MUCOOL R&D Plan - Princeton University

MUCOOL R&D PlanMUCOOL R&D Plan

Steve Geer February 2002

February 2002 Steve Geer 2

The MUTAC Report Says:The MUTAC Report Says:

“Ionization cooling remains the primary R&D issue for the collaboration. The most difficult part is the develop-ment and integration of the hardware, which is the goal of the MUCOOL efforts.”


Why is MUCOOL so Challenging ?Why is MUCOOL so Challenging ?We need to be able to operate a system in which Liquid Hydrogen is separated by a baking foil from an ignition source containing the energy of 10,000 light bulbs, and all of this is within a system of SC solenoids that might quench from time-to-time. The system must operate as 1012 charged particles pass, and WE NEED TO GET SAFETY APPROVAL.

We need to understand high gradient NCRF Cavity operationin Multi-Tesla magnetic fields, going well beyond the current state-of-the-art. We must understand and solve our present cavity breakdown problems.


What Must We Do To Meet the Challenge ?What Must We Do To Meet the Challenge ?We must become the worlds experts in high-gradient NCRF cavity operation in multi-Tesla fields Ø 805 MHz program

We must demonstrate 201 MHz NCRF Cavity operation at high-gradient in a multi-Tesla field Ø 201 MHz program

We must obtain the expertise to enable us to understand the LH2 absorber safety and cryo issues so that we can then design a system in which the absorber is next to a cavity Ø Absorber 1&2 Filling program

We must exploit the expertise from our first absorber filling to design and demonstrate an absorber operating next to a cavity, within a solenoid system Ø MUCOOL Systems Test program

We must show that cavities and absorbers will operate in an intense beam.


The MUCOOL Test AreaThe MUCOOL Test AreaOur initial plan (2 years ago) was to test absorbers and cavities in separate facilities, and have a 3rd facility for beam tests. This (i) turned out to be too expensive, and (ii) we found a better solution.

In the meantime, things have changed. We can no longer build a new 201 MHz source out of parts at Fermilab … the required modulator tubes have gone out of production. A completely new power source is estimated to cost 4 M$.

The only viable option we have to test 201 MHz cavities is to use an existing power source.There is one available at the end of the Fermilab Linac, but must build an x-ray cavern . We have been given 1.7 M$ of Fermilab cryo equipment so that we can also fill absorbers at the 201 MHz Test location. A beam tunnel exists, so we can eventually bring out a beam, building a beamline from existing magnets.

We therefore have an elegant, and cost effective solution for a MUCOOL Test Area in which we can test 201/805 MHz cavities, fill absorbers, expose everything to an intensebeam … and there is adequate floor space.


Scale of the EndeavorScale of the EndeavorThe MUCOOL Program is ambitious, and requires a very substantialcommitment of MC resources over several years.

If we execute the MUCOOL program it must be because it is considered vital to do so. Unless we have that level of commitment we are going to fail.

The test area construction will cost the MC about 2 M$ over a period of 2.5 years … about the same as we invested in the Lab G facility over a similar period of 2.5 years.

However, the MUCOOL program that will be executed in the test area will cost the MC an additional 4 M$, and will take an additional 3 – 5 years.

The MUCOOL Program is heavily leveraged: Total cost ~ 3 x cost to MC.


Test Area Construction Plan Test Area Construction Plan --11


Test Area Construction Plan Test Area Construction Plan --22


Test Area Construction Funding ProfileTest Area Construction Funding ProfileMuCool Spending Profile

W/ OHP

$142,000

$0 $0$70,840

$175,120

$292,160

$15,000

$344,160$325,040

$44,000

050000

100000150000200000250000300000350000400000

Jan-02

Feb-02

Mar-02

Apr-02

May-02

Jun-02

Jul-02

Aug-02

Sep-02

Oct-02

Nov-02

Dec-02

Amount Earned by Month

Dol

lars

834 K$ 856 K$


MilestonesMilestones

Milestone Date DeliverableComplete Design Drawings 3/29/02 DrawingsOut for RFP 4/01/02 Bid packagePermission to sign contract 5/29/02 PermissionComplete project schedule 6/04/02 Project scheduleBegin site mobilization 6/05/02 Inspection

Once contract signed we will be able to completeproject schedule & milestone list … but we estimate that …

Beneficial occupancy 12/17/02 Inspection


Construction Cost Born by MCConstruction Cost Born by MC

In FY01 Fermilab provided ~400 k$, ICAR ~150 k$, MC ~ 340 k$ &we have 274 k$ carryover

In FY02 Fermilab provides: Effort, overhead relief, & LN2 Cryo Plant

M&S Required to Complete Construction in FY02-03:

Bare Cost 1,408,320Contingency (20%) 281,664Total 1,689,984


M&S Estimate for the LH2 SystemsM&S Estimate for the LH2 SystemsTransfer Line 40,000

Line (100 ft) 10,000Refrig Room Bayonet Can 10,000Exptal Hall Expansion Cans (2) 10,000Exptal Hall Bayonet Can 10,000

Headers & Vacuum Vessel 4,200He Cooldown pipe/relief Header 2,000N2 return Header 1,20052 x Vacuum Pipe 1,000

H2 Manifold Room 29,650H2 Gas Regulator 1,000Manually Operated Valves&Switch 3,000Electrically Actuated Solenoid Valves 2,400Pneumatically Actuated Solenoid Valve 7,000Check Valves 2,600Relief Valves 6,000Rupture Disk 1,600Pressure Guages 500Pressure Switches 150Pressure Transducers 3,400Pipe, Tubing, Fittings 2,000

Absorber Cryostat 12,000Heat Exchanger 2,000Cryostat 10,000

Instrumentation & Controls 59,000Hydrogen Pump 5,000Cryogenic Heater & Controls 4,000Cryogenic Thermometry 4,000Cryogenic Control Valves 6,000Hydrogen System PLC 20,000Safety System Interlocks/Detectors 20,000

TOTAL 144,850

Assume Lab contributes the effort (otherwise double the cost)

Increase bare costby contingency (20%) & overhead(25%) Ø TOTAL = 217 K$


Cost to Implement 201 MHz Test FacilityCost to Implement 201 MHz Test Facility

M&S EffortMan Months Cost

Waveguide (Coax) 84,000 9.0 Techs 42,000+ Installation 2.0 Eng 17,000

Vacuum parts 30,000 6.0 Techs 28,000& Installation 2.0 Eng 17,000

Water System 20,000 3.0 Techs 14,000& Installation 1.0 Eng 9,000

AC Power, Integration 21,000 3.0 Techs 14,000& Diagnostics, Safety 1.0 Eng 9,000

TOTALS 155,000 21.0 Techs 150,0006.0 Eng




Cost to Implement 805 MHz at the Test FacilityCost to Implement 805 MHz at the Test Facility

M&S EffortMan Months Cost





TOTALS 124,000 19.0 Techs 140,0006.0 Eng




Fermilab Effort Required to Fill an AbsorberFermilab Effort Required to Fill an AbsorberPeople group %Alex Martinez cryo Eng 30All Moretti RF Eng 50Chuck Ankenbrandt Phys PhD 20Arkadiy Klebaner Cryo Eng 30Barry Norris Cryo Eng 30Jeaeer Reehl Cryo Draf 100Carol Johnstone Phys Phd 10Cristine Darve Cryo Eng 30David Neuffer Phys PhD 10Del Allspach Sav/Cryo Eng 50Jach Cezary EE Eng 5Jeff Sims FESS Eng 5Jim Lackey Phys MS 5Matt Ferguson Safety MS 15Elliott MacCrory Phys PhD 5Mike Gerardi Safety MS 5Mike Shea Control PhD 10Jim Preast Safety PhD 5Milorad Popovic Phys PhD 50Russell Alber FESS Eng 40Steve Geer Phys PhD 5Todd Sullivan Operation MS 5Bob Webber Operation Eng 5full time 5.2

To produce a LH2 filling facility requires a great deal of Lab expertise(~ 5 FTE).

Note that in the last year we have ramped up the cryo & safety engineering support to ~ 3 FTEs. This is a big investment. In addition, ICARhave supported one vital engineering FTE (Ed Black) … so we have ~ 4 FTEof engineering support deployed !


MUCOOL NonMUCOOL Non--MC FundingMC Funding

Fermilab Effort (FTE)Lab G 1.0Linac Area 4.5BD Scientists 3.5PPD Scientists 2.0CD Scientists 1.0

Total 12.0 FTEValue (@ 100 k$/FTE) 1.2 M$

Capital Equipment (Cryo) 1.7 M$Operations 0.1 M$G&A Relief 0.15 M$

Fermilab Total 3.15 M$

ICAR Effort (FTE) 12.0Value (@ 100 k$/FTE) 1.2 M$

M&S 0.15 M$

ICAR Total 1.35 M$

Japan Effort + M&S ~ 0.1 M$

Without this external support the MC could not develop cooling channel components


LeverageLeverageFor every $1 the MC puts into MUCOOLwe have managed to get $3.6 additionalsupport.

MC 1.27 M$Fermilab 3.15 M$ICAR 1.35 M$Japan 0.10 M$

TOTAL 5.87 M$

The MC support is VITAL since it is ourprimary source of M&S …. which in FY02 determines our schedule.

Hard to maintain such a large leverage ratio. Timely results are crucial.

New Funding ProposalsSBIR 1 R. JohnsonSBIR 2 R. JohnsonBeam Extraction C. Johnstone805 MHz R&D S. Geer805 MHz R&D J. Norem


Mapping Funding onto Approved FY02 ProgramMapping Funding onto Approved FY02 ProgramFull funding is maintained for all FY02 TB approved items on the FNAL list except for absorber filling (no longer possible in FY02)

Approved MC RemappingFY02 Funds & Comments

Test Area Prep 400 UnchangedLab G Operation 125 For Effort, M&S + Overhead Ø 100K covered by

FNAL + 5K by ICAR if this 125K is used for Test Area, + 20K by ANL

201 MHz Cavity -Coupling Solenoid -Be Window / grids 25 Covered by ICAR if this 25K used for Test AreaRF Power Source -LH2 Absorber Test 150 Reallocate to Test AreaInstrumentation 25 Lab G instrumentation tests covered by FNALLongitudinal Cooling (visitor) 90 Covered by ICAR if this 90K used for Test AreaTOTAL 815


Test Area M&S for FY02Test Area M&S for FY02

Assume we can use the 815K$ MC money earmarked for FNAL, made possible by the 120K$ additional support from ICAR, and the overhead relief (worth 200K$) and Lab G support from FNAL& ANL (worth 75K$ + 20K$).

LAB G RF Test PPD TotalGrid Area Visitor

Carryover - 274 - 274MC - 815 - 815ICAR 5 25 - 90 120TOTALS 5 25 1089 90 1209


Some Some StrawmanStrawman MUCOOLMUCOOL FY02/03 MC Funding ProfilesFY02/03 MC Funding ProfilesSensible Plan Delay Solenoid Design

Plan 1: FY02 FY03Construction 1089 601LH2 Filling - 217201/805 MHz Test Beds - 186Cavity R&D 475 425LBNL Solenoid Design 45 200Carry Over -274 -TOTALS 1335 1629

Plan 3: FY02 FY03Construction 1089 601LH2 Filling - 217201/805 MHz Test Beds - 186Cavity R&D 475 425LBNL Solenoid Design 45 -

Carry Over -274 -TOTALS 1335 1429

Plan 2: FY02 FY03Construction 1089 601LH2 Filling - 217201/805 MHz Test Beds - 150Cavity R&D 475 350LBNL Solenoid Design 45 200


Stretch out 201/805 MHz Cavity & Test Bed

Plan 4: FY02 FY03Construction 1089 601LH2 Filling - 217201/805 MHz Test Beds - 186Cavity R&D 475 200LBNL Solenoid Design 45 200


Stretch out 201 MHz Cavity Construction


Input for LongInput for Long--Range MUCOOL Program Range MUCOOL Program -- Costs & TimescalesCosts & TimescalesCost (K$) Estimated Time

R&D Sub-Program MC Other to ExecuteFuture 805 MHz Cavity R&D 100 200-1000 1-3 years201 MHz Cavity Design, foils,&grids 575 25 1-1.5 years201 MHz Cavity Construction 400 0 1 yearLH2 Absorber Prototypes 0 900 2 yearsAbsorber/RF Test Site 1690 3100 1 year leftAbsorber Filling Capability 217 200 6 months201 MHz Testing Capability 228 200 1 year805 MHz Testing Capability 186 200 1 yearSolenoid design (for cavity) 500 0 1 yearSolenoid construction (for cavity) 1500 0 1-2 yearsBeamline 500-1000 1000-1500 1-2 yearsRunning 100 200 > 3 yearsCarry Over -274SUB-TOTAL Costs (K$) ~6222 ~7325

Scientist Salaries 400 ~5000 4 yearsTOTAL ~6622 ~12325


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 1 (“Sensible Plan”)Plan 1 (“Sensible Plan”)

MC Funding (K$)R&D Sub-Program FY02 FY03 FY04 FY05 FY06 TOTAL

805 MHz Cavity R&D 0 50 50 0 0 100201 MHz Cavity Design/Grids/Foils 475 100 0 0 0 575201 MHz Cavity Construction 0 275 125 0 0 400LH2 Absorber Prototypes 0 0 0 0 0 0Absorber/RF Test Site 1089 601 0 0 0 1690Absorber Filling Capability 0 217 0 0 0 217805 MHz Testing Capability 0 186 0 0 0 186201 MHz Testing Capability 0 0 228 0 0 228Solenoid design 45 200 255 0 0 500Solenoid construction 0 0 500 1000 0 1500Beamline 0 0 446 554 0 1000Running 0 0 25 35 40 100Carryover -274 0 0 0 0 -274

TOTALS (K$) 1335 1629 1629 1589 40 6222


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 1 (“Sensible Plan”)Plan 1 (“Sensible Plan”)

MC Funding (K$)Institution FY02 FY03 FY04 FY05 FY06 TOTAL

FNAL 815 1054 749 589 40 3247LBNL 470 525 830 1000 0 2825U. Miss 50 50 50 0 0 150

TOTALS 1335 1629 1629 1589 40 6222

Plan 1 – Test Capability Milestones

Complete Test Area Construction DEC 02Complete LH2 Filling Systems JUN 03Complete 805 MHz Test Systems JUN 03Complete 201 MHz Test Systems SEP 04Complete Solenoid SEP 05Complete Beam Installation SEP 05Full Test Capability DEC 05


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 2 Plan 2 (“(“Stretch out 201/805 MHz Cavity & Test Bed”)”)



TOTALS (K$) 1335 1518 1518 1518 333 6222


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 2 Plan 2 (“(“Stretch out 201/805 MHz Cavity & Test Bed”)”)


FNAL 815 1018 563 518 333 3247LBNL 470 450 905 1000 0 2825U. Miss 50 50 50 0 0 150

TOTALS 1335 1518 1518 1518 333 6222


Complete Test Area Construction DEC 02Complete LH2 Filling Systems JUN 03Complete 805 MHz Test Systems JAN 04Complete 201 MHz Test Systems SEP 04Complete Solenoid SEP 05Complete Beam Installation APR 06Full Test Capability JUL 06


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 3Plan 3(“Delay Solenoid Design”)(“Delay Solenoid Design”)



TOTALS (K$) 1335 1429 1429 1429 600 6222


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 3 Plan 3 (“(“Delay Solenoid Design”)”)


FNAL 815 1054 849 479 50 3247LBNL 470 325 530 950 550 2825U. Miss 50 50 50 0 0 150

TOTALS 1335 1429 1429 1429 600 6222


Complete Test Area Construction DEC 02Complete LH2 Filling Systems JUN 03Complete 805 MHz Test Systems JUN 03Complete 201 MHz Test Systems SEP 04Complete Solenoid SEP 06Complete Beam Installation SEP 05Full Test Capability DEC 06

≠ BAD FOR MICE

≠ BAD FOR MICE


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 4Plan 4(“(“Stretch out 201 MHz Cavity Construction”)”)



TOTALS (K$) 1335 1404 1404 1404 675 6222


LongLong--Range MUCOOL Hardware Program Range MUCOOL Hardware Program –– Plan 4 Plan 4 (“(“Stretch out 201 MHz Cavity Construction”)”)


FNAL 815 1054 299 404 675 3247LBNL 470 300 1055 1000 0 2825U. Miss 50 50 50 0 0 150

TOTALS 1335 1404 1404 1404 675 6222


Complete Test Area Construction DEC 02Complete LH2 Filling Systems JUN 03Complete 805 MHz Test Systems JUN 03Complete 201 MHz Test Systems SEP 04Complete Solenoid SEP 05Complete Beam Installation OCT 06Full Test Capability JAN 07 ≠ BAD FOR MICE


Comparing LongComparing Long--Range MUCOOL Hardware PlansRange MUCOOL Hardware Plans

PLAN FULL TEST PEAK ANNUALCAPABILITY FUNDING (K$)

1 DEC 05 1629

2 JUL 06 1518

3 DEC 06 1429

4 JAN 07 1404

SCHEDULE RISK : The development of cooling channel components requiresan ambitious R&D program, entailing significant schedule risks that are not reflectedin the schedule above. To allow for the schedule risk a stretch factor of 1.5 does not seem unreasonable.


Instrumentation R&DInstrumentation R&DI recommend that the fast timing R&D, plus any other instrumentation R&Drelevant to MICE, be relabeled a MICE project (Dan co-ordinates). Hence,Dan will cover this R&D.

Developing beam diagnostics for a cooling channel is also part of the MUCOOL R&D program … but we don’t know enough to tackle this yet.I will assume that the time to focus on beam diagnostics will be in 3 or 4 years from now, after the MUCOOL systems test, and after we know moreabout the optimal cooling lattice (ring coolers , ….).


SUMMARYSUMMARY


Cost to Implement 201 MHz at Lab GCost to Implement 201 MHz at Lab GM&S Effort

Man Months Cost

Modulator Parts 460,000 14.0 Techs 65,000+ Re-Engineering 14.0 Eng 119,000





TOTALS 570,000 37.0 Techs 361,00021.0 Eng

Increase bare cost(931 k$) by contingency (20%) & overhead (25%)

TOTAL = 1397 K$

THIS PLAN IS NOLONGER VIABLESINCE WE CAN NO LONGER GETTHE MODULATORTUBES.

MUCOOL R&D Plan - Princeton University

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