(E)DR Magnet Design Overview

1. (E)DR Magnet Design Overview ... for the Magnet System Group Magnet EDR Overview

2. Outline • Design Overview • What is a detailed design? • What are deliverables? • Issues in the Design Process • ‘Limited’ (E)DR Approach • What can we expect with the existing constraints on funding and schedule? • Integration of Areas, Systems, and all that Magnet EDR Overview

3. (E)DR Magnet Design & Deliverables • Design for each magnet style: • Magnetic design 2D (and, if needed, 3D) magnetic field simulations to confirm specified field quality and magnet performance; • Pole profile and geometry optimization for better integrated field quality; • Mechanical and thermal analysis; • Magnet documentation. • Magnet documentation package should include at least: • Magnet specifications with all necessary parameters; • Results of magnetic field analysis as well as mechanical and thermal calculations. Magnet EDR Overview

4. (E)DR Magnet Deliverables, cont. • Magnet Documentation, cont. • Magnet drawings - at a minimum cross-sections, transverse and longitudinal views, with all connections to power, water, and instrumentation and corresponding schematics; • Description of all materials: iron, copper, insulation, epoxies, cables, etc… • Description of magnet manufacturing technology: coil winding technique, epoxy impregnation, curing, stamping laminations, yoke and magnet assembly, etc… • General views of the magnet support structure with adjusting mechanisms • Drawing of the magnet support in the tunnel. Magnet EDR Overview

5. Design Issues • Design issues and related items: • The design process and information flow, requires data exchange between different areas, regions, institutions, teams, and specialists. We should expect that a large fraction of time will be spent waiting for additional information, technical decisions, changes in specs, etc… • Integration with other sub-systems and making technical decisions for all areas simultaneously on the same issue and problem. • Finding professionals for magnet design and integration with the required experience. Magnet EDR Overview

6. Design Issues, cont. • Converting R&D projects into useful results for EDR • The large fraction of specialists’ time needed for meetings, reports, reviews, & travel will have a significant impact on EDR progress • Changes in the lattice or general magnet parameters will cause magnet redesign and a corresponding design time increase • The late start of EDR • Industry cost estimation for different regions and firm ranks(?) Magnet EDR Overview

7. Design Approach for an (E)DRwith Limited Resources • Priorities for detailed design effort need to be established - key magnets: complexity, cost, quantity (and/or all of the above) • Detailed design & cost estimate • Optimization of parameters, e.g. peak field vs. integral required • Conventional vs. superconducting • FMEA/Reliability • FY08 budgets do not appear to support any significant magnet engineering effort (for detailed design) Note: truth in labeling laws apparently do not apply to not-yet-approved projects Magnet EDR Overview

8. Design Approach, cont. • Magnet reliability is a major concern • MTBT assigned for magnets in the range 10 – 20106 hrs • Reliability must be ‘built in’ – part of the design process – and addressed early in the project • FMEA – Failure Modes and Effect Analysis - is a structured, qualitative approach to understanding • FMEA need to be carried out on specific magnet detailed designs, representative of the magnet spectrum • This is an important ‘up front’ engineering task which is part of the design process and cannot be left to the end Magnet EDR Overview

9. (E)DR – A magnet-centric assessment given the boundary conditions • (E)DR – time scale FY07-FY09 • FY2007 is over (funds are gone; magnet design not begun) • FY2008 has very limited resources for magnets… • FY2009 appears to have some additional resources for magnet detailed design (mostly rumor…) • The conclusion is that there will not be a significant number of magnet styles with detailed designs by FY2010 • Without detailed designs, the cost estimate will not be significantly more accurate or reliable • Consequences of deferring design efforts will not go unnoticed… Magnet EDR Overview

10. (E)DR – Assessment, cont. • Ready for approval process in FY2010 (?) • Lack of (E)DR resources for magnet design compresses all of detailed design into the ‘pre-production’ and ‘early’ project phases • Pile-up of work on magnet designers, draftspersons, etc. • Potential schedule impact on vendors and machine installation • Competition for resources (and/or schedule problems) if all efforts are pushed downstream • Not a realistic schedule w/res to ~130 magnet designs Magnet EDR Overview

11. Detailed Design  Integration Issues • (E)DR Magnets – ‘Interface/Integration’ Topics • Vacuum chamber (aka ‘beam pipe’) treatments • Power Systems • Coordination with Technical and Global Systems • AC Power • LCW system • Controls interfaces • Installation Does this get defined separately (and differently) for each Area System? • Kickers and Pulsed Magnets • R&D on fast pulsers is centered in DR effort • Separate effort for other Area Systems? • Is there a mechanism in the EDR approach to find a solution across Area System boundaries? Magnet EDR Overview

12. Integration Issues, cont. • More general integration concerns across Area Systems • Common Design Standards • Coordination among an unknown number of independent work packages • Design Review Formalism • Cost Estimation Standards • Measurement & test • Separate facilities for each Area System(?) • Obviously not, but where does this issue get addressed? • ‘Global’ Reliability/Maintainability Studies • Materials/components • Processes • Operating regimes & environments Magnet EDR Overview

13. Integration Issues, cont. • Kickers and Pulsed Magnets • R&D on fast pulsers is centered in DR effort • Separate efforts for other Area Systems? • Is there a mechanism in the EDR approach to find a solution across Area System boundaries? • There should be one person coordinating / integrating the overall fast pulser R&D • Kicker, Septum magnets, etc… • Superconducting Magnets – coordination / integration • Quadrupoles in cryomodules - Main Linac, RTML, e+ source • Differ only in energy range • Minimize number of different styles Magnet EDR Overview

14. Conclusions • If resources are limited and magnet design is deferred • Cost estimate will not be significantly improved • Different people can apply different guesses but the ‘data’ will not have changed appreciably • Detailed design occurs later • In labs or in industry, it will require a greater number of engineers and designers in a shorter time period • The required technical oversight burden will be greater – more designs, less time – and will require more magnet engineers • Potential for ‘Pile-Up’ in schedule • Production facilities saturated • Alternative is more, less experienced, less qualified vendors • Costs will increase • More capital investment (tooling, production lines) • Risk of Installation Schedule issues • Late magnets will clog the system Magnet EDR Overview

15. Conclusions, cont. • There are solutions • Admit to a more realistic schedule • No one believes this one… • Spread the (E)DR over 4 reasonably funded years (not 1 ¼ …) • More funding for FY08, FY09 • ‘Yeah, right…’ • Admit that the cost estimate will not be substantially more detailed or accurate • Rename the (E)DR to something closer to the truth… • Avoid another 2 years of ‘throw away’ effort on pseudo-designs for a not-more-reliable cost estimate…(aka ‘continuous fire drills’…) • Call it the “Enhanced Reference Design” and don’t claim any significant improvement in the cost estimate uncertainty • Or, why not a Realistic Schedule with Realististic Goals, consistent with actual resources… Magnet EDR Overview