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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• Muon beamline 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

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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 – LH2 absorber 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

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• 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

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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

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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

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MICE Target ProgressRe-engineered Vespel bearings

Showing relieved anti-Rotation collar

‘Before and after’polished bearing surfaces ontitanium shafts

Core body

Dust ‘can’ assembly(in blue)

Shaft

Upper stop position(held by stator)

Lower stop position(unpowered)

Lower bearing

Bellows

MICE Target Progress

Managing Dust– Dust ‘catcher’ = Fitted to T2.4 & T2.5

Dust onoutside of

lower bearing‘before’

Dust catcher & shaft with

no dust‘after’

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

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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

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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

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• R&D cryostat, valve panel, enclosure and transfer line• Tested and delivered last November• 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

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Have only very recently been able tostart the real CAD work, due to shortageof staff.but, good start made, beginning tounderstand waveguides, water loads,services, hardware etcGood news is that on first lookthings seem to fit with floor

RF Infrastructure

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 Qi Huan in Beijing

• Quite useful – at least I’ve been allowed to form my own idea of the ‘problems’ for the first time

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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 – Qi Huan, 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

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Sequence of events (I think!)

• Design work for the CC is overseen by Wang Li and Lixin Yin

• The coils are wound by Qi Huan 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

• Qi Huan manufacture the vac-vessel• Cold mass is shipped back to Qi Huan, who do the final

assembly• Magnet is presumably cooled and tested with CCRs at Qi

Huan• Then it’s shipped to LBNL for RF cavities and vac vessel to

be fitted

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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

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Risks & worries

In no particular order:– Fabrication of the cryostats and post machining is a huge job –

were unable to see Qi Huan’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

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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

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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 Qi Huan – 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!

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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.......

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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.....

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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

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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

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