Risk Description: Bus Tapes WBS  6.2.1 Type Threat Risk ID  RD-06-02-01-001 Status  Active Expires  27-Apr-21 Title  Bus tapes do not meet specification Summary The mechanical specifications of the bus tapes are based upon the past observation that a) tapes stretch in co-cure and b) delivered tapes are very uniform mechanically. If this is not the case in production we will need to lower the yield factor. Owner Carl Haber  Probability Pre 20% Post 10% Cost Lo  $93K Hi $280K Schedule  2.0 mo.  6.0 mo. Tech Impact  1 (L) Post Mitg Prob  3 (L) Impact Score  2 (M) Sched Rank= 60 Mitigation We will be monitoring and screening all cables which arrive in batches of 25-50. So we are insured at the cost of one batch. The mechanical specs are part of the contract. Good resutls so far. Response We would need to re-run the offending batch of cables. Comments Exposed with only one vendor. Worst case cost impact is calculated as follows. Total cost of materials and inspection = 640K+460K=1.1M. Set the max cost to half of this. Phase Affected Pre-production, Production US ATLAS HL-LHC CD-3a Review, July 9-11, 2019

Risk Description: Foam WBS  6.2.1 Type Threat Risk ID  RD-06-02-01-002 Status  Active Expires  27-Sep-21 Title  Carbon foam is unavailable Summary Allcomp is only supplier of the very low density high TC foam. We would have to go to a somewhat higher mass material, with some performance implication, not a cost issue. Owner Carl Haber  Probability Pre 20% Post 10% Cost Lo  $186K Hi $560K Schedule  4.0 mo.  12 mo. Tech Impact  1 (L) Post Mitg Prob  3 (L) Impact Score  3 (H) Sched Rank= 140 Mitigation We will be monitoring the supplier Allcomp for continued availability of the low density foam throughout the project. Response We would move to a higher density carbon foam with expected decrease in overall performance. Comments Exposed with only one vendor. The total cost of the Allcomp foam material is 180K for all of ATLAS strips (half goes to the UK). We set the maximum cost impact to 200K as if we have to buy another entire set from someone else (unlikely) Phase Affected Pre-production, Production US ATLAS HL-LHC CD-3a Review, July 9-11, 2019

Risk Description: Insulators WBS  6.2.1 Type Threat Risk ID  RD-06-02-01-003 Status  Active Expires  25-Sep-20 Title  High volume, low cost electrical insulator breaks to be established Summary The cooling lines require an insulating break which must be very reliable. While these have been demonstrated in small quantities the production performance is still forthcoming. Owner  Carl Haber Probability Pre 20% Post 10% Cost Lo  $23K Hi $233K Schedule  0.5 mo.  5.0 mo. Tech Impact  3 (H) Post Mitg Prob  3 (L) Impact Score  2 (M) Sched Rank= 60 Mitigation We will continually monitor the production of larger quantities of insulators along with performance. We will also search for alternative suppliers or techniques. Response We would add personnel to make multiple batches of a small number of insulators to meet assembly demands. Comments Exposed with only one vendor. Worst case cost we have to re-engineer (70K) and delay stave lamination for 1 year (430K) =500K. Phase Affected Pre-production, Production US ATLAS HL-LHC CD-3a Review, July 9-11, 2019

Risk Description: Cooling Loops WBS  6.2.1 Type Threat Risk ID  RD-06-02-01-004 Status  Active Expires  1-Sep-23 Title  Cooling loops not available Summary The cooling loops are an external dependency from the UK. They could experience technical difficulties causing these to be delayed or not available at all. Owner Carl Haber  Probability Pre 20% Post Cost Lo  $47K Hi $420K Schedule  1.0 mo.  9.0 mo. Tech Impact  3 (H) Post Mitg Prob  5 (M) Impact Score  2 (M) Sched Rank= 90 Mitigation We will continually monitor the production of larger quantities of loops along with performance. We will also search for alternative suppliers or techniques. Response We would have to develop a US source for these loops. Comments UK Deliverable. Exposed with only one vendor. We set the worst case cost impact to develop a US source and delay in stave laminations of 9 months to $840K. Set the max cost to half of this. Phase Affected Pre-production, Production US ATLAS HL-LHC CD-3a Review, July 9-11, 2019

Risk Description: Personnel WBS  6.2.1 Type Threat Risk ID  RD-06-02-01-005 Status  Active Expires  1-Sep-23 Title  Loss of key personnel Summary Expert staff exist at Yale and LBNL. If we lost these we would have to hire and train replacements. All area long term already employed at their respective institutions. Owner Carl Haber  Probability Pre 10% Post Cost Lo  $47K Hi $280K Schedule  1.0 mo.  6.0 mo Tech Impact  2 (M) Post Mitg Prob  3 (L) Impact Score Sched Rank= 60 Mitigation Cross-training and dissemination of information. Developing backup strategies. Response A position would be posted and a new hire made. In the interim the existing staff would assume additional responsibility. Comments These are long term employess of the institutions with a strong commitment to the project. Worst case scenario is a delay in stave core laminations by 6 months = $560K. Set the max cost to half of this. Phase Affected Pre-production, Production US ATLAS HL-LHC CD-3a Review, July 9-11, 2019

Risk Description: Bus Tapes WBS  6.2.1 Type  Threat Risk ID  RD-06-02-01-006 Status  Active Expires  1-Jan-2023 Title  Exposure Due to Single Bus Tape Vendor Summary While we have worked with a single vendor on the bus tape for ~10 years, we remain exposed in case of changes in technical capabilities, business model, etc Owner Carl Haber  Probability Pre  25% Post  10% Cost Lo  $47K Hi  $687K Schedule  .1  4.0 Tech Impact  2(M) Post Mitg Prob  3(L) Impact Score  3(H) Sched Rank=140 Mitigation Search, find, and qualify a second vendor, well ahead of production. Be prepared to switch quickly if needed. An alternative would be to redesign the tape to be composed of two shorter sections. This would require that the EOS card be moved to mid-stave. This would affect the design of the assembly tooling for the cores and the EOS, which are non-US deliverables.  Response  If we have qualified a second vendor we will have them make a small number of parts to verify their capability, well ahead of production Comments  The overwhelming majority of vendors cannot manufacture the ATLAS bus tapes since they are longer than possible in these standard processes. Worst case scenario is a 4 month delay in stave core laminations = $373K. We set the max cost to half of this ($187K) plus an added procurement cost of $500K, for a max cost of $687K. Phase Effected Pre-production US ATLAS HL-LHC CD-3a Review, July 9-11, 2019

CD-3A Drill Down: Bus Tapes From BOE pg. 12, Table 11; Attachment 3 US provides bus tapes for 365 cores (US + UK) Each core needs 2 bus tapes Vendor cost is $598 / tape ($FY17) Each core cost is $1196 Total for 365 cores is $436,540 From Drill Down Report SC200474MM for $30,000 SC200475M for $407,000 Total $437,000 Jeff Ashenfelter BNL Director's Review, May 15-17, 2019

CD-3A Drill Down: Pre-preg From BOE pg. 12, Table 11; Attachment 4 US provides pre-preg for 138 cores (US + UK) Each core needs 1.836 m2 of pre-preg Vendor cost is $303 / m2 ($FY17) Each core cost is $556 Total for 138 cores is $76,728 From Drill Down Report SC200510M for $37,800 SC200720M for $39,000 Total $76,800 Jeff Ashenfelter BNL Director's Review, May 15-17, 2019

CD-3A Drill Down: Honeycomb From BOE pg. 12, Table 11, Attachment 6 US provides honeycomb for 151 cores (US + UK) Each core needs 0.139 m2 Vendor cost is $7091 / m2 ($1787 in $FY17 for 0.252 m2) Each core cost is $984 Total for 151 cores is $148,584 From Drill Down Report SC501204M for $149,000 Jeff Ashenfelter BNL Director's Review, May 15-17, 2019

BNL Director's Review, May 15-17, 2019 CD-3A Drill Down: Foam From BOE pg. 12, Table 11; Attachment 5 US provides foam for 147 cores (US + UK) Each core needs 339 cc Vendor cost is $0.997 / cc ($2352 in $FY17 for 2360 cc) Each core cost is $338 Total for 147 cores is $49,686 From Drill Down Report SC501210M for $49,816 Jeff Ashenfelter BNL Director's Review, May 15-17, 2019