WBS DICTIONARY - indico.fnal.gov · 19-Apr-2017 302.2.11 WBS name and scope updated 01-May-2017 302.2.02 Updated per Ruben e-mail 07-May-2017 All General minor updates, clarified

Work Breakdown Structure

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This document is uncontrolled when printed. The current version is maintained on http://us-hilumi-docdb.fnal.gov

US HL-LHC Accelerator Upgrade Project

WBS DICTIONARY

Approved by:

Giorgio Apollinari, US HL-LHC AUP Project Manager, FNAL


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Revision History

Revision Date Section No. Revision Description

14-Mar-2016 All Initial Release

11-Apr-2017 302.2.02 Updated per revisions to BOE US-HiLumi-doc-118

19-Apr-2017 302.2.01 Updated 302.2.01 adding M&S for shipments monitoring

19-Apr-2017 302.2.11 WBS name and scope updated

01-May-2017 302.2.02 Updated per Ruben e-mail

07-May-2017 All General minor updates, clarified L3/L4 LOE is excluded from WBS scope and clarify deliverable is for WBS deliverable (not project)

09-May-2017 302.2.02 Correction of typographical errors (LDC)

10-May-2017 302.2.06 Added fab of shipping fixtures

25-May-2017 302.3.02.03

302.3.02.06

Adjusted RFD cavity testing and re-processing rates to match BOE files

24-Jul-2017 302.2.11 Fixed test requirements reference (US-HiLumi-doc-449)

4-Aug-2017 302.1 Renamed “Project Engineering” to “System Integration Engineering”

15-May-2018 Various Updated to match latest WBS structure

23-Jun-2018 Various Miscellaneous updates for CD-2/3b Directors review


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WBS Code WBS Name Control Account

302 High Luminosity LHC Accelerator Upgrade Project No

WBS Description

Scope of Work

Entire project 302 scope. For details, see US-HiLumi-doc-93 “Project Execution Plan”

Scope Assumptions/Exclusions

See Key Assumptions Document US-HiLumi-doc-78

Not in scope:

- Installation and commissioning of deliverables

WBS Deliverables

Inner Triplet Focusing Quadrupoles (Q1 and Q3):

Threshold: 5 Q1 cryo-assemblies and 4 Q3 cryo-assemblies for HL-LHC tunnel installation are accepted

by CERN after testing at HL-LHC nominal temperature and ultimate gradient for the magnets, and

functionality for the Cryoassembly. The Cryo-assemblies will be assembled from Cold Masses built by HL-

LHC AUP and Cryostat kits provided by CERN. Procurement of components for 1 additional Q1/Q3 cold

mases. Objective: assembly of 1 additional Q3 cryo-assembly, accepted by CERN after testing at HL-LHC

nominal temperature and ultimate current for the magnet, and functionality for the Cold Mass. The Cryo-

assembly will be assembled from Cold Masses built by HL-LHC AUP and Cryostat kits provided by

CERN

SRF Crab Cavities:

Threshold: 8 Radio Frequency Dipoles (RFDs) dressed cavities for HL-LHC Crab Cavity System tunnel

installation are accepted by CERN after being tested at HL-LHC nominal temperature, within the nominal

frequency range, and ultimate cavity voltage. The “dressed” cavity is comprised of the bare cavity, the

magnetic shields, the helium containment vessel with tuner interface, and RF ancillaries (H-HOM coupler,

V-HOM coupler, and RF pickup). Procurement of components for 2 additional RFD dressed cavities.

Objective: 2 additional dressed RFD dressed cavities for the HL-LHC Crab Cavity system accepted by

CERN after being tested at HL-LHC nominal temperature, within the nominal frequency range, and

ultimate cavity voltage.


302.1 Project Management Yes

WBS Description

Scope of Work

Provide labor resources for Project Management, Systems Integration Engineering, Project Controls,

Finance, ES&H, Quality, Risk, and Procurement. Most of the labor is in the form of Level-of-Effort and is

based on assigned personnel and estimated effort. It includes the following Level 3 scope:

302.1.01 Project Office Management

- Project Manager, Deputy Project Manager, Systems Integration Engineer, L2 Managers, Systems

Integration Engineer, Lead Project Control staff, Scheduler, and managers for Finance, ES&H, Quality,

Risk, and Procurement.

302.1.02 BNL Management

- BNL representative


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- BNL Project Controls

- Points of Contact for QA and ES&H

302.1.03 LBNL Management

- LBNL representative

- LBNL Project Controls

- Points of Contact for QA and ES&H


Each laboratory provides Project Control Support staff for their respective scope

WBS Deliverables

Documentation required for 413.3b DOE Order. Includes project Documentation required for DOE critical

decision reviews, resource loaded schedule, risk register, configuration control, internal review reports,

monthly performance reports, etc.


302.2 MQXFA Magnets Fabrication No

WBS Description

Scope of Work

Final design and fabrication of MQXF magnets for 1 Q1/Q3 cryo-assembly prototype, 5 production Q1

cryo-assemblies, and 5 production Q3 cryo-assemblies. Each production cryo-assembly contains two

MQXFA magnets.


Testing of MQXFA magnets is not part of the scope of this WBS, but test analysis is included in the scope.

One 4 m prototype magnet (MQXFAP1) and one 4.2 m prototype magnet (MQXFAP2) to be received from

LARP, and to be used for AUP cryo-assembly prototype. This WBS element includes re-work of these

prototype magnets to meet requirements for cryo-assembly prototype.

WBS Deliverables

20 accepted MQXFA magnets, one 4.2 m MQXFAP prototype magnet, and one 4 m MQXFAP prototype

magnet.


302.2.01 Magnet Design, Integration, and Coordination Yes

WBS Description

Scope of Work

Complete the magnet final design, and MQXFA Final Design Report. Integrate products from other WBS

elements into the complete magnet assembly. Coordinate WBS elements regarding MQXFA magnets, for

example: analysis of prototype and production magnet test results and feedback into design or fabrication

process, magnets assembly re-work, etc. Procure accelerometers and shock-sensors for monitoring and

recording shocks during shipments, and perform analysis.


WBS Deliverables

Conceptual Design Report, Final Design Report, and integration documentation.


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302.2.02 Strand Procurement Yes

WBS Description

Scope of Work

- Procure, or obtain from LARP inventory, sufficient Nb3Sn strand to manufacture 102 cables. The

Strand Unit Length (UL) is the length of each strand re-spooled onto the cabling machine. The strand

UL (500 m) is longer than the cable UL to accommodate the cable lay and twist.

- Perform Quality Control (QC) verification of supplier’s product. QC verification is manly based on

electromagnetic properties such as critical current (Ic), residual resistance ratio (RRR).

- Mount coil witness samples on reaction barrels and perform tests of electromagnetic properties (Ic and

RRR).


- Strand for 12 cable units is assumed to be available to the project from LARP inventory and is

excluded from the WBS. QC testing for strand in LARP inventory is also excluded from the WBS.

- Each cable has 40 strands.

- Lab performs QC on 50% of pieces.

- 6 witness sample tests are co-reacted with each coil, from which 3 successful sample tests must be

derived.

- A 90% testing yield is assumed for electromagnetic property measurements

WBS Deliverables

40 (strands) × 102 (cables) = 4,080 Accepted Unit Lengths (UL) of strand and related strand QC reports

and witness samples test reports.


302.2.03 Cable Fabrication Yes

WBS Description

Scope of Work

Fabricate 102 Unit Lengths (ULs) of insulated cable. The Cable Fabrication UL is 455m, which is the

length of cable required to fabricate a coil plus length for QC testing samples, braiding, coil winding leads,

and buffer lengths. Each cable uses 40 Nb3Sn strand elements of 500 m long each. The minimum UL of the

delivered cable for coil fabrication is 431 m.

Quality Control activities in this WBS include RRR testing of extracted strands and measurement of post-

braiding insulation thickness by the ten-stack method.


- Cable production yield is assumed to be 90% (i.e., 1 cable out of 10 will be rejected and scrapped)

- RRR testing samples assumes 5 extracted strand samples required per cable

- The LBNL cabling machine is available for this work

- 4 Unit Lenghts of insulated cable to be received by LARP.

WBS Deliverables

A minimum of 96 Unit Lengths (minimum UL continuous length for delivered cable is 431 m) of accepted

cable and related QC reports. This is the minimum number of cables required to support the fabrication of

96 coils.



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302.2.04 Coil Parts, Materials, and Tooling Yes

WBS Description

Scope of Work

1. Procure coil parts (excluding insulated cable) for the fabrication of 96 coils. Major parts include

poles, wedges, end parts, traces, and consumable materials.

2. A total number of 19 coil part sets are assumed to be available from LARP and the balance (77)

are procured with project funds.

3. Procure additional tooling required to increase coil production throughput at both FNAL and BNL

locations. Additional tooling includes 4 reaction fixtures, 2 impregnation fixtures, 10 storage

fixtures and a FNAL second winding mandrel.

4. Procure 3 CMM measurement systems

5. Ship corresponding parts and additional tooling to BNL for coils to be fabricated at the BNL

location as part of 302.2.06 “Coil Fabrication at BNL”.


• 19 coil part sets are available from LARP

• One set of coil production tooling is available from LARP at both FNAL and BNL location

• BNL also requires a second winding mandrel, but it will be procured at BNL as part of 302.2.06

“Coil Fabrication at BNL” because this mandrel is specific to the BNL winding machine.

WBS Deliverables

• Parts for the fabrication of 96 coils (49 sets for FNAL, 47 sets for BNL)

• 1 winding machine mandrel for FNAL

• 4 reaction fixtures (2 for FNAL, 2 for BNL)

• 2 impregnation fixtures (1 for FNAL, 1 for BNL)

• 10 storage fixtures (5 for FNAL, 5 for BNL)

• 3 CMM machines (1 for FNAL, 1 for BNL and 1 for LBNL)


302.2.05 Coil Fabrication at FNAL Yes

WBS Description

Scope of Work

Fabricate 6 pre-series QXFA coils and 43 production QXFA coils at Fermilab. Fabrication steps include

Winding and Curing, Reaction, and Impregnation. Includes shipping of accepted coil to LBNL for magnet

assembly. Detailed description of QXF coil fabrication process provided by US-HiLumi-doc-95.


- One set of coil fabrication tooling is available from LARP, installed and fully functional in Fermilab

Industrial Building 3 (IB3). This includes a winding machine with one mandrel, a curing press, a

reaction oven and an impregnation fixture, an impregnation station (in IB2) and an impregnation

fixture.

- Coil witness sample testing is covered under the scope of WBS 302.2.02 Stand Procurement

- Coil production yield is assumed to be 87.5% (i.e., 1 coil out of 8 will be rejected and scrapped)

WBS Deliverables

A minimum of 43 accepted QXFA coils with their corresponding QC reports.


302.2.06 Coil Fabrication at BNL Yes

WBS Description


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Scope of Work

Fabricate 3 pre-series QXFA coils and 44 production QXFA coils at BNL. Fabrication steps include

Winding and Curing, Reaction and Impregnation. Includes shipping of accepted coils to LBNL for magnet

assembly. Also includes winding and curing of one practice coil. Detailed description of QXF coil

fabrication process provided by US-HiLumi-doc-95.

In addition, it includes procurement of additional winding tooling for the BNL winding machine to increase

production throughput. Also included is the fabrication of 4 additional coil shipping fixtures and 3

additional magnet shipping fixtures.


- One set of coil fabrication tooling is available from LARP, installed and fully functional in BNL

Building 902 of the BNL Superconducting Magnet Division. This includes a winding machine with

one mandrel, a curing press, a reaction oven and a reaction fixture, an impregnation station and an

impregnation fixture.

- Coil witness sample testing is covered under the scope of WBS 302.2.02 Stand Procurement

- Coil production yield is assumed to be 87.5% (i.e., 1 coil out of 8 will be rejected and scrapped)

WBS Deliverables

A minimum of 41 accepted QXFA coils with their corresponding QC reports; 4 additional coil shipping

fixtures and 3 additional magnet shipping fixtures.


302.2.07 Structure Fabrication and Magnets Assembly Yes

WBS Description

Scope of Work

Re-assemble magnet prototype MQXFA-2b, fabricate pre-series magnets MQXFA-03 and MQXFA-04,

and fabricate 19 MQXFA series production magnets. Scope includes:

- Parts procurement for 21 magnet structures (shell, Yoke, masters, pads, collars, axial support

components, keys, strain gauges and wires)

- 25 magnet assemblies (1 prototype re-assembly, 1 pre-series, 20 series production, and 3 re-

assemblies). Assembly includes install strain gauges on shells, Fabricate Yoke/Shell subassemblies.

Receive, check and prepare coils. Assemble collar packs and coil packs. Insert coil packs, setup

bladders, and perform azimuthal and axial preload, and conduct electrical QC

- Prepare for shipment and ship to magnet assembly to BNL for vertical testing


- Fabrication of magnet prototype MQXFA-2 is off-project (by LARP), only MQXFA-2b re-work is on

project

- One set of magnet fabrication tooling is available from LARP, installed and fully functional in LBNL

Building B77a.

- 15% of the magnets (3 out of 20) are assumed to be re-worked before passing acceptance test. Parts are

assumed to be re-used for this re-work.

- 1 Magnet structure is assumed to be irreversibly damaged, due to shipping and handling, and therefore

assumed lost after vertical test.

WBS Deliverables

- Re-assembled prototype magnet MQXFA-2b, pre-series magnets MQXFA-03 and MQXFA-04, and a

minimum of 19 accepted production MQXFA magnets with their corresponding QC reports



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302.4. Q1/Q3 Cryo-assembly Fabrication No

WBS Description

Scope of Work

Final design and fabrication of 11 Q1/Q3 Cold Masses (1 prototype, 1 pre-series, 9 series production)

including final design and fabrication of the Q1/Q3 Cold Mass fabrication tooling. Installation of CERN-

provided Q1/Q3 Cryostat tooling and assembling of Q1/Q3 cryo-assemblies (1 prototype 1 pre-series, 9

series production Q1/Q3 cryo-assemblies) using CERN provided cryostat kits. Includes Vertical testing of

27 magnets: 3 prototypes, 2 pre-series, and 22 series production (19 plus 3 re-worked) and Horizontal

testing and shipping of the 11 Q1/Q3 cryo-assemblies to CERN.


CERN is the Design Authority for the Q1/Q3 Cryostat design. The Q1/Q3 Cryostat tooling procurement is

the responsibility of CERN. The cryostat kit, cryostat tooling, and some cold mass parts are provided by

CERN including initial inspection of these items at CERN and shipping to Fermilab. The complete list of

CERN provided components can be found in “Exchange of components between HL LHC AUP and CERN

for the triplet”, CERN EDMS 1825173.

Q1/Q3 Cryo-assembly installation and commissioning is not in the project scope

WBS Deliverables

1 Q1/Q3 cryo-assembly 1 prototype 1 pre-series, 9 series production Q1/Q3 cryo-assemblies fully tested

and documented.


302.4.01 Magnets Vertical Test Yes

WBS Description

Scope of Work

Test 27 magnets at the BNL vertical test facility: 3 prototypes, 2 pre-series, and 22 series production (19

plus 3 re-worked). Includes test preparation, magnet test, and magnet shipment to LNBL or FNAL.

Includes procurement and fabrication of a second top plate and minor infrastructure upgrades to meet test

production throughput.


- The BNL vertical test facility is assumed to be available from LARP, installed and fully functional in

BNL Building 902 of the BNL Superconducting Magnet Division.

- 15% of the magnets (3 out of 20) are assumed to not pass vertical testing and sent back to LBNL for re-

work and are re-tested before passing acceptance test.

WBS Deliverables

- A total of 27 magnet tests with their corresponding Test Reports


302.4.02 Cold Mass Assemblies Fabrication Yes

WBS Description

Scope of Work

Final design and fabrication of 11 Q1/Q3 Cold Masses (1 prototype, 1 pre-series, 9 series production, 1

re-work) including final design and fabrication of the Q1/Q3 Cold Mass fabrication tooling. Some cold

mass parts are provided by CERN and the scope includes design verification of these components.



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Fermilab is the Design Authority for the Cold Mass design. The complete list of CERN provided

components can be found in “Exchange of components between HL LHC AUP and CERN for the

triplet”, CERN EDMS 1825173.

WBS Deliverables

- 11 Q1/Q3 Cold Masses (1 prototype, 1 pre-series, 9 series production) with their corresponding QC

and safety reports


302.4.03 Cryo-assemblies fabrication and shipment Yes

WBS Description

Scope of Work

Assemble 12 Q1/Q3 cryo-assemblies (1 prototype, 1 pre-series, 9 series production, 1 re-work). Each cryo-

assembly has one cold mass assembly inside the CERN-supplied cryostat. Activities include receive a

complete kit of cryostat parts from CERN, assemble the CERN cryostat, insert the cold mass assembly into

the cryostat, and deliver to Horizontal Test Facility for testing. After a successful horizontal test, prepare

the cryo-assembly for shipment and ship to CERN.


- The following items are off project scope:

o Q1/Q3 Cryostats design (CERN is the design authority).

o CERN is responsible for the procurement of kits and tooling for the assembly of the

Q1/Q3 cryostats, including shipment to AUP at Fermilab.

o CERN is responsible for the development of assembly plans and QA/QC plans for the

Q1/Q3 cryostats assembly.

- CERN will provide guidance to support the tooling installation and onsite support to train AUP

personnel during the assembly of the prototype cryo-assembly.

- 10% of the cryo-assemblies (1 out of 10) are assumed to need to be re-worked before they can pass

horizontal acceptance test.

WBS Deliverables

- One Q1/Q3 cryo-assembly prototype and 5 Q1 and 5 Q3 accepted cryo-assemblies shipped to CERN


302.4.04 Cryo-assemblies Horizontal Test Yes

WBS Description

Scope of Work

- Test 12 Q1/Q3 cryo-assemblies at the Fermilab horizontal test stand 4 in Industrial Building 1 (IB1)

(1 prototype, 1 pre-series, 9 series production, 1 re-work). Activities include test preparation, test,

and test report documentation. The scope includes upgrading the test stand to meet the Q1/Q3 cryo-

assembly test requirements (see US-HiLumi-449), but it does not include refurbishment of the test

stand required for reliable cryogenic and electrical operation. The scope also includes development

of the magnetic measurement system to be used at the Fermilab horizontal test stand.


- The IB1 horizontal test stand is assumed to be brought back to reliable cryogenic and electrical

operation off-project.

- Adequate cryogenic services availability from IB1 is assumed to sustain the peak production test

throughput.

- 10% of the cryo-assemblies (1 out of 10) are assumed to not pass horizontal testing and sent back


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for re-work and are re-tested before passing acceptance test.

WBS Deliverables

- Test facility upgrades to meet Q1/Q3 cryo-assembly test requirements A total of 12 Q1/Q3 cryo-

assembly tests with their corresponding Test Reports.


302.4.04.01 Cryo-mechanical Horizontal Test Stand Upgrade No

WBS Description

Scope of Work

- Cryogenic and cryo-mechanical upgrades of the existing horizontal test stand in Industrial Building

1 (IB1) to meet the Q1/Q3 cryo-assembly test requirements (see US-HiLumi-449). The scope is

limited to test stand capability upgrades. Zero-magnet test for commissioning the cryo-mechanical

upgrades at the horizontal test stand.


- The IB1 horizontal test stand is assumed to be brought back to reliable cryogenic operation off-

project.

- All equipment required to upgrade and verify the test stand cryo-mechanical capabilities will be

developed at FNAL.

WBS Deliverables

- Test facility cryo-mechanical upgrades to meet Q1/Q3 cryo-assembly test requirements. Completion

of a Zero Magnet Test to verify as many as reasonably achievable cryo-mechanical capabilities in

this configuration.


302.4.04.02 Instrumentation and Mechanical Horizontal Test Stand

Upgrade

No

WBS Description

Scope of Work

- 25 T crane upgrade at test facility to allow lifting of Q1/Q3 cryostat assembly. Development of

magnetic measurement systems for testing cryostat assemblies at Horizontal test stand. Power bus

upgrade to accommodate the Q1/Q3 cryo-assembly test requirements (see US-HiLumi-449).

Miscellaneous instrumentation and mechanical tasks not included in the WBS 302.4.04.01 scope.


- The IB1 horizontal test stand is assumed to be brought back to reliable cryogenic operation off-

project.

- Refurbished Data Acquisition and Quench protection systems, as well as test facility specific

instrumentation will be provided off-project.

- Probe drive and position reading for the rotating coil measurement system will be provided off-

project

WBS Deliverables

- Test facility crane and power bus upgrades to meet the Q1/Q3 cryo-assembly test requirements.

Magnetic measurement systems for the prototype and series cryo-assemblies at room or operating

temperatures.


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302.4.04.03 Horizontal Test Stand Operations No

WBS Description

Scope of Work

- Test 12 Q1/Q3 cryo-assemblies (1 prototype, 1 pre-series, 9 series production, 1 re-work) at

horizontal test stand.


- Adequate cryogenic services availability from IB1 is assumed to sustain the peak production test

throughput.

- 10% of the cryo-assemblies (1 out of 10) are assumed to not pass horizontal testing and sent back

for re-work and are re-tested before passing acceptance test.

WBS Deliverables

- A total of 12 Q1/Q3 cryo-assembly tests with their corresponding Test Reports.


302.3 RFD Dressed Crab Cavities Fabrication No

WBS Description

Scope of Work

Design, fabricate, process, test and document Dressed Radio Frequency Dipole (RFD) cavities.

The number of cavities produced will be 2 Prototypes + 2 Pre-Series + 10 Series. Dressed cavities

include the bare cavity, magnetic shields, helium containment vessel, tuner interface components and RF

ancillaries (HOM couplers, RF pickup).


Hardware will be fabricated almost exclusively through procurements with industry. On the other hand,

inspections, chemical processing, heat treatments, cleanroom preparations and qualifications will be

managed at Fermilab and performed primarily at Fermilab and ANL.

Fundamental power couplers for RFD cavities are excluded from the scope and installed at CERN, by

CERN after acceptance and delivery.

String assembly and Cryomodule integration of RFD cavities are also excluded from the scope and

responsibility of CERN.

WBS Deliverables

10 Dressed and qualified RFD cavities fully documented and shipped to CERN.


302.3.01 RFD Cavities Design, Integration, and Coordination Yes

WBS Description


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Scope of Work

Develop and finalize the electro-magnetic design, the mechanical design, the interfaces, the fabrication and

qualification strategy of RFD cavities and ancillary components.

Includes L3 management level-of-effort and travel for 302.3.01 (Design, Integration and Coordination) and

302.3.02 (Fabrication and Testing).

Includes oversight and travel for all procurements in the RFD scope.

Includes oversight for all in-house processing and qualification activities in the RFD scope.

Includes control account management tasks, such as planning, meetings, project reviews and other

communications, coordination and oversight, documentation preparation and/or review,

Includes EVMS reporting for 302.3.01 (Design, Integration and Coordination) and 302.3.02 (Fabrication

and Testing).


EM design of cavity ant HOM dampers: AUP

Mechanical design of cavity: AUP-CERN joint effort

Specification Drawings of all prototype hardware: AUP (or CERN where possible)

Specification Drawings of all series hardware: CERN (external dependencies)

WBS Deliverables

Conceptual Design Report, Preliminary Design Report, Final Design Report. Functional Requirements,

Technical Specifications, Acceptance Criteria, Interface Control Documents and any documentation

necessary for each project stage.


302.3.02 RFD Cavities Fabrication and Testing Yes

WBS Description

Scope of Work

Includes in-house discrete work effort and procurements in industry and at other laboratories, to fabricate,

process, test and document Dressed Radio Frequency Dipole (RFD) cavities and ancillary devices.

The number of cavities produced will be 2 Prototypes + 2 Pre-Series + 10 Series. Dressed cavities include

the bare cavity, magnetic shields, helium containment vessel, tuner interface components and RF ancillaries

(HOM couplers, RF pickup).

Scope Assumptions

Hardware will be fabricated almost exclusively through procurements with industry (managed by

Fermilab).

Inspections, chemical processing, heat treatments, cleanroom preparations and qualifications will be

managed performed primarily at Fermilab and ANL, with other collaborating labs as back-up.

Exclusions

L3 management level-of effort and EVMS reporting effort for this Control Account are included in

302.3.01

WBS Deliverables

10 Dressed and qualified RFD cavities fully documented and shipped to CERN.

EVMS reporting for control account 302.3.02


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302.3.02.01 Procurement of Services No

WBS Description

Scope of Work

Procure services from other laboratories and institutions to carry out design, integration and coordination

activities in support of the RFD scope.

Services from SLAC, ODU and BNL are anticipated to continue throughout the life of the project.

Responsibilities of different teams are identified in a separate document.

Scope Assumptions

Resources at other laboratories and institutions will be made available on a yearly basis to achieve

deliverables as agreed on statement-of-work documents which are prepared each FY.

Exclusions

L4 Management LOE is excluded from the WBS scope and included in WBS 302.3.01

WBS Deliverables

Obtain support from other laboratories for the design, integration and coordination activities, throughout

the lifetime of the project as agreed in the SOW documents


302.3.02.02 Materials and Bare Cavity Procurement No

WBS Description

Scope of Work

Procurement of raw materials for 12 bare cavities (2 Pre-Series + 10 Series).

Procurement of 14 bare cavities (2 Prototypes + 2 Pre-Series + 10 Series)

Raw materials include:

- Bulk RRR Niobium sheets, tubes and rods

- Niobium-Titanium alloy plates

- 316LN Stainless Steel plates

- Nb-SST braze joints for cavity extremities

Perform incoming inspection of all material and provide to Cern samples and documentation as needed.

Serialize all material for traceability. Ship materials to bare cavity suppliers.

Procurement of Bare Cavities in industry includes:

- Development of fabrication drawings

- Fabrication of tooling for forming, machining and electron-beam welding

- Fabrication of all cavity components, final trim-tuning and electron-beam welding

- Fabrication documentation, final QC reports

- Packaging and shipping to Fermilab

Incoming Inspections for bare cavities include:

- Visual inspections

- Dimensional inspections

- RF survey

- Leak check

Scope Assumptions


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Incoming inspection (visual & dimensional) performed by Fermilab TD Quality Control. Staff to be

available as necessary to perform all inspections in a timely manner.

Ultrasonic inspections requested by CERN for raw materials will be performed in industry.

Additional qualification of raw materials if requested by Cern will be carried out at Cern with shipping

responsibility of AUP.

Exclusions

Raw materials for 2 Prototypes is already available from LARP and excluded from the scope.


WBS Deliverables

14 inspected and documented bare cavities (2 Prototypes + 2 Pre-Series + 10 Series). Manufacturing

reports, certifications, final inspection reports in form of electronic travelers.


302.3.02.03 Bare Cavity Qualification No

WBS Description

Scope of Work

Define preparation recipe for RFD cavities (details of chemical processing, heat treatments, high pressure

rinsing, clean room assembly).

Develop all facility and infrastructure modifications to accommodate bare RFD cavities processing and

testing.

Process, prepare and test at cryogenic temperature 14 bare cavities (2 Prototypes + 2 Pre-Series + 10

Series).


- L4 Management LOE is excluded from the WBS scope and included in WBS 302.3.01

- 50% of cavities is assumed to re-process and re-test once (e.g. 10 cavities = 15 cycles)

- Buffered chemical polishing, high pressure rinsing, and cleanroom assembly for testing are performed

at the SCPF at Argonne National Lab.

- Hydrogen degasification and low temperature baking is performed in MP9 at Fermilab.

- Cavity SRF performance is measured in the IB1 Vertical Test Area.

- ANL SCPF facility and staff as well as at FNAL MP9 are available as necessary to process and re-

process the bare cavities.

- Cryogenics at the VTA are available as necessary to test the bare cavities.

WBS Deliverables

14 bare cavities, processed and tested and delivered to WBS 302.3.02.04.

Processing and testing traveler documentation.


302.3.02.04 Dressed Cavity Procurement No

WBS Description


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Scope of Work

Procurement of magnetic shields in industry, procurement of helium tanks in industry (including raw

materials, machining, assembly, and welding around bare cavities).

Procurement of RF ancillaries at JLab (including raw materials, fabrication drawings, manufacturing,

chemical processing, documentation, shipment)

Final inspections of dressed cavities performed at Fermilab (visual, dimensional, frequency, vacuum).


Fabrication of dressed cavities will be carried out as a series of procurements. Inspection, measurements,

cleaning and preparations will be performed at Fermilab.


Work carried out in industry. Magnetic shields and bare cavities are shipped to supplier of helium vessels

for integration and welding.

Tuner interface components procured and installed as part of helium vessel procurement.

Pressure testing of helium vessels performed at supplier per CERN requirement.

WBS Deliverables

14 dressed RFD Cavities (2 Prototypes + 2 Pre-Series + 10 Series) delivered to WBS 302.3.02.05.

Manufacturing records and final inspection documentation in the form of electronic travelers.

14 RF Ancillaries sets, ready for installation on dressed cavities.

Each set is comprised of:

- 1 vertical HOM

- 1 horizontal HOM

- 1 RF pick-up


302.3.02.05 Dressed Cavity Qualification No

WBS Description

Scope of Work

Develop all facility and infrastructure modifications to accommodate dressed RFD cavities processing and

testing.

Process, prepare and test at cryogenic temperature a maximum of 14 bare cavities (2 Prototypes + 2 Pre-

Series + 10 Series).

Deliver to Cern 10 cavities that meet acceptance criteria (8 for tunnel installation + 2 spares).


- L4 Management LOE is excluded from the WBS scope and included in WBS 302.3.01

- Buffered chemical polishing, high pressure rinsing, and cleanroom assembly for testing are performed

at the SCPF at Argonne National Lab.

- 50% of cavities is assumed to re-process and re-test once (e.g. 10 cavities = 15 cycles)

- Low temperature baking is performed in MP9 at Fermilab.

- Cavity SRF performance is measured in the IB1 Vertical Test Area.

- ANL SCPF facility and staff as well as at FNAL MP9 are available as necessary to process and re-

process the bare cavities.

- Cryogenics at the VTA are available as necessary to test the bare cavities.

WBS Deliverables

- Delivery of 10 fully qualified RFD cavities to CERN (8 for tunnel installation + 2 spares).


Dictionary

US-HiLumi-doc-39

Date: 23-Jun-2018

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