# Presentation: 357851

## US LHC Accelerator Project OverviewJim StraitFermilab

- DOE Review
- 10 June 2002

***brookhaven - fermilab - berkeley***

_**US LHC ACCELERATOR PROJECT**__**                               **_

## Outline

- Project Technical and Schedule Status
- Cost and Schedule Performance
- Contingency and Risk Management
- Appendices:
- Responses to May Review Recommendations
- Table of Active Milestones

## US LHC Accelerator Project

**US LHC Accelerator Project**

- IR Final Focus Systems: Points 1, 2, 5, 8
- US-built quadrupoles (FNAL)
- Japanese-built quadrupoles (KEK)
- CERN-provided correctors
- Cryostats for all quadrupole assemblies (FNAL)
- US-built beam separation dipoles (BNL)
- US-built IR feed boxes (LBNL)
- US-built specialized absorbers (LBNL)
- RF Region: Point 4
- Beam separation dipoles (BNL)
- Wire and Cable for Main Magnets:
- Measurement of SC wire & cable (BNL)
- Cable production support (LBNL)
- Accelerator physics (all 3 labs)
- __________________________________
- Project management and oversight (FNAL)

## IR Quadrupoles are in production.
MQXB #1-4 complete.
MQXB #5 coil being prepared for collaring.
MQXA #1 (KEK) and 1st 2 CERN correction coils are at Fermilab.
First Q2 cold mass assembly almost complete:	MQXB + CERN corrector + MQXB and insertion into the cryostat is imminent.
But
Production is 2-3 months behind schedule
Shorts have required all magnets so far to be re-worked.  This appears to have been solved now, but requires verification.
System integration, especially bus work and instrumentation wiring, have taken more effort than estimated.

- MQXB #1-4 complete.
- MQXB #5 coil being prepared for collaring.
- MQXA #1 (KEK) and 1st 2 CERN correction coils are at Fermilab.
- First Q2 cold mass assembly almost complete:	MQXB + CERN corrector + MQXB and insertion into the cryostat is imminent.
*But*
- Production is 2-3 months behind schedule
- Shorts have required all magnets so far to be re-worked.  This appears to have been solved now, but requires verification.
- System integration, especially bus work and instrumentation wiring, have taken more effort than estimated.

**Project Status**IR Quadrupoles

## Beam separation dipoles are in production.
D1	-	Construction of all 5 D1’s is complete.	-	Four have been successfully tested and 1 is ready to ship.
D2	-	Six magnets + 2 cold masses complete, last D2 is in process. 	-	First 2 have been tested.D4	-	Coil winding is complete.
D3	-	Design complete, except for interface issues with CERN.	-	Coil winding has started.
But
Production is 5-6 months behind schedule.
Assembly problems required rework of 4 of 5 D1s.
Test system and coil winder problems (now fixed).
Some interface issues with CERN:
Changed QRL jumper height for D2 and D4.
D3 interfaces to CERN-provided QQS/DFBM and undulator.

- D1	-	Construction of all 5 D1’s is complete.	-	Four have been successfully tested and 1 is ready to ship.
- D2	-	Six magnets + 2 cold masses complete, last D2 is in process. 	-	First 2 have been tested.D4	-	Coil winding is complete.
- D3	-	Design complete, except for interface issues with CERN.	-	Coil winding has started.
*But*
- Production is 5-6 months behind schedule.
- Assembly problems required rework of 4 of 5 D1s.
- Test system and coil winder problems (now fixed).
- Some interface issues with CERN:
- Changed QRL jumper height for D2 and D4.
- D3 interfaces to CERN-provided QQS/DFBM and undulator.

- Project StatusBeam Separation Dipoles

## Project StatusIR Feed Boxes

- Substantial progress on the IR Feedbox (DFBX) in past 6 months.
- Completed “Rev 0” of all ~460 drawings required . . . Design “Rev A” moving forward rapidly.
- 8 of 10 Functional and Interface Specifications have been approved by CERN.
- Pirelli has been given the green light for HTS lead production.
- Lambda plate prototype is a success.
- Three qualified and interested vendors for the DFBX fabrication have been identified and budgetary quotes received from them.
*But*
- Still 5-6 months from signing the contract for DFBX fabrication.

## IR Feed Boxes

- Why the delay?
- Underestimated time required to
- Complete the drawing package
- Complete interface specs, engineering and safety notes.
- Prepare and obtain CERN agreement on acceptance criteria.
- More time now allowed between RFP release and contract signing.
- These account for about half the delay.
- The rest results from:
- Recent design reviews showed problems with pipe supports and flexibility for thermal contraction.
- Fundamental design unaffected, but many detailed changes result.
- Took opportunity to introduce additional changes to make design more robust and simplify fabrication.

## IR Feed Boxes

- Actions taken.
- Senior cryo engineer at FNAL (Tom Peterson) assigned to help guide the design to completion, supported by FNAL eng. and design staff.
- Tom works directly with DFBX manager (Joseph Rasson) at LBNL, who retains overall responsibility and directs the work of the LBNL staff.
- LBNL has added additional staff on a short-term basis to help with targeted engineering tasks.
- PRR conducted on May 7; Design review scheduled for June 18.
- FNAL assigned the task of testing the HTS power leads.
- LBNL-FNAL team is working well and design is converging rapidly.
- PMO and LBNL management working together to contain EDIA costs.
- FNAL engineering partially offsets effort at LBNL.
- Some cost savings have been identified in related areas.

## IR Feed Boxes

- Current plan:
- Design, including all drawings and eng notes, complete in August.
- Release RFP in September.
- Sign contract with fabricator before the end of the year.
- Expect delivery of 1st box to CERN ~March 2004, just at beginning of scheduled IR8 Left installation period.
- CERN installation schedule has sufficient flexibility to deal with delivery up to 6-8 months later than this.

## IR Feed Boxes

*RFP*

*PO*

*the end of *

*the year *

## IR Absorbers production assembly has started.
Pre-assembly review in February gave OK for production start.
Functional and Interface Specifications have been brought up-to-date and resubmitted to CERN.
But
Assembly started about 6 months behind schedule.
Some recent cost increases in component fabrication, partially offset by favorable costs on assembly
Interfaces of TAS with ATLAS and CMS shielding have been changed by CERN, despite having approved Interface Specifications.
May require some parts re-work.
Additional EDIA effort required.

- Pre-assembly review in February gave OK for production start.
- Functional and Interface Specifications have been brought up-to-date and resubmitted to CERN.
*But*
- Assembly started about 6 months behind schedule.
- Some recent cost increases in component fabrication, partially offset by favorable costs on assembly
- Interfaces of TAS with ATLAS and CMS shielding have been changed by CERN, despite having approved Interface Specifications.
- May require some parts re-work.
- Additional EDIA effort required.

- Project StatusIR Absorbers

## Production SC cable testing continues.
Relative to plan made in 2001, sample rate from CERN over past 6 months is 55% of planned rate (=55% of BNL’s capacity.)
Some signs of acceleration in the past 2-3 months.
Peak rate expected to be reached  soon and will continue through FY2004.
Recent cost experience is favorable.
Testing likely to continue beyond end of FY2005.

- Relative to plan made in 2001, sample rate from CERN over past 6 months is 55% of planned rate (=55% of BNL’s capacity.)
- Some signs of acceleration in the past 2-3 months.
- Peak rate expected to be reached  soon and will continue through FY2004.
- Recent cost experience is favorable.
- Testing likely to continue beyond end of FY2005.

- Project StatusSuperconductor Testing

## Schedule situation remains satisfactory:
Overall the project is ~5 months behind our schedule.
Somewhat less for quads (2-3 months)
Somewhat more for absorbers and cable test (~6 months)
DFBX was not re-baselined last year, and is ~1.5 years behind its (old) baseline; first delivery is expected to just in time.
Minor schedule issues with delivery of CERN-provided components are being addressed.
New CERN installation schedule delays our required delivery dates by 3-6 months . . . and in most cases another ~6 months of flexibility exists in the CERN schedule for our items.
We remain ahead of schedule for delivery of our equipment to CERN by the required installation dates.

- Overall the project is ~5 months behind *our *schedule.
- Somewhat less for quads (2-3 months)
- Somewhat more for absorbers and cable test (~6 months)
- DFBX was not re-baselined last year, and is ~1.5 years behind its (old) baseline; first delivery is expected to *just in time.*
- Minor schedule issues with delivery of CERN-provided components are being addressed.
- New CERN installation schedule delays our required delivery dates by 3-6 months . . . and in most cases another ~6 months of flexibility exists in the CERN schedule for our items.
- We remain ahead of schedule for delivery of our equipment to CERN by the required installation dates.

- Project StatusSchedule Summary

## Cost and Schedule Performance Through April 2002

- EV = $77.9M(76% complete)

- CV = -$1.0M*  (-1.3%)

- SV = -$-6.4M  (-7.6%)~half is DFBX ... not re-baselined last year.

*________________________*
** Corrected for $0.4M accounting issue at Fermilab.*

## Cost and Schedule Performance

## Cost and Schedule Performance

- Causes of unfavorable cost and schedule trends cited in summary of technical program status.
- Start-up problems with quads and dipoles appear to have been solved.
- Difficulty completing DFBX design is being addressed.
- While these problems are being or have been dealt with, others may still arise.
- Cost risk from CERN-imposed changes still exists.
- We are working with CERN to minimize the number of changes and to find ways to offset the costs.

## Contingency Status

## EAC and Contingency History

- Contingency computed from EAC continues to be in the 15-20% range.
- Constant vigilance on costs and “scope creep” is required.
- Further cost decreases at LBNL may increase contingency 16% -> 17%.
- Other cost savings measures are being held in reserve.

## Contingency Analysis and Risk Management

- The PMO works with the three labs, on an on-going basis, to identify potential risks – technical, schedule and cost – and to develop strategies to mitigate them.  Major risk factors include:
- Delays in completing designs and starting production.	*All systems are now in production except the DFBX.*
- Late delivery of key components.	*Most components are in-house.  Close attention being paid to **	**key components, especially those provided by CERN.*
- Unforeseen difficulties in magnet production.	*Some have occurred, and have been dealt with successfully.*
- Failure of a magnet that requires it to be re-built, or failure of cryogenic system for magnet or cable testing.	*Maintain:**	**sufficient spare components.**	**	**at least 1 magnet’s worth of schedule float.**	**	**sufficient  contingency.*

## Summary

- Technical progress is excellent.
- There are no major schedule issues.
- Cost situation requires continued vigilance.
- Excellent and constructive working relations continue with CERN (and KEK).
- We remain fully committed to deliver on our commitments to CERN
- Full technical performance,
- On time,
- Within our budget,
- 	and every action is and will be taken to ensure success.

## Appendix 1:    Response to Dec DOE Review Recommendations

- _IR Quadrupoles_
- 1	Maintain the current level of management vigilance to keep the Fermilab program on cost and schedule.
*Vigilance has been maintained, minimizing the negative cost and schedule trends resulting from manufacturing difficulties.*
- _IR and RF Region Dipoles_
- 1	In support of a decision on the scope of the magnet test program, review the cost-to-complete in six to nine months.
*This will be done later this year.*
- 2	Develop a proactive plan to increase lamination inspections to assure that tooling wear does not result in out of tolerance parts .
*The supplier is required to perform inspections at the rate of about one sample lamination per hour.  BNL is now receiving acceptable laminations.*

## Response to May DOE Review Recommendations

- _IR Feedboxes_
- 1	Simplify and accelerate the feedbox RFP process and eliminate the other options.  The RFP should be in parallel with the Production Readiness Review not in series, followed by the Best and Final Offers (BAFO).
*Feedbox will be bought in a single large procurement.  The RFP is being prepared.  A PRR was held in May, and a follow-up will be held immediately prior to release of the RFP.*
- 2	Review the first article feedbox cold testing plan for infrastructure requirements, cost, and schedule.  Segregate must-have vs. like-to-have measurements.
*Cold testing of complete feedbox has been eliminated in favor of cold tests of HTS leads, cold shock and leak check of subassemblies, and careful dimensional control of the assembly.*

## Response to May DOE Review Recommendations

- _IR Absorbers_
- 1	Complete the absorbers, as soon as possible, to minimize total costs.
*Absorbers are in production.  Minor schedule slippage has occurred, largely due to last minute changes requested by CERN for the interfaces with the detector shielding.*
- _Cost and Schedule_
- 1	Maintain the contingency budget at at least 20% of the cost-to-go.
*Current contingency is 16% of the estimated cost to completion.**We continue to use 20% as the benchmark and are working to restore this level.*
- 2	Complete the U.S. deliverables on the baseline schedule, i.e., do not plan to use the schedule float relative to the CERN schedules.
*We endeavor to maintain our schedule. We are influenced by CERN delays to the extent that this delays CERN decisions on things that affect us.  We will continue to use schedule float to optimize our costs. *

## Response to May DOE Review Recommendations

- _US LHC Accelerator Research Program_
- 1	DOE should provide preliminary program guidance for the continued U.S.-CERN collaboration on the LHC machine.
*We have recently received guidance on the structure of the program, but have not yet received funding guidance.*

## Appendix 2:Table of Controlled Milestones

## Table of Controlled Milestones

## Table of Controlled Milestones

## Table of Controlled Milestones

## Table of Controlled Milestones