless in FY05 TD sustained a large effort on Run II **
**We also made significant technical contributions to the LHC Accelerator Project, Auger, HFM program, LARP, Linear Collider R&D, Proton Driver, 3.9 GHz & SCRF infrastructure**
**Cancellation of BTEV in mid year was very disruptive to TD. We had to scramble to end this work and redirect people to other projects**

- FY06 TD Budget presentation

- 10/31/05

## FY05 Closeout 

**The technology choice for ILC and the cancellation of BTeV lead to significant changes in the labor plan for FY05**
- Redirected BTeV labor into ILC, Proton Driver, and LARP
- but, the desire to grow these efforts was dampened by fiscal reality
- In other places we had good agreement between our FY05 labor plan and the actual expenditures

- FY06 TD Budget presentation

- 10/31/05

## FY05 SWF Actuals vs. the Plan

**RED =Outside Income**** **
- --BTEV cancellation => $ 930 K of outside income went away
- -LHC went up, labor to repair 2 magnets
- -$350 K overtime increased SWF total

- Other shifts due to BTEV Cancellation
- -BTEV funds  TD operations ( SWF) + PD/LC/SCRF  M&S
- -Spent $692K more on ILC/PD/SCRF SWF vs plan
- -Charged $ 1,129 K of SWF to dept codes during transition
- -Spent $359 K more on SWF for Accel Div support vs plan

- Machine shop SWF is cost neutral, actual SWF was $ 2,975 K

- FY06 TD Budget presentation

- 10/31/05

## FY05 Closeout Comments

**The cancellation of BTEV in the middle of the fiscal year resulted in several significant changes in the actual use of labor vs the FY05 plan**
**In FY05 TD charged ****$2,228 K**** worth of labor to “outside” projects (projects funded outside the TD base budget)  = ****11.5%**** of TD’s SWF **
- This was very similar to FY04 but down by 994 K wrt the FY05 plan.
- TD received redirected BTeV funds that supported the same people to work on other projects ( ILC, PD, SCRF, LHC, and Accel Div support)
**To make a sensible TD budget for FY06 we need a good estimate of all “outside” income in FY06**
**It is important to realize that “outside income” is uncertain ******** TD head needs “management reserve” in FY06 budget**

- FY06 TD Budget presentation

- 10/31/05

## Note: Machine Shop ~ broke even

- TD Dept M&S actuals = $ 2,200 K

- Total non-pass thru M&S =$9,498K

- Accel M&O =$333K

- HFM program, Auger, MTF
- support = $1,083K

-         $ 26,844 K obligation budget
-       _- $ 26,739 K_  actuals
-                  145    carryover
- ...but part of this belongs to AD

- FY05 M&S Actuals for TD depts + HFM + Auger+ Accel M&O + MS EQ =  $3,616K

- Note: SWF numbers in this table = slide 34 because they contain SWF paid to AD and PPD workers

- HQ includes $387K of machine tools

- FY06 TD Budget presentation

- 10/31/05

## FY05 Closeout Analysis

**A total of ****$ 9,498* K****  funded  M&S for “inside” projects (HFM, ILC, SCRF, PD, accelerator maintenance, etc.) and for TD department operations **
**Another $ 1178 K funded M&S for Accelerator Projects. We treat these funds as belonging to AD and carry them over.**
**FY05 base budget (incl $ 242 K equip for MS) =    $ 26,844 K**
**FY05 obligations  (ops + equip)                          =    $ 26,739 K **
**TD FY05 base budget carryover                                       145 K**
**Inventory correction (more in 2 slides) ****	****	****               -66 K**
**AD M&S  carryover (details on slide 55)    ****	****     **_**         - 59 K***_
**TD base budget carryover (corrected)                      ****$       20 K****** **
***    These M&S funds belong to TD and are carried over separately**
****  G****iven that we had about $ 500 K of requisitions in progress at the end of the year, we were lucky that it came out this close **
**Not all in the correct B&R codes... eg use of management reserve late in the fiscal year**** **

- FY06 TD Budget presentation

- 10/31/05

## FY05 “the handle” 

**TD also “handles” additional M&S money for outside projects and Accel. Division purchases**
**In FY05 we “handled”**
- $      12 K of  M&S for CMS
- $    646 K of M&S  for the LHC project
- $    394 K of US Auger funds (US portion of project is 25%)
- $ 1,020 K  for Accel. Division purchases via Material Control Dept
- $ 3,085 K of M&S and SWF flowed through the machine shops. (This organization operates on a charge back system such that it is intended to be cost neutral for the Division)
**The total M&S + SWF  “handled” by the Technical Division in FY05 was $ 34,559 K**

- FY06 TD Budget presentation

- 10/31/05

## Comment on TD Inventory 

**Inventory funds in TD are used to manage materials used to construct devices for AD**
** ****Money sloshes between AD M&S and inventory. The actual balance at any time depends on whether stock has been replenished, etc. (e.g. conductor for IQD)**
**This year the inventory balance was $ -66K**
** ****On average inventory is cost neutral to the TD base budget ******** As in the past, we remove it for the purposes of this presentation**

- FY06 TD Budget presentation

- 10/31/05

## Machine Shop

**In FY04 we increased shop rate to $ 55/hr to eliminate losses and allow for purchase of replacement machine tools**
**VERP in FY04 + VSP in FY05 helped to reduce the staff ******** ~broke even in FY05**
**To maintain a modern and efficient shop we need a mechanism to purchase replacement machine tools on a regular basis.**
- Replacement value of existing machines in shops ~ $ 8 M
- Lots of 1940- 1960’s vintage equipment (there are also ES&H issues)
- In FY04 we purchased the first large machine tool in 5 yrs ($ 142 K for CNC machining center)
- Why?  Tight budgets and priorities  no TD equipment money was available
- In FY05 we purchased a new wire EDM machine for $ 242 K
**TD needs  ~ $ 300 K /yr of equipment funds to purchase new machine tools **_**every**_** year. **
**Micro-Rant: Why does this get zeroed out each year in the guidance ???**

- FY06 TD Budget presentation

- 10/31/05

## Establishing the FY06 Budget

**Our approach to establishing our budget starts with the TD staff as of Oct 2005**
- Identify the required staffing levels to meet  FY06 goals
- Determine assignments of present staff consistent with these goals
- Identify labor shortfalls
- Identify the SWF required to support the present TD staff
- Identify the SWF income from “outside” projects
- Estimate required contingency for the Division
- Estimate the SWF burden on the TD base budget
- Estimate SWF needed to support any labor shortfalls
**Next we estimate the required M&S to support “inside” projects and TD department operations**
- Compare this with our FY06 guidance
- Iterate and adjust as required

- FY06 TD Budget presentation

- 10/31/05

## Initial FY06 Budget Guidance

**Comments:**
- FY05 guidance changed a lot because of BTEV cancellation; more money in ILC/PD/SCRF infrastructure
- RED = adjustments to TD guidance to reflect new information
- *  This is supposed to be contained in TD operating line
- LARP set to 2518 vs 2922 in guidance note based on Steve Peggs work sheets
- LHC number is from Jim Kerby
- PD, ILC, SCRF infrastructure lines are assumed to be all M&S

- FY06 TD Budget presentation

- 10/31/05

## FY06 Labor Plan

**Next we need to estimate the Division’s income from “outside” projects in FY06 **
**Also need to determine if the existing staff can accomplish the planned tasks for FY06 ******** construct a TD labor plan**
- Projects are “resource loaded” with labor
- Includes labor base activities (MTF, MDL, admin, etc.)
- All personnel in the TD are accounted for
- Labor estimates come from both Project Leaders and Dept Heads & we cross check the numbers
**The labor plan tells us that we have ~ enough labor in the Division to meet the FY06 goals except for ILC/PD/SCRF: **
- Engineering/Design is very tight  dependent on continued PPD help
- Also need to add contract designers (~3)
- Missing experts in key areas for SCRF work (more in a minute)

- FY06 TD Budget presentation

- 10/31/05

## Goals of FY06 TD labor Plan 

**Goal = 1****st**** Priority is to provide needed resources to accomplish the Lab’s Run II goals ****(necessary repairs, spares, new devices for luminosity upgrades, studies related to machine performance)**
**Goal = Meet project commitments  to LHC & Auger**
**Goal = Meet ILC R&D commitments to GDE and ramp up a serious ILC effort at FNAL**
**Goal = Complete critical Proton Driver R&D + CD1 docs**
**Goal = Develop SCRF infrastructure per plan to GDE**
- Includes SCRF materials program & support for Peoples Fellow
**Goal = HFM & LARP: Nb****3****Sn Magnet R&D **
- Meet LARP commitments
- Develop HFM infrastructure

- FY06 TD Budget presentation

- 10/31/05

## FY06 TD Labor Plan (FTE)

**Machine Shop labor & people on leave of absence appear in the “unassigned” column (Machine Shop = cost neutral with respect to SWF)**
**RED =labor for outside projects ******** use these columns to estimate TD income from these projects**

- FY06 TD Budget presentation

- 10/31/05

## Comments on labor plan for FY06

**ILC labor is shown in one column, eventually we will have to account separately for ILC tasks mandated by GDE vs ILC tasks supported by “ Fermilab”**
- Label the latter  as “Advanced Accel R&D” = B&R
**Work to complete the 3.9 GHz module for DESY is shown in a separate column this year **
**No worked planned on DES or SNAP in TD in FY06**
**By agreement with Directorate, some LHC labor was moved off-project in FY05 per original agreement, this continues in FY06 through to the end of the project **
**The Proton Driver labor is ramping up but still only 1⁄2 of the sum of ILC/SCRF infra/3.9 GHz **
**In computing cost of TD labor: used 3.4% (annual + merit + bonus) and the new  35.3% fringe rate**

- FY06 TD Budget presentation

- 10/31/05

## FY06 Cost of Labor (SWF)

**    ****Red**** = activities for which we will receive SWF funds in FY05  from sources “outside” the TD base budget = only**** ****8.4%**** of FY06  SWF**

**TD base SWF for FY06**

- FY06 TD Budget presentation

- 10/31/05

## FY06 SWF from “outside” Sources

**	****  ****1379K      LARP  ****(LHC Accelerator Research Program)(499K in FY05)**
_**	**__**     **__**238K**_**      LHC    ****(Quad const, MTF tests, etc.)  ($ 1450K in FY05)**
**$      1617K****   TOTAL**
**BTEV outside income was $ 461 K in FY05, $ 0 in FY06**
**Outside Income is down $609K from FY05**** outside income of $ 2,226K **
**Assigning a number to the TD operating line in the budget guidance scaling from previous years is not correct unless you correct for the expected outside income. **
**Given the guidance and the fact that we need the people on the TD staff to accomplish the FY06 goals and we must pay people’s salaries******** the  division must find the missing $ 609 K somewhere else**
**We choose to show the shortfall in M&S**

- FY06 TD Budget presentation

- 10/31/05

## SWF/Division Contingency Use

**Held/used $ 600K of contingency in FY02**
**Held/used $ 675 K of contingency in FY03 **
**Held/used $ 500 K in contingency in FY04 **
**Held/used $ 600 K in contingency in FY05**
****** ****reserve ****$ 500 K**** in FY06 for Division contingency because outside income is smaller this FY**

- FY06 TD Budget presentation

- 10/31/05

## Starting with FY04, SWF and M&S for all work on AD tasks has been entrusted to TD.  
This establishes essentially a level of effort in TD on AD tasks
Big improvement since it allows us to plan labor assignments, dept M&S, etc
Approach: AD M&S is Cost Neutral to TD:  
We treat these M&S funds as “belonging to AD”  TD carries over unspent funds into the next fiscal year and expects payment for any overruns in the next fiscal year
AD specifies the tasks to be completed each year 
AD is the customer and in full control 
The list of requested tasks gets revised as necessary  
If more effort is requested by AD, TD adds contract labor (AD pays) 
I believe this has worked well. Please don’t change it! 

- This establishes essentially a _level of effort_ in TD on AD tasks
- Big improvement since it allows us to plan labor assignments, dept M&S, etc
_**Approach: AD M&S is Cost Neutral to TD:**_**  **
- We treat these M&S funds as “belonging to AD”  TD carries over unspent funds into the next fiscal year and expects payment for any overruns in the next fiscal year
- AD specifies the tasks to be completed each year
- AD is the customer and in full control
- The list of requested tasks gets revised as necessary
- If more effort is requested by AD, TD adds contract labor (AD pays)
**I believe this has worked well. Please don’t change it! **

- Funding TD Work on AD Tasks

- FY06 TD Budget presentation

- 10/31/05

## Work for AD in FY06

**The list of devices to be built and/or repaired by the Technical Division for Accelerator Division is agreed upon at joint meetings at the beginning of each fiscal year**
**This “job list” of new devices and plans for shutdown labor set the overall **_**level of effort**_** that TD will provide to Accelerator Division during the year for these activities**
**The “job list” evolves during the year as devices are added or removed and as priorities change**
**We have a joint TD/AD meeting every two weeks to coordinate these AD tasks and to update the “job list”**

- FY06 TD Budget presentation

- 10/31/05

## Approach:
A “work list” that includes both repairs and new devices is maintained by TD. Priorities are established via regular meetings with AD
TD base budget supports SWF for a “level of effort” on AD tasks
Labor for an average rate of magnet repairs
Labor for shutdowns (in FY04 ~ 6 wks x 28 techs), and 
Labor to design and build “new” devices on the TD/AD “work list”
The work list includes devices for the Run II upgrades
Urgent tasks tend to get added to the list during the year. We respond with changes in priorities  and/or adding contract labor on AD M&S 
SWF for magnet measurements and MTF Operations 
TD base budget also supports Material Control Dept: provides specialized procurement services for AD Projects, vendor liaison, QC, inventory control for specialized materials.  MC Dept. also manages the magnet spares pool for Accelerator Division

- A “work list” that includes both repairs and new devices is maintained by TD. Priorities are established via regular meetings with AD
- TD _base budget_ supports SWF for a “level of effort” on AD tasks
- Labor for an average rate of magnet repairs
- Labor for shutdowns (in FY04 ~ 6 wks x 28 techs), and
- Labor to design and build “new” devices on the TD/AD “work list”
- The work list includes devices for the Run II upgrades
- Urgent tasks tend to get added to the list during the year. We respond with changes in priorities  and/or adding contract labor on AD M&S
- SWF for magnet measurements and MTF Operations
- TD base budget also supports Material Control Dept: provides specialized procurement services for AD Projects, vendor liaison, QC, inventory control for specialized materials.  MC Dept. also manages the magnet spares pool for Accelerator Division

- Funding TD Work on AD Tasks

- FY06 TD Budget presentation

- 10/31/05

## AD/TD Work List

| Sys | Job
# | Task Name | M&S
K$ | SWF
K$ |
| --- | --- | --- | --- | --- |
| B | 372 | Booster maintenance | 10 | 18 |
| B | 305 | Spare Booster kickers | 45 | 71 |
| B | 364 | Replace Booster Kickers | 20 | 126 |
| MI | 373 | Main Injector maintenance | 10 | 18 |
| MI | 351 | New coils for LEP vertical correctors | 1 | 16 |
| MI | 181 | ILA - Lambertson spares | 3 | 157 |
| MI | 170+ | IQD/IQC/IQB New Redesign | 131 | 129 |
| A | 374 | P-Bar maintenance | 10 | 18 |
| A | 360 | Spare PMAG core sets | 5 | 20 |
| Rcy | 375 | Recycler maintenance | 10 | 18 |
| Tev | 376 | Tevatron Maintenance | 10 | 18 |
| Tev | 302 | Study anchor anomalies | 5 | 48 |
| Tev | 341 | Repair Choke | 5 | 33 |
| Tev | 368 | Rebuild H spools | 20 | 46 |
| Tev | 352 | Upgrade spool leads | 5 | 26 |
| Gen |  | Other shutdown work |  | 49 |
|  |  |  | 290 | 810 |

| Sys | Job
# | Task Name | M&S
K$ | SWF
K$ |
| --- | --- | --- | --- | --- |
| A | 225 | New Debuncher extraction kicker | 10 | 57 |
| Tev | 379+ | Prepare for separator installation | 10 | 15 |
| Tev | 337 | Condition and repair Separators for installation | 10 | 35 |
| B | 203 | OrBump replacements | 45 | 128 |
| Tev | 349 | Reshim Tevatron dipoles | 20 | 178 |
| Gen |   | Other shutdown work |  | 98 |
|  |  |  | 95 | 515 |

- R2LU

- Accelerator M&O

- Proton Plan

| Sys | Job
# | Task Name | M&S
K$ | SWF
K$ |
| --- | --- | --- | --- | --- |
| B | 291 | Booster trim packages - prototype | 32 | 350 |
| B | 384 | 400 MeV Booster chopper | 150 | 153 |
| B |   | Gamma-T jump quads | 205 | 97 |
| MI | 295 | WQB Larger aperture quads | 25 | 181 |
|  |  |  | 412 | 781 |

- FY06 TD Budget presentation

- 10/31/05

## Potential PPD Work 

- MuCool Beam Line

**No Official request, but small.**
**Funds must cover both M&S and SWF in TD ******** full recovery as far as TD is concerned. **
**We are willing to do the work, but will have to add contract labor and rearrange assignments.  **
**~ Cost neutral => not included in SWF or M&S estimates**

| System | Job
# | Task Name | M&S
K$ | SWF
K$ |
| --- | --- | --- | --- | --- |
| MC |   | MuCool pulsed dipoles |  | 6 |
| MC |   | Refurbish quads for MuCool beam |  | 13 |
| MC | 354 | Cooling Ring dipole for MuCool (CDA) | 5 | 22 |
|  |  |  | 5 | 42 |

- FY06 TD Budget presentation

- 10/31/05

## TD work for AD Summary

|  | FY05 Plan |  | FY05 Actual |  | FY06 Plan |  |
| --- | --- | --- | --- | --- | --- | --- |
|  | M&S | SWF | M&S | SWF | M&S | SWF |
| M&O* | 264 K | 844 K | 461 K | 479 K | 290 K | 810 K |
| R2LU | 480 K | 874 K | 343 K | 961 K | 95 K | 515 K |
| Proton Plan (not AIP) | 434 K | 464 K | 316 K | 811 K | 412 K | 781 K |
| Total | 1178 K | 2182 K | 1119 K | 2251 K | 797 K | 2106 K |
|  |  |  |  |  |  |  |
| Proton Plan (AIP) | -- | -- | -- | -- | 1060 K | 26 K |
| MTA | -- | 139 K | -- | 1 K | 5 K | 42 K |

- * These funds pay for misc new devices or major repairs to AD devices
- During FY05 tasks sloshed from R2LU, Proton Plan into the M&O bucket
- This table says we should carry over  **$ 59 K**, the number shown on slide 37.
- A lot of this has to do with redefinition of tasks as in or out of “projects.”
- Details don’t matter just the totals because M&O (in operating line) estimated bottoms up

- FY06 TD Budget presentation

- 10/31/05

## FY06 M&S estimate for items on the TD/AD work list is  $ 1,857 K, including $1,060 for the Booster corrector AIP’s.  
This is up substantially from the FY05 estimate of $1,178K and actual of $1,119K
PP AIP will obligate M&S in FY06 but will not require technician SWF until FY07.
M&S carryover from FY05 is $59K.
TD has 27.3 FTE’s in the FY06 labor plan to support this work
This total does not include  21.6 FTE’s in MTF operations, MTF upgrades, or D&T magnet physicists.   Several FTE’s on accelerator support.
We estimate that the overall Technical Division effort on AD tasks in FY06 will be about the same as FY 05.
All salaries are paid from the TD operating line except when contract techs are required. This gets charged to AD M&S.
TD estimates do not include work on MuCool. 

- This is up substantially from the FY05 estimate of $1,178K and actual of $1,119K
- PP AIP will obligate M&S in FY06 but will not require technician SWF until FY07.
**M&S carryover from FY05 is $59K.**
**TD has 27.3 FTE’s in the FY06 labor plan to support this work**
**This total does not include **** ****21.6 FTE’s in MTF operations, MTF upgrades, or D&T magnet physicists.   Several FTE’s on accelerator support.**
**We estimate that the overall Technical Division effort on AD tasks in FY06 will be about the same as FY 05.**
**All salaries are paid from the TD operating line except when contract techs are required. This gets charged to AD M&S.**
**TD estimates do not include work on MuCool. **

- Funding TD work on AD tasks

- FY06 TD Budget presentation

- 10/31/05

## FY06 TD Budget Analysis

**    ****19,212K****      SWF  in FY06 Labor Plan********* ****(slide 47)**
_**	**__** **__**-1,617K**_**      SWF plan = ****sell to “outside” projects**** ****(slide 48)**
**	****17,595K****      SWF burden on TD base budget**
**Estimated using TD Staff actual salaries Oct 1, 2005; 3.4% increase from annual/merits/bonus & 35.3% fringe rate + estimate for how we will fill existing openings **** **** **

- FY06 TD Budget presentation

- 10/31/05

## FY06 TD Budget Analysis

** ****21,371K      ****Budget Guidance**** ****(slide 42)**
**-17,595K****      SWF burden on base budget ****(slide 57)**
**     ****-500K****      SWF contingency ****(slide 49)**
_**        **__**20K**_**      FY05 carryover ****(slide 37)**
**   ****3,296K****      Available for FY06 M&S **
**Total**** ****M&S available for Accelerator M&O + MTF operations + TD departments + Auger + High Field Magnet Program + Machine Shop equipment.**
**This is to be compared with  $ 3,616 K of M&S available in FY05 to support these activities. (slide 36) To this we should add ****$ 55K**** transferred from TD to FESS**
- Dept M&S, HFM effort and Auger all expect to be flat effort wise in FY06, cut 87 K equip
- FY06 Accel M&O estimate = 290 K vs 328 actual in FY05  so this will be $ 38 K less
- GPR unit + training will cost $ 75 K more
- Depts running at 2001 levels, need to include inflation, many fixed costs
- Including inflation, required FY06 M&S is (3,616+55)* 1.03-38+75-87= $ 3,731K
**ILC/PD/SCRF M&S = guidance ( look at these numbers vs need at the end ) **
**TD  dept +HFM M&S shortfall is 3,731-3,296 =   $ 435 K**

- FY06 TD Budget presentation

- 10/31/05

## M&S: ILC, PD, & SCRF infra

**For simplicity in discussing the TD FY06 budget situation the PD, ILC, SCRF infrastructure M&S is fixed at exactly at the guidance levels**
**Any TD M&S shortfall are assigned to depts, HFM, Auger **
**Reminder:**
- ILC M&S guidance =                           $ 4929 K
- Proton Driver M&S guidance =            $ 2836 K
- SCRF Infrastructure M&S guidance =  $   488 K
**Also, ended FY05 with  $ 0.5 M of requisitions in process and many items deferred due to lack of funds**
**A separate talk will outline what the M&S  needs are for these three activities vs guidance:**

- FY06 TD Budget presentation

- 10/31/05

## M&S discussion

**Two versions of M&S assignments are shown**
**One in which the M&S budgets are reduced to meet the FY06 guidance.  It would be difficult to manage the dept M&S budgets to this level**
**A second “tight” version with dept M&S, HFM, Auger, and equipment funding restored levels similar to FY05. This would be tough but manageable**
**One concern is the continued deferral of items like replacement vehicles, building repairs (roofs, siding, paint etc). **_**TD has 37 buildings!**_

- FY06 TD Budget presentation

- 10/31/05

## TD Base Budget M&S needs for FY06

**TD Base Budget M&S needs for FY06**

- FY06 TD Budget presentation

- 10/31/05

## What Does the Guidance Accomplish?

**Provides adequate funds for continued strong support for Run II from the Technical Division**
**Allows us to meet our commitments to LHC, Auger, and LARP **
**Continues the Nb****3****Sn magnet core program at FY05 levels to honor our commitment to use this program to support infrastructure for LARP**
**Allows us to continue an effort on PD, ILC, and SCRF infrastructure, but significantly short of our stated FY06 goals **

- FY06 TD Budget presentation

- 10/31/05

## What isn’t Accomplished with the Guidance?

**TD guidance is insufficient to provide the required M&S to fund the 3.9 GHz module we promise in the DESY MOU**
**Funds are inadequate for PD, ILC, and SCRF infrastructure given our stated goals ( more in a separate talk)**
**Would need to cut something to maintain Dept M&S. choices =ILC, Proton Driver, SCRF infrastructure, or HFM.  None are very attractive**
**There is no flexibility in the TD to hire needed experts in SCRF cavities, cavity testing, and high power RF**

- FY06 TD Budget presentation

- 10/31/05

## TD Wish list

**  ****200 K:****  Peoples Fellow support ****(ramp up materials program at U of W, ****	**** ****	****     NW, and begin research aimed at cavity cost reduction)**
**  ****320 K:****  Rapidly clean out ICB building for SCRF work after ****	****      ****	****   end of LHC magnet production **
**   ****30 K:****  Provide funds for new vehicle (2) purchases **
** ****160 K:****  Provide funds to replace the roof on IB-center**
** ****100**** ****K:**** Provide for deferred building maintenance**
** ****240 K:****  CAD maintenance fees move from CD to TD ?**
**   ****And of course no money in FY06 GPP for a much needed building addition to IB3 to house the materials development lab and replace >20 yr old trailers**

- FY06 TD Budget presentation

- 10/31/05

## 
Infrastructure:
Technical Division space in the village is old and far from TD central complex Need more R&D space in the industrial complex
Project proposed :IB3 addition (AML)
Need $1.5 M GPP to start this in FY05 (competes with Run II, LC + PD R&D)
Many buildings require maintenance ( IBcenter, IB1 siding, HVAC/offices, village machine shop, model shop, etc) Most have been deferred.
Machine tools in the shops are old (lots of 1940’s vintage machine tools)
We have a big infrastructure of machine tools, CMM’s, large ovens, winding machines, MTF refrigerator, etc. to maintain 
For the long term health of TD a reasonable equipment budget needs to be maintained to support this infrastructure 
Guidance has only $ 50 K of equipment this year vs a need of ~ 400 K
TD needs equipment money and an operating budget that permits us to spend it on equipment for the Division vs being force to convert it to operating salaries and expenses

**Infrastructure:**
- Technical Division space in the village is old and far from TD central complex Need more R&D space in the industrial complex
- Project proposed :IB3 addition (AML)
- Need $1.5 M GPP to start this in FY05 (competes with Run II, LC + PD R&D)
- Many buildings require maintenance ( IBcenter, IB1 siding, HVAC/offices, village machine shop, model shop, etc) Most have been deferred.
- Machine tools in the shops are old (lots of 1940’s vintage machine tools)
- We have a big infrastructure of machine tools, CMM’s, large ovens, winding machines, MTF refrigerator, etc. to maintain
**For the long term health of TD a reasonable equipment budget needs to be maintained to support this infrastructure **
**Guidance has only $ 50 K of equipment this year vs a need of ~ 400 K**
**TD needs equipment money **_**and**_** an operating budget that permits us to **_**spend it on equipment for the Division**_** vs being force to convert it to operating salaries and expenses**

- FY05: Infrastructure & Equipment

- Last year’s slide but it is all still all true

- FY06

**300 K**

- FY06 TD Budget presentation

- 10/31/05

## Conclusion

**     ****Can TD live with the FY06 budget guidance?**** **
**Yes: ****It allows TD to provide the required Run II labor**
**Yes: ****TD**** can pay the salaries of people in the Division working on HFM, ILC, PD, Auger, etc.**
**No****... Dept M&S budgets cannot erode away each year by inflation. There are fixed costs, and some that increase with time. We need at least an additional    ****$ 435 K**** to make up for lost outside income. (down by $ 609 K) or take it from project M&S**
**No****... ILC and SCRF infrastructure will be a lot less than FNAL told GDE**
**No****... Proton Driver will not be able to accomplish planned FY06 goals for CD-1 **
- Both programs would be starved for M&S relative to what is needed to make real progress
- We have no flexibility to hire needed SCRF experts, RF power engineers, and Accelerator physicists.
**These R&D efforts are the future of this lab **
**  ****More on ILC, PD, SCRF infrastructure needs in the next talk by Bob**** **

- FY06 TD Budget presentation

- 10/31/05