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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 conceptual 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

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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 Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004

  2. Topics • Scope of work • Spool design parameters • Spool conceptual design • Cost and schedule • Key milestones • Critical path analysis • Risk analysis • Summary Director’s CD-2/3a Review of the BTeV Project – September 28-30, 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 Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  4. Scope of Work • Design and oversee production of two sets of spools plus one spare set. • Each set consists of 5 spools (X1H, X1V, (2) X2, X3) for a total of 13 spools. • 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. Director’s CD-2/3a Review of the BTeV Project – September 28-30, 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: 250 mm OD x 1200 mm long • X2 spools: 250 mm OD x 550 mm long • X3 spools: 250 mm OD x 800 mm long • BPM length: 10 inches * MAWP is Maximum Allowable Working Pressure Director’s CD-2/3a Review of the BTeV Project – September 28-30, 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) Director’s CD-2/3a Review of the BTeV Project – September 28-30, 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 Director’s CD-2/3a Review of the BTeV Project – September 28-30, 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 1.43 0.48 0.48 V&H 2x10kA 2x100A+SL X2 pac kb48 1.43 0.48 0.48 V&H 2x10kA 2 x100A X3 packc0u 1.43 0.48 0.48 7.5 V&H 2x10kA 3x100A+200A X3 packc0d 1.43 0.48 0.48 7.5 V&H 2x10kA 3x100A+200A X2 packc12 1.43 0.48 0.48 V&H 2x10kA 2x100A X2 packc13 1.43 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) Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  9. X2 Spool Conceptual Design Corrector leads Relief valves HTS Leads Suspension ports Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  10. X2 Spool Cross Section HTS Leads Liquid Nitrogen volume 2-phase heat exchanger Vacuum break BPM Helium vessel Corrector Vacuum vessel Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  11. 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: • March 2006 – October 2009 • Production oversight: 1 FTE Summary of spool cost: (Based on LHC DFBX and preliminary fabrication study) Base cost: $5.038M (Material: $3.448M, Labor: $1.590M) (Does not include spares.) Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  12. Spool Schedule Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  13. Spool Cost Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  14. Spool Labor Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  15. Key Milestones • Start of detailed design – October, 2004 (FY05) • Bidding process: March, 2006 • 1st Spool fabrication begins: October, 2006 • Series production begins: November, 2007 • Production and test complete: November, 2008 Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  16. 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. Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  17. Risk Analysis Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

  18. Summary • The conceptual 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. • The cost to design and build the new spools: $5.038M Director’s CD-2/3a Review of the BTeV Project – September 28-30, 2004 BTeV Spools – Thomas Page

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