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MICE Report to the CMPB

February 2008

• Ken Long, Andy Nichols and Richard Apsimon• 22nd Feb 2008

1. Project Manager’s Report 2. Project Status, risks and schedule3. Financial status

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Conclusions and principal issues:

• Conclusions: The increase in the pace of the MICE-UK project has now been

maintained since June 2007• Technical progress from RA and AN …

The outturn forecast is in excess of the £9.72M envelope• A possible de-scope option (magnetic shield wall procurement postponed

to Phase II) has been identified

• Issues: Phase I resources need to be carried over into financial year

2008/09 Since some magnetic shielding walls are required for Phase II, the

best way forward needs to be identified:• Noting that the infrastructure project now has gathered momentum, the

project teams preference is:– To review rapidly the design with a view to reducing complexity and cost and

to identify whether a staged build is possible; and– To push ahead as close to the present schedule as possible

It is urgent to resolve the funding of Phase II

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MICE Target (in ISIS)

• Target & Controls . Pre-installation Stepper motor & interlocks ok. Target actuated 1000 times ok. Good vacuum (3.3×10–7 mbar). Absolute position w.r.t. beam pipe measured.

• Moved to ISIS and connected Sunday 20th Several damaged fibres discovered. (Poor

installation) Optics (approximately) set up. Stepper motor & interlocks checked. Target raised & lowered several times. Operation from MICE LCR difficult without

network.

• Some work remaining for Installed Target Adjustment of optical amplifiers, interlock

programming, gate valve to be open, PPS ………. Stepper motor control under investigation at

DL• and, of course, permission from ISIS to

operate!

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Secondary MICE Target

• Actuator & electronics (almost) completed & tested in Sheffield – 50,000 pulses.

• To RAL 13th February and re-assembled in R78. Unusual pulse-to-pulse variation. Failed after ~600 pulses. One coil (of 24) found shorted to ground & burnt out.

• Internal ground not connected in Sheffield test! Spare stator installed New welded seals at Daresbury last week Brought back to RAL immediately (untested.)

• All electronics now at RAL. Problems still exist so has now be taken back to Sheffield

for further investigation. N.B. Stator currently in ISIS had done >2M pulses ok.

• Future – investigating better quality insulation (double layer?) with manufacturer.

• Need new QA procedures for coil insulation.

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Phase I beamline in MICE Hall

• Shielding complete & D2 positioned

• Since then:- D2 fully connected PSI Decay solenoid installed

• With shielding• Aligned

Q4,5 & 6 installed All girder boxes built & installed Power & interlocks connected Water being finished Alignment complete

• Still to do Cherenkov mounted

• Stand required modification ToF0 delayed. Due early March

• Install with Cherenkov Q4-6 water and final tests Q1 power supply due last week PPS to be connected – this week

Sept 2007

Feb 2008

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Work in ISIS vault during Xmas shutdown

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Status of tracker build: schedule

• Tracker schedule: Tracker #1 complete in R8

Tracker #2 to be fabricated by end March ’08

• (means assembled space frame in coffin)

Cosmic ray test of tracker #1 started before end March ’08

Continuing resolution of installation:

• Run with cosmics, install in solenoid, run with cosmics?

• Run with cosmics, install/de-install in Hall, run with beam?

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Linde refrigeration

• Spec:- 66W @ 4K (56Wsolenoid +

10Wtransfer) In November we saw about 51W + 10W

• Managed to cool decay solenoid to ~20K– Ran out of time, not cooling

• Problem ‘traced’ to missing insulators Jan 08, a reduction to 47W + 10W

• Problem now believed to be turbines– Evidence of carbon / graphite dust– Bearing failure?

• Turbines due back last week• Engineer ready to re-fit & re-test

We trust that this the end of the problem. Scaffolding built around decay solenoid Gas rack and piping ready Need access to DSA and permission to

dismantle transfer line. DeMaCo will return to re-install transfer

line into DSA 17th March.

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Technical Co-ordination, Phase One

• The shared post of PM/TC has worked quite well• Six months ago there was much for us to learn:

Revised the WBS Now have a clearer picture of tasks and responsibilities Led to better understanding of the project Technical detail and information flow was not obvious Engineering content of Infrastructure WP had been grossly

underestimated New Hall Manager, together with re-structured meetings,

is a vital link in the project Some very good progress has been made in the Hall

build-up, but there have been a few technical problems…

• Clear that we have to plan better for Phase Two

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Technical Co-ordination, Phase One• Delay to target running:

Ideally, management of design and manufacture should have been in one place

Mechanical design of the bearings and shaft could have been improved to mitigate dust problems

• delays and QA problems On & Offline targets should have had parallel working One Project Engineer identified at Daresbury for target,

effective, but rather too late to make big difference• If there is a limited target programme in Phase Two:

Mechanical re-design, bearings, shaft (important) Single engineering oversight Should ISIS take responsibility for installation?

• Start up of Q4,5,6 Has been delayed as they are not connected to water Result was we missed completing before ISIS started and lost

access to DSA• All services and ancillaries must be captured on

installation drawings with parts lists – simple stuff, but surprisingly difficult to implement

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Technical Co-ordination

• The Infrastructure project: Magnetic Shield walls Rolling platforms False floor Concrete floor removal Excavation of ISIS mound DSA Roofing Air Conditioning Water Electrical

• The engineering content was seriously under-estimated, what have we done?

We now understand it (Don’t like what we’ve found though!) Broken it into more digestible chunks, i.e. North, South, etc Appointed new WP1 Manager (Tim Hayler) Limited de-scope possibility (rolling platforms) Tenders, orders, etc underway, see Richard’s slides

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Technical Co-ordination

• Infrastructure technical status: Following big-ticket items are committed:

• South shield wall support structure• Air conditioning units• Concrete floor removal

Design work almost complete for:• False floor• North wall shield support structure• DSA roofing and walkways

Four sensible offers received for ALL magnetic shield plates (£150k – £200k)

Remaining design work:• MICE Hall roof layout (not yet started) & check the roof’s

structural rating– Fence between MICE roof and Injection Hall

• Installation drawings for CDM records (hopefully a collating exercise)

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Technical Co-ordination

We have been asked to provide these but have no funds to do so

– Fence (or hand rails ) around the entire perimeter of the MICE roof– Permanent stairway giving access to roof

• So the Infrastructure will over-run Phase One…. Three main effects:

• Will delay Step II & III of MICE• Stack-up of deadlines means Heavy civil work will be concurrent

with tracker/solenoid integration – cannot be allowed• Spending on infrastructure (manpower & capital) carried into

Phase II Open questions:

• We can stage the build of the magnetic wall, not a cost saving, in fact probable cost increase, but we can tailor to meet Phase II beamline build schedule better?

– Direct cost saving from change of rolling platforms 2-6 for off-shelf slides

• Carry on as we are option: basically the infrastructure work dominates the Hall until mid July 2008

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Technical Planning for Phase Two• We have to plan better:

The Phase One Infrastructure Work Package should convert into Integration & Services for Phase II:

It’s very important that this is understood and properly resourced, because the risks are greater:

• More diversity in the beamline elements• Safety, technical, financial and collaborative issues• The Hall will be full of equipment – less space than we think

The current WP1 Manager can do it, but must be backed up by suitable, technical person

Better use to be made of the Technical Board• Integration & compatibility issues will become more important

• Currently the Hall baseline layout is a huge 2D CAD drawing ‘owned’ by one person. We will fail if we carry on like this

The drawing is too large and crowded It has no dimensions or datums for beamline items No services detail shown All technical integration decisions are on the critical path at the mercy

of one overloaded person

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Technical Planning for Phase Two

• We will convert it to 3D CAD assembly – partly done already:

Access by multiple controlled users possible Engineering decisions can be made in parallel CAD models more easily shared among collaborators Dimensioned plans can be extracted

• A couple of worries: The RF and LH2 projects both have the potential for

large unforeseen expansions of engineering effort:• The RF power distribution is currently ill-defined• The LH2 is an R&D project at present and the lead

engineer left last year (replacement identified – Mike Courthold)

Interaction with the rest of MICE for both these activities will not be straightforward

The Phase II effort profile estimate is taking shape, but it must allow sufficient margin for the above and identify the right person – discussions underway with EID

Integration & services must be identified as a discrete Work Package.

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Organisation• Project management team established:

A.N. Other PPD: P. Flower, in place from October• Took responsibility for testing completed Q35s and D2 (and other things!)

MOM team now in place:• Past: Blondel, Long, Zisman • Present: Gianninni (present MOM)• Future: Apollonio, Kyberd, Ellis, Grauhlich, Long, Bross, Zisman, Kaplan,

Blondel

• Project on much better footing, but: PM (R.Apsimon) has applied for early retirement

• Consultation over successor has started P.Flower has applied for early retirement Other staff have applied for redundancy/retirement

• Uncertain times!

• WBS: change in infrastructue work package manager: T.Hayler replaced C.Nelson from January 2008

• Preparation of reports: Much better, but still some work to do … For Phase II plan to set up a data-base (in common with UKNF) …

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Phase I finances:

Baseline Spend Future

Costed Risk(CR)

Out turn (incl. CR)

Variance (baseline-outturn)

Variance as at

Item Total £M Total £M Total £M Total £M Total £M Total £MSeptember

OsC £M

Project Oversight .91 .87 .13 .98 -.07 -.05

MICE Muon Beam 1.69 3.18 .27 .10 3.55 -1.76 -2.12MICE Infrastructure 1.81 .90 1.53 .01 2.44 -.62 .55

MICE R&DRF Power .60 .50 .18 .68 -.09 -.36Hydrogen .32 .31 .27 .01 .60 -.27 -.13

FC Module Design .80 .45 .45 .35 .61

Detection and Measurement 1.20 1.07 .24 1.31 -.11 -.09

Travel .20 .25 .01 .26 -.06 -.03

Total Phase 1 7.52 7.53 2.62 .13 10.27 -2.62 -1.63

Working Margin .73Contingency 1.46

Total incl. WM & C 9.72 7.53 2.62 .13 10.27 -.55 .56

£10.16 MTotal spend plus requirement without costed risk:

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Phase I finances: infrastructure

Total Infrastructure

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

Time Scale

Baseline (loaded)

Spend

Future

Baseline (unloaded)

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Phase I finances: over-run:

£kStaff

January to March 2008 As presented in interim report 587April to June

Infrastructure Under review 225Liquid hydrogen R&D 30RF amplifier refurbishment 35

Total additional staff cost since C2C revirew 877

'Big-ticket' capital itemsMagnetic shield walls As presented in February report 368False floor, plinth, rolling platforms As presented in February report 139Water and air services As presented in February report 535Budget As presented in February report 328

Cost of capital items minus budget 714

Total additional manpower and capital cost increase over budget 1,591

Staff etc. following Cost-to-Completion review and April OsC meeting 380Additional resourcecs required (estimate) 1,211

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Phase I: possible re-definition of scope

• Outturn forecast in excess of allocation +WM + contingency

Therefore seek a re-scope that will bring the total spend within the £9.72 envelope

• Option: Move procurement/installation of magnetic shield walls

out of Phase I Undertake redesign with a view to simplification of

design and reduction of cost as part of Phase II• Technical details from Andy Nichols

• Magnetic shielding will be required in Phase II Possibilities for cost reduction:

• Simplify support• Reduction in quantity of steel

– Thickness– Perhaps north (linac side) wall need not be as thick

» Extreme possibility: north wall is not needed (unlikely)

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Phase I: possible re-definition of scope

• Present schedule for build of magnetic shielding: Start April; complete end of June Heavy civil construction in conflict with running MICE with tracker:

• Concrete dust/metal swarf incompatible with tracker electronics• Agreement with FNAL precludes heavy construction work in vicinity of

VLPC cryostats (VLPC cassettes are D0 live spares) Significant schedule issue

• Delay/redesign magnetic shielding: pros and cons: Pros:

• Design for a cost saving: reduce capital cost and perhaps a staged build• Staged build:

– Would allow ‘just enough’ steel to be installed for each stage in MICE build up• Staged build

– May allow data-taking to be scheduled in between sections of build

Cons:• Redesign implies delay to installation start and increase in staff effort

required• Staged build likely to result in an overall increase in cost:

– Though the spend profile may be more easily managed

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Phase II finances:

• MICE-UK Phase II deliverables:

● Work-package 1: MICE Hall, infrastructure, and management of installation and integration:

The implementation of the additional infrastructure in the MICE Hall to support Phase II of the experiment (e.g. RF power supply and distribution), the management of the engineering integration of the experiment, and the management of the installation of the Phase II equipment in the MICE Hall;

● Work package 2: Focus-coil module:

The construction, installation, and commissioning of the focus-coil modules that are required to focus the beam at the centre of the liquid-hydrogen absorbers. Note that, in line with the PPRP recommendation, the allocation makes provision for the procurement of only two of the three focus-coil modules that are required in MICE; and

● MICE-UK operations and analysis:

MICE-UK contributions to the operation of the experiment, the data analysis, and the preparation of the results for publication.

•STFC funding cuts likely to imply a significant reduction in resources …

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Phase II finances: guidelines from J.Womersley

• Seek to defend a continuing accelerator R&D programme at the level of ~£10M / year

• Guidelines for the MICE-UK and UKNF programmes:

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Phase II finances: consequences:

• Significant (and unrecoverable) delay: Above assumes contract for focus-coil modules is let on the 29Feb08

• Implies first payment this financial year To get close to requested profile, had to introduce arbitrary 3 month

delay to start of manufacture of second set of coils• Moves payments into financial year 2010/11

+11 months

+14 months

Urgent action is required!

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Phase II finances: consequences: risk

• Risk: loss of post. doc. Staff: Significant damage to expert UK team established in

Phase I Implies significant reduction in potential for UK impact

in analysis/exploitation phase• Tragic!

Urgent action is required!

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Reputation risk:

• STFC RAL is the host laboratory: Over the past year, the international collaboration (the

US in particular) has increased its investment in MICE Phase II

For the UK to delay the schedule of the experiment risks not only the timely inward investment, but the UK reputation as a reliable collaborator and host

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Project Milestones – progress since last OsC

Total # milestones 147100.0%

Complete at 9/07 74 50.3 %

Therefore # remaining 73 49.7 %

Of these 49.7% we have……..

Completed by 2/08 41 27.9%Not complete but unchanged 14 9.5%Milestone now within 30 days 2 1.4%Milestone past and not complete 16 10.9%

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Project Milestones – progress since last OsC

Milestones remaining after OsC 9/07

Not complete but unchanged

Milestone now within 30 days

Milestone past and not complete

Completed by 2/08

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Project Milestones – progress since last OsC

• Not complete but unchanged (14)• 7 will finish by 31/3/08• 3 due to finish at end of Phase I infrastructure• 4 are part of Phase II

• Milestone now within 30 days (2) • Linde refrigeration – before 31/3/08

• Milestone past and not complete (16)• 1 finished since writing paper• 6 will finish by 31/3/08• 8 due to finish at end of Phase I infrastructure• 1 is part of Phase II