BTeV Spools (WBS 2.1.2.3)

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BTeV Spools (WBS 2.1.2.3)

• Thomas Page

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Topics

• Scope of work
• Spool design parameters
• Spool design
• Cost and schedule
• Key milestones
• Critical path analysis
• Risk analysis
• Summary

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Organization (or You are here)
2.1.3 Project Management
WBS 2.1 Magnet Fabrication Test
2.1.2 New Spools
2.1.1Q1 to Q5 Quadrupoles
2.1.2.3Spool Assembly
2.1.2.2Corrector Magnets
2.1.1.4 Q1 to Q5 Fabrication
2.1.2.1 HTS Leads
2.1.1.1Cold Mass
2.1.1.2Cryostat
2.1.1.3 MTF Test Stand
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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.

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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
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Spool Pieces
Q1Q2X3Q3 (mirror image about IP not shown for
space)

• 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

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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

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Spool Information
(Details)
(Interfaces)
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X2 Spool
Corrector Leads
Relief valves
HTS Leads
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X2 Spool Cross Section
Support Post (same as quad)
Liquid Nitrogen volume
Vacuum break
BPM
Helium vessel
Corrector
Vacuum vessel
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X2 Lead Stack Helium Pipe
HTS Leads
Corrector Leads
Safety Leads (for Tev bus)
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X2 Lead Stack Cross Section
Quench Stopper (for Tev bus)
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X2 Vacuum Vessel
ASME BPV Code VIII-1 Appendix 13 Sketch 3
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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)
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Spool Schedule
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Spool Cost
FY05 k No Contingency No Escalation GA
Included Construction Costs
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Spool Labor
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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

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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.

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Risk Analysis
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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.