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sPHENIX Detector Cost, Schedule, and Status Review

A review of the cost, schedule, and status of the sPHENIX Detector project was held at BNL. The goal was to gain approval of the I&F Cost and Schedule Baseline.

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sPHENIX Detector Cost, Schedule, and Status Review

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  1. Support for the sPHENIX Detector A Cost, Schedule and Status Review was held Oct 16-17 at BNL. It was a BNL Director’s(ALD) Review. The sPHENIX Project Management goal was to get approval of the I&F Cost and Schedule Baseline. Fortnightly

  2. sPHENIX I&F Review Agenda Fortnightly

  3. Review Charge • Project scope: Is the project’s scope likely to meet the required performance? E O’B, G Young, L2 Managers • Cost and Schedule: Are the cost and schedule estimates credible and reasonable considering the maturity of each component of the project? Has the impact of a RHIC run in FY22 been properly evaluated, including the impact on schedule and resources? Are the plans for an early finish of the project, including resources credible? E O’B, G Young • Management: Is there a capable team in place, and the required resources identified, to effectively manage risks, and interfaces to successfully execute the proposed baseline? E O’B, G Young, J Mills., R Feder • Risks: Are the risks properly understood and mitigation plans developed? Does the project include adequate scope, cost and schedule contingency?  G Young, E O’B • Prerequisites: Is the required documentation in place from previous Director Review? See posted documents • Recommendations: Have the recommendations for the Infrastructure and Facility Upgrade Project from past reviews been appropriately addressed? GY or EO’B • Has the project made sufficient progress to date against the proposed baseline plan? All talks • Is the environment, safety and health (ES&H) and quality being properly addressed given the current state of the project? C. Gortakowski The review committee concluded that we had met all of the requirements of the review charge Fortnightly

  4. sPHENIX I&F Review Committee Fortnightly

  5. sPHENIX I&F Baseline Scope Infrastructure and Facility Upgrade (2.X): • SC-Magnet (formerly of BaBar) installed, mapped, commissioned and ready to operate at full current. • Includes cryogenics, power supplies and controls supporting SC-Magnet operation • Steel Flux return for the SC-Magnet • Includes barrel flux return built in 32 sectors and pole tips on each end • Carriage/Cradle and mechanical structures necessary to support the detector • Includes magnet barrel flux return, pole tips, support platforms, access (stairs, ladders, egress) • Infrastructure in Building 1008 to support the detectors operation • Includes, HVAC, PS, water, gas systems, smoke detection/fire protection, safety systems including ODH, racks, cable trays • Concrete reinforcement of the steel tracks that support the sPHENIX detector • Integration and Installation of both sPHENIX detector subsystems and detector support services • Engineering design to support the project deliverables • Project Management to carry the project scope through to a successful on time and on budget completion. Fortnightly

  6. sPHENIX I&F Management Structure All Control Account Managers are at L2 Fortnightly

  7. sPHENIX Engineering Staff Experienced Staff – Most Leads have been with sPHENIX since 2014. Some turnover of key people. Fortnightly

  8. Engineering Design Staff Chief Design Engineer/Detector Integration - R. Ruggiero (PH) Fortnightly

  9. Engineering Controls • Engineering – • Follows sPHENIX Procedures, CAD Procedures, BNLSBMS Engineering Design Standards, Applicable Industry Codes and Standards • Documentation – • Drawing Numbering Plan and Revision Control is documented in procedure. • Archiving of all Engineering Documents to be at sPHENIX Project office. • Final approval to be from the sPHENIX Project Office and L2 Managers. • Design changes will follow change control procedures, requiring approvals as appropriate and as designated by project office. • Autodesk Vault to be used for sPHENIX released drawing and document revision control. • Reviews – • Suite of Engineering Design and Production Readiness Reviews • Fabrication – • Fabrication will follow BNL-Planning, Performance, and Quality Management Guidelines and Procedures. Fabrication Documents at non-BNL facilities will be reviewed and approved by sPHENIX PM, Safety, and Q/A. Fortnightly

  10. Engineering Meetings and Progress Review • Regularly scheduled Subsystem-specific Engineering Working and Status Meetings • attended by subsystem lead engineer (designer and support engineers), sPHENIX Project Scientist, Chief Engineer, Project Engineer, and L2/L3 scientists when appropriate. • Bi-weekly sPHENIX Project Engineering Meeting • all engineers meet to review progress, problems and to discuss technical issues. General interface issues are discussed with follow-up meetings scheduled. Chaired by sPHENIX Project Engineer and attended by Project Scientist and Chief Engineer. • Weekly Construction Coordination and Safety Meeting • technical staff and project management meet to review ongoing scheduled work and planned future work. Safety related issues and schedule discussed. Chaired by C. Pontieri, sPHENIX L2 Installation and Integration staff, attended by sPHENIX Project Director, PE, CE, Safety, Q/A, CAD Liaison Engineer, Liaison Scientist and CAD Safety, and often attended by BHSO. • Standing Integration Meeting – Office of Systems Integration • Chaired by sPHENIX Chief Engineer Meetings are usually documented via INDICO and conducted using BlueJeans video conferencing. INDICO documents are accessible for reference to all sPHENIX staff. Fortnightly

  11. Technical Reviews • All engineering reviews are attended by sPHENIX Safety and Q/A TYPES OF REVIEWS • sPHENIX Conceptual Design, Preliminary Engineering and Design, Final Design Review, Interim Engineering Design Review • sPHENIX Procurement/Production Readiness Review • sPHENIX System Readiness and Safety Reviews to be conducted for all subsystems prior to the start of Subsystem Commissioning, Full Detector Operational Readiness Review • Other BNL reviews - Laboratory Environment, Safety & Health Committee Review (LESHC), Experimental Safety Review (ESR), Lifting Safety (Critical Lifts), Pressure Vessel and Cryogenic Safety • All Reviews are part of the sPHENIX P6 Workflow Fortnightly

  12. 2.X Engineering Reviews 2015-2019 • 28 Reviews Performed • Reviews are in sPHENIX Resource Loaded Schedule Fortnightly

  13. sPHENIX Project Controls and Work Management Documents • sPHENIX Procedures and Documents for Engineering, Design, Fabrication, and Installation • Signed and released for use • sPHENIX Procedure Guidelines • sPHENIX Configuration Management • sPHENIX Document Control • sPHENIX Quality Assurance Plan • sPHENIX Conduct of Design Reviews • sPHENIX Work Planning • sPHENIX Awareness Training • sPHENIX Bottom’s-Up Estimate Uncertainty Guidelines • Interface Control Document/Interface Design Drawing • Integrated Safety Management Plan/Safety Hazard Analysis Document/CAD Conduct of Operations • Comment Resolution Database Fortnightly

  14. sPHENIX I&F Accomplishments • We have developed a detailed resource-loaded schedule and cost plan for the sPHENIX Infrastructure and Facility Upgrade. It has been reviewed this week and the review committee recommends that BNL (ALD) approve it. • The SC-Magnet has been cold tested at BNL to 105% of operating current. • The Power supply, cryo controls and quench protection circuitry has been tested during the cold test • The valve box extension has been modified to match our flux return design. • All 32 Outer Magnet Steel/HCal sectors now at BNL. All passed mechanical inspection. • Components needed to bring cryogenics into Bldg 1008 RFP. Bid process is complete. Award is pending. • Carriage/Cradle FDR held in August. Carriage/Cradle is on the critical path for the I&F project. Checking and sign-off of final drawings ongoing. • Design work advanced on many sPHENIX I&F components. Fortnightly

  15. Installation and Integration Design Periodic space claim checks using detailed models identify clashes in the compact sPHENIX core. This is a view of TPC, INTT and MVTX sPHENIX Integration Envelope Control drawing (205-000-000, Rev A) under configuration control in Vault  sPHENIX uses the envelope control drawings, detailed 3D Inventor models and Interface Control Documents (ICDs) to track and manage interfaces for design and installation. Fortnightly

  16. Plan and Elevation View of sPHENIX Detector Fortnightly

  17. Infrastructure Design, Procurement and Installation See Talk by Rob Pisani See Talk by Brian Streckenbach WBS 2.5.3-2.5.12 sPHENIX Mechanical Construction Fortnightly

  18. WBS 2.5.3-2.5.12 sPHENIX Installation The iHCAL barrel slides in from the North The base will be built on top of the AH rails The full oHCAL barrel weighs ~480 tons Magnet mount hardware is also attached The rings also work to stabilize the magnet The magnet is lowered in to the oHCAL bore TPC Work on sPHENIX will stop for the time needed to remove the shield wall There are 64 EMCAL sectors each installed one at a time with a special tool TPC slides in the EMCAL bore from North There is a 5-foot move North in the IR Results from an sPHENIX OPERA EM FEA Beam pipe is supported temporarily as a few locations for MVTX installation MVTX has a 2mm clearance to the beam pipe iHCAL, EMCAL, TPC and INTT Supports Fortnightly

  19. Technical Challenge: How do we install it? The oHCAL engineering team is working through a series of prototypes to practice installation of the final “keystone” oHCAL sector. Each of the 32 oHCAL sectors weighs 15 tons. The iHCAL assembly weighs 16 tons and needs to be inserted into the magnet bore from the north in the AH. Engineers are working on the preliminary design of these insertion structures. sPHENIX engineering and the MIT based MVTX design team are working together to design a MVTX installation practice prototype. MVTX requires a 2 mm radial clearance with the beam pipe and a careful precise installation plan is essential. There are 64 EMCAL sectors that will be inserted into the iHCAL barrel bore using a special lifting and position device that is under development. Fortnightly

  20. Technical Challenge: Does it fit? • 2D and 3D models of Bldg 1008 are updated for installation choreography and for developing cost and schedule estimates • Identify space for all tooling and potential clashes or integration issues Example of a potential clash with the magnet cryo services valve box and the south shield wall opening. This has been checked using the choreography CAD models. Shield Wall Magnet cryo valve box Fortnightly

  21. sPHENIX Installation Schedule ` We are evaluating various installation efficiencies to give us more schedule contingency • Start: March 21’ • Key Predecessors • AH/IR Rail Mods • Cradle-Base Ready ORR 01-Nov-22 Start RHIC 30-Jan-23 FY21 RHIC Run 1/4/21 to 5/13/21 FY22 RHIC Run 9/1/21 to 12/30/21 Fortnightly

  22. Summary • The 1008 Infrastructure and Facility Upgrade has a well-defined scope, solid cost estimate and strong management team. • We have a mature Resource-Loaded Schedule fully integrated in P6 with the RLS for the sPHENIX MIE. We have a detailed Cost estimate and Basis of Estimate documents. • Designs are advanced for many I&F deliverables. • In some cases, Barrel Magnet steel, the deliverable is already at BNL. • We are strongly supported by BNL. We have been granted the BNL extraordinary overhead rate. We have received significant contributions from labor resources in PO, CAD, IO, SMD, PMC, PPM, ES&H, NSLS II, etc. • We have proposed the I&F Cost and Schedule baseline to BNL through the review committee and they have recommended the BNL approve it. Fortnightly

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