1. nEDM Cost and Schedule Review, February 11, 2005 Upper Cryostat and Valves Cost and Schedule for WBS 3.2, 3.3, 3.4, and 8.2 L. M. Bartoszek D. H. Beck S. E. Williamson UIUC Overview of systems Cost and schedule drivers

2. nEDM Cost and Schedule Review, February 11, 2005 EDM Upper Cryostat Overview Services and preparation Main components –purification system – 3 He collection volume Ancillary functions –dilution refrigerator inserts –feedthroughs for detector lightguides, HV, instrumentation –magnetic shielding –thermal shielding –He II valves

3. nEDM Cost and Schedule Review, February 11, 2005 What is the Upper Cryostat? 3He Storage (Collection) Volume (WBS 3.4) Vacuum Vessel (WBS 3.2) DR LHe Volume (WBS 3.2) Dilution Refrigerator (WBS 3.9) 4He Purifier Assembly (WBS 3.3) Lower Cryostat Upper Cryostat 50 K Heat Shield (WBS 3.2) 4 K Heat Shield (WBS 3.2) Multi-layer μmetal Shield (WBS 5.1) 3 He Spin Holding Coil (WBS 6.7) Not Shown: Supports for components Feed-throughs Thermal links from DR Shields in “elbow” region

4. nEDM Cost and Schedule Review, February 11, 2005 C&S Methodology: Design Further subdivided into 3 activities –Engineering design: calculations, material and part selection performed by one engineer and one physicist tasks interleaved duration based on engineering experience –Solid modeling: create 3D model based on engineering design performed by one engineer duration is typically 2/3 of time for drawings –Shop drawings: create 2D drawings based on solid model number of drawings estimated duration = number of drawings × average 3 hours/drawing multiple draftsmen could reduce duration Cost directly related to schedule

5. nEDM Cost and Schedule Review, February 11, 2005 Design Upper Cryostat (3.2.1) TaskWho FTE Weeks Shielding designPhysicist1 Design for ASME B&PVCEngineer2 Design for assemblyEngineer2 Design of supports for componentsEngineer2 Design feed-throughs on all flangesEngineer12 Design interface to lower cryostat shieldingEngineer4 Design thermal links from DR to lower cryostatEngineer4 Thermal modeling of upper cryostatEngineer6 Solid modeling of upper cryostatEngineer8 Shop drawings - (150 drawings, ~3hrs/drawing)Draftsman12 Not a terribly exotic technology Complexity (interference, thermal constraints, number of parts) is main driving factor – the details ASME B&PVC Required for Lab safety Largest time spent on feed-through design scaled with number of feed-throughs might appear elsewhere in WBS? Lifting fixtures, pick points, steps for assembly

6. nEDM Cost and Schedule Review, February 11, 2005 C&S Methodology: Procurement Duration and cost based on engineering experience –10 years as staff engineer at FNAL –15 years as independent consultant –Recent projects: G 0 cryostat, MiniBooNE horn Include “procurement paperwork” time –vendor consultation and plant visits –bid spec writing Generous contingency is driven by cost risk (i.e. engineering judgment)

7. nEDM Cost and Schedule Review, February 11, 2005 Procure Upper Cryostat (3.2.2) Procurement paperwork, 2 FTE weeks$ 3,600.00 Upper vacuum shell set of halves $ 30,000.00 Bottom elbow vacuum shell set of halves $ 40,000.00 Top Flange $ 40,000.00 DS End flange $ 40,000.00 Misc ports, (pressure relief, assembly) $ 20,000.00 Non-valve Feed-throughs (PMT, bellows pump, HV actuator) $100,000.00 Instrumentation feed-throughs $ 10,000.00 Instrumentation $ 10,000.00 50 K shields (upper and lower halves) $ 30,000.00 4 K shields (upper and lower halves) $ 30,000.00 Supports for shields $ 10,000.00 Multi-layer insulation (rolls and cut shapes) $ 20,000.00 Some items not included (e.g. DR LHe reservoir) Compensated by duplication elsewhere in WBS Time required for procurement: 9 months (with 50% contingency) Simple flange/feed- through example (G 0 ) Estimate assumed “non- magnetic stainless steel” – now aluminum (~same cost)

8. nEDM Cost and Schedule Review, February 11, 2005 C&S Methodology: Installation Install: the effort to assemble the manufactured parts and merge the resulting component into the next larger item. –Minimal machining/fabrication –includes testing required before installation into larger item –shipping of subassemblies not included Most of the work performed by “high level” technicians, e.g. –Leak checking –Sensor wiring –Crane operation –Alteration/fitting/machining Physicist and Engineer “look over shoulders” of techs 1/3 of the time. –Engineer: $90/hr, 0% overhead –Physicist: $0/hr  Overhead on technician labor –Assume University rates ($54/hr, 50% overhead)

9. nEDM Cost and Schedule Review, February 11, 2005 Install Upper Cryostat (3.2.3) Purifier and 3 He storage subsystems assumed to be assembled at this stage Assemble and test in University environment to save on overhead Ship to SNS for final integration –Disassembly, fixtures and shipping of this large sub assembly may reduce the saving. Task FTE Weeks Supervision - Physicist4 Supervision - Engineer4 High Level Technician112 High Level Technician212 High Level Technician3 (welder)12 Total duration: 3 months – all working at the same time.

10. nEDM Cost and Schedule Review, February 11, 2005 The 4 He Purifier (3.3) Thermal Standoff: maintains height of purifier (and thus 3 He storage volume during cooldown Activated Charcoal Cryo Pump: Pumps 3 He released by purifier Superfluid He Film Burner: contains He II in purification volume. (not in quite the right spot) Purification Volume: Large surface to volume to enhance evaporation Superfluid-tight valve: He contained in purification volume until purification complete. Pure 4 He Staging Volume: meters volume of 4 He required by cells, provides reservoir during cycle (not in estimate – added after)

11. nEDM Cost and Schedule Review, February 11, 2005 The 4 He Purifier (3.3) Take advantage of D 3 ~T -7 at low T, low concentration – 3 ~ container size at lowest T –large free surface –relatively large diameter film burner avoid HeVaC 1 problems –expect trapping in surface states to be small effect v 3 ~ 50 m/s –diffusion + evaporation (R. Golub) Purifier schematic (M. Hayden) T (K) 0.300.450.600.750.90 t pump (s) 100 75 50 25 11 cm 20 cm 30 cm Depth d ~2 x V meas He II @ 0.3 – 0.5 K Charcoal sorption pump (4 K) Superfluid film Passive film burner + knife edge @ 1.8 – 2.0 K d 1 Helium Vapor Compression

12. nEDM Cost and Schedule Review, February 11, 2005 Design 4 He Purifier (3.3.1) TaskWho FTE Weeks Design regeneration “thermal switch”Physicist2 Design regeneration “thermal switch” and heaterEngineer3 Design charcoal trap vacuum system and vesselEngineer5 Design film burnerEngineer2 Design purifier vesselEngineer2 Design conduction linksEngineer2 Design supportsEngineer2 Design temp and pressure instrumentationEngineer1 3D modeling of purifier systemEngineer2 Shop Drawings (30 drawings, 3 hrs/drawing)Draftsman3 1 M. Hayden and R. Golub, “Mike Hayden’s Idea for Purging 3 He”, nEDM Internal Report 2 Salmelin et al., J. Low Temp. Phys., 76, 83 (1989) Geometry of purifier and film burner is critical to purifier operation. 1 Support must maintain 3 He storage volume at constant height (tube-within-tube design). Cryopump concept from existing design. 2

13. nEDM Cost and Schedule Review, February 11, 2005 Procure 4 He Purifier (3.3.2) Outside of upper cryostat holding field – some non-magnetic stainless steel (fittings, etc.) probably OK Temperature and pressure instrumentation duplicated in cryogenic support equipment (3.7.2) but….. “Pure 4 He Staging Volume” not included in estimate. Total Procurement time: 4 months (60% contingency) Procurement paperwork, 5 FTE weeks$10,800.00 Adsorption pump on charcoal trap $ 5,000.00 Charcoal trap vessel $10,000.00 Film burner $ 1,000.00 Purifier vessel $10,000.00 Vacuum system/plumbing for charcoal trap $10,000.00 Conduction link between trap and DR (4K) $ 1,000.00 Conduction link between purifier and DR (.3K) $ 1,000.00 Heater in trap for regeneration $ 2,000.00 Supports between Purifier and Trap $ 5,000.00 Supports between Trap and Top flange $ 5,000.00 Temp and pressure instrumentation $ 5,000.00

14. nEDM Cost and Schedule Review, February 11, 2005 Install 4 He Purifier (3.3.3) Total duration: 1 month Estimated for assembly university Task FTE Weeks Supervision - Physicist2 Supervision - Engineer2 High Level Technician14 High Level Technician24

15. nEDM Cost and Schedule Review, February 11, 2005 3 He Storage (injection) Volume (3.4) 1.Interface between 3 He source and preparation volume –reduce magnetic field to ~ B 0 100 mG –low pressure on source end ~ 10 -7 T –cooled to 4 K, then to operating temp (0.3 – 0.5 K) 2.Preparation volume –reduce film thickness with knife edge –negligible HeVaC effect: film burnoff has large conductance to free surface reduce burner power by multiple knife edges –mfp of 3 He ~ 10 cm in vapor 2 x V meas He II @ 0.3 – 0.5 K To 3 He source Film burner + knife edge @ 1.8 – 2.0 K Superfluid film B0B0 Preparation volume schematic (M. Hayden) 3 He

16. nEDM Cost and Schedule Review, February 11, 2005 Design Polarized 3 He Storage Volume (3.4.1) TaskWho FTE Weeks Material selectionPhysicist3 Design storage vesselEngineer2 Design ports on top and bottomEngineer1 Design NMR system to measure polarizationPhysicist2 Design NMR system to measure polarizationEngineer1 Design conduction link to DREngineer1 Design supports to purifier vesselEngineer2 Design temp sensorEngineer1 3D modeling of storage vesselEngineer2 Shop drawings - (20 drawings @ 3hr/drawing)Draftsman2 NMR to measure 3 He polarization – need to be sure that collection is working. Material must not depolarize 3 He (glass, glass coated non-magnet metal, acrylic)

17. nEDM Cost and Schedule Review, February 11, 2005 Procure Polarized 3 He Storage Volume (3.4.2) Total Procurement time: 4 months (60% contingency) Procurement paperwork 2 FTE weeks$ 3,600 Storage vessel $ 15,000 Ports on top and bottom $ 5,000 NMR system to measure polarization $ 8,000 Conduction link to DR $ 1,000 Supports to purifier vessel $ 5,000 Temperature sensor $ 5,000 Unusual material properties drives the cost of the vessel

18. nEDM Cost and Schedule Review, February 11, 2005 Install Polarized 3He Storage Volume (3.4.3) Total duration: 2 weeks Task FTE Weeks Supervision - Physicist1 Supervision - Engineer1 High Level Technician12 High Level Technician22

19. nEDM Cost and Schedule Review, February 11, 2005 Valves (8.2) Super-fluid tight cryogenic valves are required to control LHe in purification-injection- measurement cycle Low heat load to 0.3 K Special materials required in some cases –Low neutron activation –Must not depolarize 3 He or n Must be reliable: 100,000 cycles ●Superfluid tight ●Low n activation ●Must not depolarize 3 He ●Must not depolarize n

20. nEDM Cost and Schedule Review, February 11, 2005 4K Shield 300 K actuator First stage bellows at 4K 300K to 4K transition Second stage bellows at 4K sized to provide 100 lbs seating force (FNAL experience) LHe in LHe out Superfluid-tight valve seat 4K to 0.3K transition “Pneumatic” plumbing for gaseous He at 0.75 atm. Valve springs open when not actuated 0.3K Superfluid Valve Operation

21. nEDM Cost and Schedule Review, February 11, 2005 Design Valves (8.2.1) 7.5 months (40% contingency) to get manufacturing drawings. Biggest challenges: –Materials selection –Heat load budget –“Pneumatic” actuation (operation, placement) TaskWho FTE Weeks Material selection, apertures, leak rate Physicist5 Warm actuator designEngineer1 Feed-through from warm to 4K piston and cylinderEngineer2 4 K piston and cylinder in upper cryostatEngineer2 4 K piston and cylinder on 4K shield near cellEngineer2 Gaseous Hydraulic plumbing connecting cylindersEngineer1 0.3 K valve designEngineer4 Thermal FEAEngineer6 Specify large aperture vacuum valveEngineer1 3D modeling of all valvesEngineer4 Shop drawings (100 drawings, 3 hrs/drawing)Draftsman2 Commercial superfluid LHe valve (from EADS Space) and FNAL experience provide a starting point

22. nEDM Cost and Schedule Review, February 11, 2005 Procure Valves (8.2.2) Total Procurement time: 6 months (60% contingency) Cell valves are the most expensive: $55k each Valve for 4 He staging volume not costed – adds $40k Qty.Unit CostTotal Cost Procurement paperwork - Engineer 4 FTE Weeks$ 14,400 Warm actuators8 $ 2,500.00 $ 20,000 Feed-through from warm to 4 K piston and cylinder7 $ 5,000.00 $ 35,000 4 K piston and cylinder in upper cryostat7 $10,000.00 $ 70,000 4 K piston and cylinder on 4 K shield near cell or on purifier7 $ 10,000.00 $ 70,000 Gaseous He pneumatic plumbing connecting cylinders7 $ 2,500.00 $ 17,500 Large aperture vacuum valve, 4 K1 $ 10,000.00 $10,000 0.3 K superfluid tight valve, not friendly to UCN, 3 He1 $ 10,000.00 $ 10,000 0.3 K superfluid-tight, 3 He friendly valves2 $ 15,000.00 $ 30,000 0.3 K superfluid-tight, 3 He & UCN friendly valves4 $ 25,000.00 $100,000

23. nEDM Cost and Schedule Review, February 11, 2005 Install Valves (8.2.3) Includes: –Assembly individual valves and actuators –Testing (warm and cold) –Inclusion in larger sub-systems: Drain volumes and bellows pump Reservoirs within the upper cryostat Upper and lower cryostat Total duration: 7 weeks Task FTE Weeks Supervision - Physicist3 Supervision - Engineer3 High Level Technician17 High Level Technician27

24. nEDM Cost and Schedule Review, February 11, 2005 Upper Cryostat and Valves WBS and cost sheets –provide a reasonable estimate of the cost and schedule –large contingency at this stage of the project Further refinements as the R&D program proceeds