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BTeV Spools (WBS 2.1.2.3)

BTeV Spools (WBS 2.1.2.3). Thomas Page. Topics. Scope of work Spool design parameters Spool design Cost and schedule Key milestones Critical path analysis Risk analysis Summary. Organization (or “You are here”). 2.1.3 Project Management. WBS 2.1 Magnet Fabrication & Test.

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BTeV Spools (WBS 2.1.2.3)

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  1. BTeV Spools (WBS 2.1.2.3) Thomas Page DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004

  2. Topics • Scope of work • Spool design parameters • Spool design • Cost and schedule • Key milestones • Critical path analysis • Risk analysis • Summary DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  3. Organization (or “You are here”) 2.1.3 Project Management WBS 2.1 Magnet Fabrication & Test 2.1.1Q1 to Q5 Quadrupoles 2.1.2 New Spools 2.1.1.1Cold Mass 2.1.1.2Cryostat 2.1.1.3 MTF Test Stand 2.1.1.4 Q1 to Q5 Fabrication 2.1.2.1 HTS Leads 2.1.2.2Corrector Magnets 2.1.2.3Spool Assembly DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  4. Scope of Work • Design and oversee production of two sets of spools. • Each set consists of 5 spools (X1H, X1V, (2) X2, X3) for a total of 10 spools (installed). • The current plan is to have an outside company fabricate and build the spool assemblies based on our design. • The major components would be supplied to the vendor. • HTS Leads, correctors, other leads, bus work, etc. • The completed spools will be tested at FNAL. DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  5. Initial Design Criteria • Designed in accordance with ASME Boiler and Pressure Vessel Code • Design pressure, MAWP*: • Single phase: 200 psig • Two phase: 50 psig • LN2 system: 100 psig • Heat load to 4K: 5 W per device (spool, quad, etc.) • Corrector envelopes: • X1 spools: 200 mm OD x 1200 mm long • X2 spools: 200 mm OD x 550 mm long • X3 spools: 200 mm OD x 800 mm long • BPM length: 10 inches * MAWP is Maximum Allowable Working Pressure DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  6. Q3 L L Q1 X3 L Q2 BPM C0 C0 C0 C0 X2 X2 X2 X2 … … … … … … … … Q4 Q5 Q5 Q4 L L L L L L L L L L L L L L L L L L L L * * * * C0 * IP IP IP IP IP … … C-sector C-sector B-sector B-sector Spool Pieces • Spools are located between other components, either new quads or existing Tev equipment (not shown here) • X1 (not shown) variations driven by H/V Dipole corrector requirement Q1—Q2—X3—Q3 (mirror image about IP not shown for space) DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  7. Spool Internal Components • Spool component list: • Corrector magnets • Power leads: • 10 kA HTS leads, 2 per power spool (1 pair) • Corrector leads • 200A leads • Instrumentation leads • Beam position monitors • Relief valves: 3 per spool • Cryogenic pipe interfaces as needed • Through bus as needed • Quench stoppers • Vacuum Break DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  8. Slot * VD HD SQ Sx Q HTS Spool Location BPM Other Leads Length, 2 T. m T. m T.m/m T.m/m T.m/m Leads m X1V packb43 1.83 0.48 450 25 4x100A+SL X1H packb44 1.83 0.48 450 25 4x100A X2 packb47 1.52 0.48 0.48 V&H 2x10kA 2x100A+SL X2 pac kb48 1.52 0.48 0.48 V&H 2x10kA 2 x100A X3 packc0u 1.52 0.48 0.48 7.5 V&H 2x10kA 3x100A+200A X3 packc0d 1.52 0.48 0.48 7.5 V&H 2x10kA 3x100A+200A X2 packc12 1.52 0.48 0.48 V&H 2x10kA 2x100A X2 packc13 1.52 0.48 0.48 V&H 2x10kA 2x100A+SL X1V p ackc16 1.83 0.48 450 25 4x100A X1H packc17 1.83 0.48 450 25 4x100A+ SL Spool Information (Details) (Interfaces) DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  9. X2 Spool Corrector Leads Relief valves HTS Leads DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  10. X2 Spool Cross Section Support Post (same as quad) Liquid Nitrogen volume Vacuum break BPM Helium vessel Vacuum vessel Corrector DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  11. X2 Lead Stack Helium Pipe Corrector Leads HTS Leads Safety Leads (for Tev bus) DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  12. X2 Lead Stack Cross Section Quench Stopper (for Tev bus) DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  13. X2 Vacuum Vessel ASME B&PV Code VIII-1 Appendix 13 Sketch 3 DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  14. Spool Cost and Schedule Summary Engineering and design manpower: • Engineers: 1.5 FTEs (FY05 & FY06) • Designer/drafters: 2 FTEs (FY05 & FY06) • 1.5 years of detailed design: October 2005 – March 2006 • Bidding, fabrication, assembly and test: • April 2006 – October 2008 • Production oversight: 1 FTE Summary of spool cost: (Based on LHC DFBX and preliminary fabrication study) Base cost: $5.284M (Material: $3.712M, Labor: $1.572M) DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  15. Spool Schedule DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  16. Spool Cost FY05 k$ No Contingency No Escalation G&A Included Construction Costs DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  17. Spool Labor DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  18. Key Milestones • Start of detailed design – October, 2004 (FY05) • Bidding process: April, 2006 • 1st Spool fabrication begins: October, 2006 • Series production begins: November, 2007 • Production and test complete: October, 2008 DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  19. Critical Path Analysis • Design of internal components: • The Corrector and BPM designs need to be complete in time so that integration into the spool can begin. • Detailed design complete: • The spool detail design needs to be completed in time so that the bidding process may start. • Vendor production schedule: • Timely delivery of components to vendor. • Production oversight is critical to keep the vendor on schedule. DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  20. Risk Analysis DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

  21. Summary • The spool design is based on the stated corrector envelopes, BPM length and (2) HTS leads per power spool. • The remaining components are well understood and the conceptual design is under way. • Cost estimates for assembly by an outside vendor are based on the LHC DFBX (feedbox) which is similar is size and function to the new spools and a preliminary fabrication study that was completed in August, 2004 by potential vendors. DOE CD-2/3a Review of the BTeV Project – December 14-16, 2004 BTeV Spools – Thomas Page

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