EDM Fast Start Presentation WBS 11 – Assembly and Commissioning

EDM Fast Start PresentationWBS 11 – Assembly and Commissioning

Vince Cianciolo, Paul HuffmanMay 23, 2006

EDM Fast Start, WBS11 2

Schedule Overview

• Fully tested B-shield

• Fully tested CV/liquifier and coil pkg.

• Fully tested insert• Fully tested 3He system

• Assemble/commission B shield

• Assemble/commission coil package into CV

• Assemble/commission insert in CV

• Assemble/commission 3He system in CV

• Re-install B shield upper half • Mate neutronics • Commissioning run• CD4/data collection :-)


Significant Planning Assumptions • Internal cryostat components arrive fully tested at cryostat assembly site

– Measurement cell insert– 3He injection and purification system– Coil package– All related DAQ components

• This is hugely important. The full apparatus will require 6-8 weeks for a cooldown cycle and this dominates cost and schedule. As much as possible testing must be done prior to assembly, in parallel and in smaller cryogenic vessels.

• Require ability to test 3He transport w/o external shield– Otherwise grossly inflates cooldown/warmup cycle time, and mandates lots of

handling for delicate shield pieces.• M&S costs included in estimates for various subsystems (not in this WBS)

– Rails and other infrastructure equipment– Helium– Tools

• NCSU is the cryostat assembly site– Cost totally dominated by technician support (nearly 4 FTE years)

• >$300k labor savings if done at NCSU• Balances against shipping, disassembly, re-assembly, extra infrastructure

– Assembly requires continuous presence and expertise of the cryostat team for ~ 2 years• Probably significantly longer if apparatus and team not geographically close


Gantt ChartDuration – 38 months

Test coil pkg in CV (NCSU)

Test insert in CV (NCSU)

Test 3He system in CV (NCSU)

B-shield installation (FNPB)

Test entire apparatus at FNPB

Schedule dominated by repeated cooldown/testing cycles


Milestones

Subsystem inputs

Assembly and commissioning deliverables


Critical Path

• Cryostat vessel• Whichever subsystem will be the first to

install– Seemingly the coil package

• Not the B-shield, which is only needed more than two years after the start of coil package assembly into the cryostat.


Schedule Risks/Uncertainties

• Cost and schedule is totally dominated by the number of cooldown cycles required for successful commissioning:– 3 for coil package– 4 for insert– 3 for 3He components– 3 for integrated tests– 2 for commissioning run w/ beam, B-shield

• These estimates (sorry!) really are WAGs because it is impossible to know how long it is going to take to diagnose a problem.


Areas of Interface - Everything

• DAQ• Neutronics and Shielding• Cryostat• Insert• 3He Components• Coil package and shielding• Infrastructure


Technical (Scope) Issues• Is your scope well defined (yes/no)? Is it

documented? Yes and no.– We have carefully constructed this WBS so that

it only involves assembly and commissioning of fully-tested parts.

• Important that this is understood and agreed to by other subsystems.

– Also, our model currently assumes that external subsystem labor is free or costed by the corresponding subsystem.

• If this is not correct it needs to be fixed.


Cost Estimates• Work package spreadsheets not complete.• Cost estimate is entirely labor.• Dominated by NCSU and ORNL technician

time:– ORNL – ~2 FTE-years = $400k– NCSU - ~4 FTE-years = $450k– Shipping - $36k

• Pre-contingency estimates.• These estimates (sorry!) really are WAGs

because it is impossible to know how long it is going to take to diagnose a problem.


Staffing Plans• NCSU (from D. Haase talk)

– People - 5 NC State physics faculty, TUNL technical support (Engineers and electronics techs)

– Key skills - cryogenics design, implementation and testing– Recruitments - need 1 postdoc and 2 cryo technicians– Issue - funding for recruitments

• ORNL– Technicians w/ cryogenic expertise needed– Issue: not currently on staff– Issue: Need to come to grips with operational model for

the experiment, i.e., will ORNL assume general responsibility w/ relatively little involvement by collaborating scientists (“J-Lab model”) or will there be substantial, on-site presence of collaborating scientists (“RHIC model”).


Procurement Planning• We have structured this WBS element so

that there are no material purchases.


Issues

• The “62% Rule” is not always applicable:– Hourly rate for NCSU technicians assumes 52*40

hours/year (unlike ORNL, and presumably LANL) in which vacation time is built into overhead.

• To correctly cost things they should be entered as 71.4% or their hourly rate should be upped.

– Another example is an intermittent resource, like a couple of electricians who work for a couple of weeks on the project.

• ORNL, NCSU technician/engineer burdened rates in the spreadsheets are not correct.

• I started this WBS in a fresh file. I didn’t realize it was using a 5-day calendar (apparently now the MSP default). So fractions are not currently consistent with 62% rule.

EDM Fast Start Presentation WBS 11 – Assembly and Commissioning

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