PM report International & UK programmes

PM reportInternational & UK programmes • Overview • Reconstructing the schedule • The Project Management team • Progress with the target • Completion of the PPS • Liquid Hydrogen delivery system • RF Infrastructure update • RFCC module status • FC module, preparations for coil winding • Substation upgrade • Space....... Andy Nichols, STFC, UKNF/MICE OsC, 31-1-11

Overview • Muonbeamline reliable, decay solenoid now working and has been exercised • Target development is going very well, working ISIS target continues to give reliable service, offline programme making good progress, stator re-engineering made good start • FC #1 manufacture is progressing, but significant delay due to coil-winding problems • RF cavity production well on schedule, both sets of 4+1 made – major success by LBNL team • Spectrometer solenoids – in depth review complete, repair plan submitted to MAP, feedback expected end Feb – see Roy’s talk • 2MVA substation upgrade – contract placed, more later • Diffuser – design change to IRIS type, much simpler to make • PPS - is commissioned, DSA component ready for when ISIS resumes • First EMR planes delivered by July, MICE running programme planned for that date

Reconstructing the schedule • Still dominated by only a few big dates: • MICE collectively decided that there is no scientific reason not to move straight to Step IV • Minimally, we need: • Hall infrastructure general and MICE Phase One – done • PPS system – Feb 2011 • AFC floor interface – in design now • Liquid hydrogen delivery system – Q4, 2011 • AFC #1 – LH2absorber ready, FC module delivery mid 2011 • Diffuser – Q2, 2011 • Solid absorbers (various) – MICE has to define specifications, not difficult to make absorbers, hope to do at CM29 • Spectrometer solenoids - #1 January 2012, #2, April 2012, MAP hopefully converges at end Feb this year • Substation upgrade – Q3 2011 • We then have a significant amount of necessarily series operations to integrate Step IV – session reserved at CM29 to work it out • If we don’t like the date that falls out, it’s up to us to find a way to accelerate

We’ll be starting off at Step IV (above) to agree and finalise some date in • 2012, or even 2013 for ‘ready to run’ • Aim to converge at CM29 • Well aware that the MPB explicitly asked for a completion date for whole of MICE • But cannot predict beyond Step IV right now, for reasons see later • Work of Roy and others has increased confidence level for Step IV • Top level schedule cartoon will remain, but will include dates for major subsystems

Organisation and Project Management • Some changes to the project management are in process partly to address the MPB recommendation: • UK project re-modelled: • UK Project Manager - Vacancy (AN, helped by KL till filled) • System Engineer RAL – Tim Hayler • System engineer DL – Alan Grant • Project Associate – Andy Lintern • MICE Project: • Project Manager – Andy Nichols • Integration Engineer – Jason Tarrant • MICE Magnet co-ordination team • Engineering – Roy Preece • Magnetic – Mike Courthold • MICE Admin Office • Mary-Elizabeth Shewry • Rose Hayes • Major shortfall in design effort partly addressed by welcome help from DL staff

PM staff – work distribution • All posts except the Project Associate are nominally one FTE • But the two System Engineers will expect to also carry out direct, ‘non-managerial’ project work: • DL System Engineer – initial responsibility for delivering the RF system in total, also supervision of all DL design staff • Note that building an RF power station is a major undertaking and a dedicated MICE RF engineer and technicians may not be in place for some time • RAL System Engineer – Responsible for entire installation of MICE at RAL, including all design, manufacture and installation processes, some delegated safety responsibility; nominated Radiation Protection Supervisor (RPS) • Both system engineers will also share some of the everyday ‘host-lab’ necessities, sharing as necessary with the PM

Progress with the targetCourtesy J.Tarrant/G.Barber • Offline target now has all modifications and refinements • Has run around 2.3M pulses in R78, with regular inspections • Nothing untoward in terms of dust, breakage or abnormal wear • Looks like the mechanical assembly is robust and stress-free enough to tolerate stator magnetic eccentricity – good • But stator re-design is going ahead anyway: • Precise coil former made • Design work well underway • Winding trials started with square conductor • Mapping rig is made

MICE Target Progress Re-engineered Vespel bearings ‘Before and after’ polished bearing surfaces on titanium shafts Showing relieved anti- Rotation collar

MICE Target Progress • Managing Dust • Dust ‘catcher’ = Fitted to T2.4 & T2.5 Dust catcher & shaft with no dust ‘after’ Dust on outside of lower bearing ‘before’

Completion of the PPS • The PPS (Personal Protection System) is the primary safety framework between ISIS/MICE and users and visitors • It’s basically a system of electro-mechanical interlocks, based on design for SRS • Led by DL Controls Group, John Alexander • He’s retired now, Craig Macwaters of RAL has taken over • Organisationally the PPS is separated into two systems: • The DSA PPS – becomes part of the ISIS synchrotron – hazards and methodology similar to existing ISIS practice • The Main Hall PPS – the rest of MICE – hazards more specialised, eg RF, magnetic fields, MICE has more control for this reason

Completion of the PPS • Status: • Installation of both systems is complete • Commissioning with ISIS was completed before Christmas last year – huge effort by DL staff, John, Craig and Mark Arnold of ISIS • The DSA part of the PPS will come online as part of the ISIS synchrotron for start of March user run • The Main Hall PPS can then be ‘switched on’ when convenient for MICE: • A suitable goal might be when Step IV starts • Need to balance the need for flexible access during construction with the PPS regime though • Remaining work: • Niggling jobs on the installation • Documentation – instruction manual for MICE (on PM’s job list) • Physically separate the main Hall & DSA racks at ISIS request

Update on liquid hydrogen and RF infrastructure • Given late delivery of spectrometer solenoid, UK effort was redirected for FY10/11 to LH2 & RF, both high technical risks • Much liquid hydrogen hardware delivered • SIL rating exercise completed • A serious start made on RF infrastructure layout • Priority is identifying hardware to buy • Refurbishment of second LBNL amplifier well underway

R&D cryostat, valve panel, enclosure and transfer line • Tested and delivered lastNovember • Installation making good progress • Vent system design is designed • Electrical installation for controls and safety going well • Parallel exercise with safety documentation – plenty of niggles

Liquid Hydrogen system • Milestone commentary: • Electrical work complete – end February 2011 • Mechanical installation complete - April 2011 • Start ventilation ductwork – end January, 2011 • Start Helium testing (a pre-requisite to hydrogen operation) - April 2011 • Complete Helium tests – June, 2011 • Pre hydrogen operation safety case prepared – July, 2011 • Then start hydrogen tests – Q3, 2011

RF Infrastructure Have only very recently been able to start the real CAD work, due to shortage of staff. but, good start made, beginning to understand waveguides, water loads, services, hardware etc Good news is that on first look things seem to fit with floor

RFCC Module Update - Introduction • The Radio Frequency Coupling Coil (RFCC) modules are the most significant parts of MICE Steps V & VI • The are managed by LBNL for MICE, with a large input from four Chinese organisations • Until CM28 in October, they were more or less a closed book (to me anyway) • But I got invited by Derun Li to the following: • Cryostat final design review in Shanghai • Tour of Harbin Institute of Technology • Tour of QiHuan in Beijing • Quite useful – at least I’ve been allowed to form my own idea of the ‘problems’ for the first time

Magnet/cold mass Cryostat/vac-vessel RF cavities RF vac-vessel

Organisation and responsibilities • MICE RFCC WP Manager – Derun Li, LBNL • MICE RF Cavity Manager - Allan DeMello, LBNL • Chinese funding agency – Guo Bin, Harbin Institute of Technology (HIT) • Testing of cold masses, welding of cooling tubes and cover plates – Liyi Li, Institute of Cryogenic and superconducting Technology (ICST) • All manufacturing and fabrication – QiHuan, a private company, nominated by HIT without meaningful MICE involvement • Project management in China, including engineering drawings – Wang Li, Shanghai Institute of applied Physics (SINAP) • Day to day engineering management at ICST – Feng Yu • Ditto at SINAP – Lixin Yin

Sequence of events (I think!) • Design work for the CC is overseen by Wang Li and Lixin Yin • The coils are wound by QiHuan and then shipped to ICST for: • Welding on of cooling jacket/pipes (the magnet is indirectly cooled by conduction) • Testing of the complete cold mass in a simple cryostat using a Linde plant (which has not been used for some time) that is similar to ours • QiHuan manufacture the vac-vessel • Cold mass is shipped back to QiHuan, who do the final assembly • Magnet is presumably cooled and tested with CCRs at QiHuan • Then it’s shipped to LBNL for RF cavities and vac vessel to be fitted

Status • Technical baseline has been approved by MICE • A detailed project plan (but mostly in Chinese) exists • A ¼ scale test coil (final diameter, but with fewer coils has been made • Some detail manufacturing drawings of the cryostat are complete • The first real coil (called #1) is wound and is just having the banding applied - it will go to either MICE or MuCool • Some work has been done to get the cooling test set up done, transfer lines, control electronics, etc • Test cryostat is made

Risks & worries • In no particular order: • Fabrication of the cryostats and post machining is a huge job – were unable to see QiHuan’s facilities as they are moving • Not clear that indirect cooling will work – apparently this was raised by a Review Committee – mitigation is >100% cooling margin, but track record is appalling! • Despite assurances about reorganisation, skilled manpower at ICST is lacking • No work done yet on tooling or fixtures for welding cooling jackets • The cryostat is now very large, static weight must have increased by 50% and will definitely interfere with South mezzanine • QA and general discipline is very weak, eg – important features like lead support and heat sinking are being designed on the hoof • Simply getting about and communicating, even with a native speaker in tow, is a real challenge

What we might do about them.... • Offer material help, eg: • Take responsibility for discrete items, cryostat, tooling, weld fixtures and so on • Offer technical help, get Linde plant running • Assist with controls engineering – in fact this could be part of our ‘common approach’ to this topic • Help Derun with schedule construction – this is a priority • All the above will need non-Chinese resources • And we need to make sure our help is welcome – not clear at the moment • Also hampered by the fact that the PM does not have formal authority over the situation • KL and AN, with support from Alan Bross, both believe that there is an opportunity to formally widen the collaboration and share the risk to the whole project with a properly thought out formal approach from the UK/US • MRI grant of $1.6 could be used to offset in lieu of UK RF expenditure

RFCC Schedule & Milestones • From discussions mainly, it looks like this: • Cooldown test rig to 4.2K – end Jan 2011 • Complete cooling and testing of test coil – May 2011 • Install coil #1 in cryostat & test – June/July 2011 • Ship coil #1 to ICST – August 2011 • This is the limit of understandable information..... • My own interpretation takes over: • Weld cooling jacket to cold mass –December 2011 • Ship cold mass back to QiHuan – Q1 2012 • Assembly of magnet #1 in cryostat – Q3 2012 • Ship to LBNL – Q4 2012 • Assemble RF cavities, vac vessels & test – early 2013, who knows!

RFCC Schedule & Milestones • At some point MICE has to decide if magnet #1 goes to MICE or MuCool • If it goes to MICE, it’s conceivable that it comes to RAL around mid-late 2013 (my view only of course) • That would point to doing Step V in early 2014 • But as with the spectrometer solenoid, AN will not endorse or believe any delivery dates until the detail schedule and risks have been understood • Hot off the press: • M.Zisman is proposing to MAP (Muon Accelerator Programme)five options for proceeding – these are not plans, just brief statements • Ranging from staying as we are(!) to a complete start again with new vendors and organisation • Guidance from MAP awaited.......

FC – preparations for coil winding • Almost ready for coil-winding at Tesla • Much work done to finalise the G10 interlayer between coil former and winding – critically important • But two problems: • Control software defect with winding m/c, not serious • Tesla Project engineer has left, very serious • FC still promised for mid 2011, difficult to see how they’ll make it.....

Substation upgrade • Reminder: MICE needs 2MVA electrical supply to run at Step IV • Good news: permission given by STFC last year to go ahead • Option with all new equipment has been approved • Specification written and design work complete • Trouble-free tender exercise • Two realistic, almost in budget, offers from TES and JV Morris, from three approaches, DL’s preferred contractor did not bid • JV Morris selected as contractor, hope to place order next week • Detailed schedule at discretion of vendor • But installation will be late Spring – need to watch for EMR run in July • Project led by Building Project Group, but with technical input by DL Electrical and Controls Group

Space at RAL • If things go to (the new) plan, delivery of the two spectrometer magnets, the AFC and EMR might be separated by only about nine months • We will NOT be able to assemble things safely in the MICE hall all at once • Must have some space for parallel pre-integration at RAL • This is a familiar request, but believe it is now time to make a serious attempt to escalate this – no constructive feedback or guidance has been received from any of the STFC Accommodation Committees

PM report International & UK programmes