1008 Infrastructure & Facility Upgrade Review October 16 ......at RHIC. 6 years as Project Engineer...

1008 Infrastructure & Facility Upgrade Review

October 16-17, 2019

Brookhaven National Laboratory

October 16-17, 2019 1008 I&F Upgrade Review 1

sPHENIX Overview


sPHENIX is a major upgrade to the PHENIX detector. It is a large-acceptance, high-rate detector for Heavy Ion physics that repurposes >$20M in existing PHENIX equipment, infrastructure and support facilities.

The detector is optimized to measure jet and heavy quark physics by incorporating a Time Projection Chamber, Electromagnetic and Hadronic Calorimeter with a high rate DAQ/Trigger and a 1.4 T solenoidal magnetic field.

1008 I&F Review Agenda


Review Charge1. Project scope: Is the project’s scope likely to meet the required performance? E O’B, G Young, L2 Managers

2. 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

3. 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

4. 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

5. Prerequisites: Is the required documentation in place from previous Director Review? See posted documents

6. Recommendations: Have the recommendations for the Infrastructure and Facility Upgrade Project from past reviews been appropriately addressed? GY or EO’B

7. Has the project made sufficient progress to date against the proposed baseline plan? All talks

8. Is the environment, safety and health (ES&H) and quality being properly addressed given the current state of the project? C. Gortakowski


The presentations and documentation associated with this review will show that we have met all of the requirements of the review charge

Documentation Requirements• Development of a Project Management Plan (PMP) to include descriptions of the Project scope, how the project will

be managed including funding, project assumptions, project organization, project management tailoring, staff roles and responsibilities, risk management process, procurement process, baseline change control process, earned value performance measurement and analysis, monthly progress reporting and thresholds, ES&H, Quality Management, transition to operations and project close out.

– Described and detailed in the I&F PMP and Assumptions document posted on the review site

• Development of Project Risk Register with cost schedule impact and Risk Mitigation strategies

– Described in the I&F Risk Register and Risk Management Plan posted on the review site

• Project Cost Estimate and Basis of Estimate documents

– Detailed in Basis of Estimate documents and Cost Book posted on the review site

• Project Detailed Schedule and Critical Path

– Both the Detailed Schedule and Critical Path are posted on the review site

• Examples of monthly reports

– Once we establish the Cost and Schedule baseline we will produce monthly I&F reports similar to the example reports posted for the sPHENIX MIE

• Documentation indicating resolution of Director’s Review action items

– All Director’s Review recommendations are addressed. See talk by Glenn Young.


I&F Baseline ScopeInfrastructure 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.


WBS MIE1.1 Project Management1.2 Time Projection Chamber1.3 EM Calorimeter1.4 Hadronic Calorimeter1.5 Calorimeter Electronics1.6 DAQ/Trigger1.7 Minimum Bias Detector

sPHENIX MIE (WBS 1.X)

October 16-17, 2019 71008 I&F Upgrade Review

To counting house

The final design of sPHENIX is driven by 3 principles:• Design a detector to meet the Science Mission of

measurements of Jets and Upsilons in RHIC environment• Maximize cost effectiveness and utilize modern

technologies where appropriate (SiPM, fast TPC readout)• Build on existing $20M+ PHENIX infrastructure

1008 Infrastructure & Facility Upgrade(WBS 2.X)

WBS I&F Upgrade

2.1 I&F Management

2.2 SC Magnet

2.3 Carriage & Structural Components

2.4 Infrastructure

2.5 Installation & Integration


Three large M&S items:• Barrel Magnet steel• Carriage/Cradle/Poletips/Platform• Cryogenics for 1008

Three main labor items:• SC-Magnet• Carriage/Cradle/Poletips/Platform(engineering design)• Installation/Integration

1008 Infrastructure & Facility Management Organization

1008 I&F Upgrade Review 9October 16-17, 2019

The same management team that oversees the sPHENIX MIE also manages 1008 Infrastructure and Facility Upgrade.

2.01I&F Management I.

Sourikova

2.02SC-Magnet

K. Yip

2.02.01Reviews & Tests

K. Yip

2.02.02Transport & Assembly

M. Anerella

2.02.03Cryogenics

R. Than

2.02.04PS, Controls, Quench

ProtectionC. Shultheiss

2.02.05Magnet Mapping

J. Haggerty

2.03Carriage & Structural

ComponentsC. Pontieri

2.03.01

Carriage/CradleJ. Mills

2.03.02Inner RingsC. Pontieri

2.03.03Magnet Barrel Steel

C. Pontieri

2.03.04End Caps/Pole tips

J. Mills

2.03.05 Bridge, Platforms &

Access J. Mills

2.04Infrastructure

R. Pisani

2.04.01Detector Support

ServicesJ. Vasquez

2.04.02Facility Support Services

B. Streckenbach

2.05Installation Integration

R. Feder

All Control Account

Managers are at L2

10October 16-17, 2019

I&F Management Structure to Level-3

1008 I&F Upgrade Review

Project Team ExperienceJohn Haggerty

Project Scientist Senior Scientist, Physics Department, BNL

Relevant ExperienceBNL AGS/E-787 1986-1996, DAQ and 500 MHz waveform digitizers; PHENIX Deputy Project Manager, 1997-2001; PHENIX Data Acquisition Coordinator, 2001-2007; PHENIX Deputy Operations Director, 2008-2016; PHENIX Run Coordinator 2009-2010; sPHENIX management 2012-present. Design, construction, implementation, and software support for PHENIX timing system, slow controls of front end electronics, high speed PCI interface to DAQ. Managed BaBar solenoid move to BNL. Lead Scientist for Fermilab T1044, the prototype sPHENIX Calorimeter test, 2014-2018.

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Edward O’BrienProject DirectorSenior Scientist, Physics Department, BNL

Relevant ExperienceFive years as sPHENIX Project Director. Thirteen years as PHENIX Operations Director during which time he coordinated the addition of $25M in upgrade detectors to PHENIX and managed a staff of 25-30 FTEs. Four years as project manager of the $10M PHENIX Central Tracking system. Eight years as head of the PHENIX Central Tracking group and Project Manager of the $4M Time Expansion Chamber. Designed and built major components of the E814/E877 Tracking System, a BNL AGS fixed-target HI experiment.

Glenn YoungProject ManagerSenior Scientist, Physics Department, BNL

Relevant ExperienceGlenn Young was at Oak Ridge National Laboratory from 1978 until 2009, serving in many capacities, including Physics Division Director. He led ORNL’s work on a series of heavy ion experiments at CERN (WA80, WA93, WA98). He was one of the founders of the PHENIX experiment in 1991 and led contributions by the Oak Ridge group to many PHENIX systems, and served as the experiment’s Deputy Spokesperson. He went to Thomas Jefferson National Accelerator Facility in 2009, and led the experimental program for the 12 GeV upgrade. He joined sPHENIX as Project Manager in 2017.

Cathy Lavelle, PMPResource CoordinatorHead of the BNL Project Management Center

Relevant ExperienceShe obtained BNL Earned Value Management Systems (EVMS) Certification in 2008 and maintained certification to present day through DOE and Internal Surveillance Reviews and Implementation. She worked as NSLS-II Project Controls Manager from Project Inception February 2006 through completion March 2015, CFN, BGRR, HFBR and INSP Project Controls Specialist from 1994 through 2006. She worked for EG&G on the Superconducting Super Collider Project from 1990 through 1994 as the Cost Performance Manager and has worked for DOD contractors (Lockheed Sanders/GE Joint Venture, Honeywell, and Northrop Corporation) from 1980 through 1990 as a Project Scheduler and Project Controls Supervisor.


Project Team ExperienceIrina Sourikova, PMP Project Controls Physics Department, BNLAdvanced Applications Engineer

Relevant ExperienceSixteen years as PHENIX software Engineer, database developer and database administrator. Designed, implemented and supported PHENIX calibrations and collaboration databases providing legacy data migration, data archival and replication. Two years as sPHENIX Project Controls. Certified Project Management Professional.

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James Mills, P.E. Project Engineer Senior Project Engineer, Collider-Accelerator Department, BNL

Relevant ExperienceOver 37 years of Engineering and Project Management experience at Brookhaven National Laboratory. 8 years as Manager of the Modernization Project Office Engineering and Design Group (2006-2014) with overall responsibility for the successful completion of a portfolio of projects in excess of $15 million annually; 6 years as Project Engineer for conventional construction in support of facility operations at Brookhaven (2000-2006); managing projects up to $6 million in total scope. 4 years of experience as Head of the Facility and Experimental Support Group, RHIC Project (1996-2000). Responsible for approximately $13 million dollars of conventional construction in support of experiments at RHIC. 6 years as Project Engineer for the STAR Magnet (1990-1996), providing engineering analysis and design of the 0.5 Tesla solenoidal magnet.

Russ Feder, PE, PMPChief Mechanical Engineer Mechanical Engineer, Physics Department, BNL

Relevant Experience Twenty Five years as a Mechanical Engineer including nineteen years at Princeton Plasma Physics Lab (PPPL). Most recently served as Project Manager for the NSTX-U Recovery Project and before that spent seven years as Chief Mechanical Engineer and WBS Manager for US ITER diagnostic systems contributions to ITER. M.S. in Nuclear and Mechanical Engineering and has experience in structural analysis, nuclear shielding, optical design and various aspects of engineering management.

The Project team has decades of experience managing DOE (NP, BES, HEP and FES) projects, including sPHENIX, PHENIX, NSLS-II, JLab 12 GeV, STAR, NSLS, BNL F&O, ITER, NSTX-U…


I&F Technical Accomplishments • 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. Checking and sign-off of final drawings complete.

• Design work progressing on most sPHENIX I&F components.


sPHENIX SC-Magnet


All 32 Barrel Magnet Steel Sectors at BNL as of Aug 2019


Barrel Flux Return Instrumented Sectors


Collaborators fromBaruch, ISU, Lehigh, Ohio U, Rutgers & Wayne State working on instrumenting the first 6 sectors of the flux return.

All electronics for 6 sectors at BNL. Will light tight and test OHCal sectors w/ cosmics

• Final Design Review held 8/7/2019

– Received memo 9/10 (being reviewed)

– Cradle Carriage drawings are in checking stage (2-3 weeks)

– Prepared weldment cradle package -ready for checking

– Starting work on the SOW

• Base Platform drawings are 100% complete and checked

• Upper Platform drawings are 80% complete

• End Caps drawings are 35% complete


Carriage/Cradle for Detector


Bldg 1008 Track Modification

• IR tracks will be cast in concrete.• Piping/cable tray/track will need to be removed • Removing these items will open up access to

underneath the carriage base

Tracks were designed to handle 450 tons, not the 900 tons we require for sPHENIX• Continued detailed analysis of track modifications

• Timeline• Fall 2019- Design track system, Begin to remove items in IR

after North magnet job is complete (2 weeks per C. Biggs)• Spring 2020- bidding process• Summer 2020- Construction begins

1008 I&F Cost Estimate process • Developed by the L2 and L3 Managers by WBS

• WBS is product oriented and is comprehensive by identifying all work scope for MIE, Infrastructure/Facility Upgrade and the associated contributed labor.

• Activity based resource loaded schedule, logically linked.

• The estimate includes:– All resource hours and material and travel direct dollars required to execute

the work scope.

– The cost element data (labor and non-labor) needed to complete the product/deliverables with estimate uncertainty.

– Documented assumptions, risk, contingency analysis and basis of estimate.

1008 I&F Upgrade ReviewOctober 16-17, 2019 19

I&F Cost/Schedule Assumptions

Cost/Schedule Assumptions document describes the assumptions for how the cost estimate, and schedule were developed. Cost Estimate:• BNL Labor Bands were used to estimate project labor

requirements.• Contributed labor is included in the estimate.• FY19 Labor, Burdened Rates are provided by Budget Office as a

composite rate in P6.• Extraordinary Project Rate was approved for the MIE project.• Escalation 3.0% labor, 2% Material

Schedule:• Schedule resource loaded and planned within funding

constraints and critical decision milestones.• Activities developed based on WBS Dictionary, • Durations estimated and resources assigned by L2/L3 Managers.


Details can be found in the I&F Assumptions document posted on the review site

Proposed Cost Baseline


~ $1M increase from April 2019 Director’s Review due to:- Addition of PM labor $500K

- Scope addition tracks $250K- Omission in SC-Magnet. $150K

Proposed BAC - $28,554KWork Accomplished $ 8,775KRemaining Work $19,779KContingency $ 4,846% of Work Rem’g 24.5%

I&F Cost, Obligation and Funding Profile


I&F Cost Profile by Level-2


I&F FTE Profile by Labor Category


I&F Estimate Uncertainty: Labor and M&S


Bottom –Up Contingency

Total Risk in Risk Registry $110k

Bottom-up Estimate Uncertainty $4718k

Total available contingency is 24.5% on the ETC as of Aug 2019


I&F Critical Path


Director's Baseline Magnet Early Complete

Review Review Operational

Design

Magnet SC Magnet Design

Carriage/Cradle Carriage and Structural Components Design

Infrastructure Magnet Infrastructure

Integration & Installation Integration & Installation Design

Procurement

Magnet Magnet Procurement

Carriage/Cradle Carriage/Cradle Procurement

Infrastructure Infrastructure Procurement

Integration & Installation

Fabrication & Assembly

Magnet Magnet Fabrication & Assembly

Carriage/Cradle Carriage/Cradle Fab & Assem.

Infrastructure Infrastructure Fab & Assembly

Integration & Installation

Firmware Development

Magnet Magnet Programming

System Testing

Magnet Magnet Sys. Test

Carriage/Cradle

Infrastructure Infrastructure System Testing

Installation

Magnet Magnet Installation

Carriage/Cradle Carriage/Cradle Install

Integration & Installation Integration and Installation

Commissioning

Magnet

Carriage/Cradle

Infrastructure

Integration & Installation Integ. & Inst Comm

Legend Completed Planned Today

Key Milestone Schedule Contingency

FY21 FY22 FY23FY20

sPHENIX Infrastructure and

Facility Upgrade Project

Schedule

FY17 FY18 FY19

The I&F Critical path goes through the Carriage/Cradle design, fab and installation followed by SC-Magnet/Detector subsystem integration and subsystem commissioning.

ES&H and QAThe sPHENIX MIE has ES&H and QA experts embedded by BNL in the project.

• The ES&H and QA reps have led the effort to develop sPHENIX specific Safety and quality documents: Hazard Analysis Report, Quality Assurance Plan.

• The QA rep developed QA procedures and criteria for work on preproduction prototypes and production, at collaborating universities, and R&D contracts with vendors .

• ES&H experts are being used to develop plans for sPHENIX detector component fabrication areas at BNL.

See talks by Chuck Gortakowski

ES&H: https://indico.bnl.gov/event/6950/attachments/25024/37255/sPHENIX_Hazard_Analysis_Report_final.pdf

QA: https://indico.bnl.gov/event/6950/attachments/25058/37318/QA_Plan_sPHENIX_IF_Project.pdf


Oversight of the 1008 I&F Upgrade Project• Biweekly reporting to the Project Management Group

– NPP ALD committee run by Co-Director of Office of Project Planning and Oversight

• Monthly reporting to BNL Project Oversight Board

– Deputy BNL Director’s committee that reviews all significant BNL Projects including 1008 I&F

• Monthly reporting to DOE-ONP

– Report to DOE Nuclear Physics Facilities Manager overseeing the 1008 I&F Upgrade

• Annual BNL (Associate Lab) Director’s Review (held since 2017)

• Meetings with BNL Safety committees at appropriate stages of the project: Factory set-up or work start, major procurements w/ ES&H impacts, FDRs and ORRs.

• In addition sPHENIX Management holds numerous internal reviews of I&F L2 and L3 components covering design, performance, safety, procurement, C&S, risk.


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. Our detailed Cost estimate is available in the Basis of Estimate documents.

• Designs are advanced for many I&F deliverables.

• In some cases, e.g. Barrel Magnet steel, the I&F deliverable is complete.

• 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 are ready to set the I&F Cost and Schedule baseline


Back Up


I&F Cost Profile Sorted by Labor and Non-Labor


Cost Performance Report


Practice BaselineBCWP – cum work performed

sPHENIX MIE OverviewTPC Project Director Last CD Achieved % Complete CPI SPI

$27.0M AY Edward O’Brien PD-2/3 26.6% BCWP/BAC @ 8/31/2019 1.0 0.95

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Scope• Detector systems produced, tested and ready for installation: Time Projection Chamber w/

electronics, Electromagnetic Calorimeter w/ electronics, Hadronic Calorimeter w/ electronics, DAQ/Trigger, Minimum Bias Detector, Project Management

Not in scope• SC-Magnet, Bldg/Det Infrastructure, Installation and System Commissioning

Schedule• CD-0 received Sept 2016• CD-1/3A received Aug 2018• PD-2/3 received Sept 2019 • Early completion Oct 2021• PD-4 Dec 2022

Cost• $27.0M AY Total Project Cost including 29.7% contingency on ETC


1008 Infrastructure & Facility Upgrade

Scope• SC-Magnet support including the Flux Return, Cryogenics into Bldg 1008, Detector Carriage/Cradle,

other Bldg 1008 Infrastructure improvements

• sPHENIX Installation, Integration and System Commissioning is part of the scope

Updated RLS for 1008 Infrastructure and Facility.

Schedule• sPHENIX Upgrade Completion date December 2022

• First RHIC run of sPHENIX Feb 1, 2023

Cost• $33.4 M AY Total Project Cost (Proposed baseline) with 24.5% contingency on Work to go

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TPC Project Director Last CD Achieved

% Complete CPI SPI

$33.4 M AY Edward O’Brien N/A 30.7% BCWP/BAC @ 8/31/2019 I&F: Pre-baseline I&F: Pre-baseline


sPHENIX MIE + Infrastructure & Facility + Silicon Detectors


The same management team with an expanded organizational structure manages the sPHENIX MIE, the 1008 Infrastructure and Facility Upgrade and the Silicon Detector Upgrades

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1008 Infrastructure & Facility Upgrade Review October 16 ......at RHIC. 6 years as Project Engineer...

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