1. The Construction of the LHC Detector Gas Systems ? Ferdi Hahn PH-TA1-GS Detector Steering Meeting 4th of June 2004

2. Content Context and TA1-GS section Description of Gas Project Problem Areas Manpower Schedule and Milestones Conclusions as of Today

3. Context Part of Central support group, in charge to build the gas systems for the 4 LHC experiments. Size of the Project (baseline): Method: –Split up the systems in functional and scalable modules that can be standardized. – Be genuine partner for the experiments, helping them to solve their problems. 4 MSF Components + Materials 60 man-years Staff, fellows and PJAS 34 man-years External manpower Type B: Type A:

4. TA1-GS Section: 3 Physicists (2 Staff and 1 PJAS): –Work out the solutions with the experiments –Management of the project –Definition of gas system controls (Collaboration with IT/CO) 5-6 Technicians/Engineers –Planning + organization of the construction, ordering of material etc. –Handle Industrial contracts 5-10 persons FSU + institute manpower –They assemble and install the gas modules. Type A Type B

5. Gas Project Gas Systems TA1 Deliverables

6. Our Activities Baseline: All detector gas systems of the four LHC experiments. Extras: Auxiliary systems for the LHC detectors, e.g. Flushing systems, etc. Temporary Installations for the LHC detectors for commissioning of chambers, etc. Test systems: GIF,…. Support Work: Test beam support, MFC calibrartion, etc FT experiments Limited to 1 FTE/y Case by case …. Prime activity!

7. Baseline Systems (Detector Volumes [m 3 ]) ATLASCMSALICELHCb MDT (800m 3 ) DT (250 m 3 ) TPC (100 m 3 ) CPC (9 m 3 ) RPC (18 m 3 ) RPC (14 m 3 ) TRD (28 m 3 ) OT (4 m 3 ) CSC ( 2m 3 ) CSC (66 m 3 ) TOF (16 m 3 ) RICH 1 (4 m 3 ) TGC (16 m 3 ) HMPID CPV PMD CPC RPC ( all < 2 m 3 ) RICH 2 (100 m 3 ) TRT (3 m 3 ) 3485 => All together 20 systems In Black: Re-circulation systems In Blue: Single pass systems

8. Baseline Construction Program ModulesATLASCMSALICELHCb No. of Modules Mixer538218 Purifier434415 Circulation Rack333413 Pump533415 UX Distribution3524121081 Analysis42219 US Distribution580417 Membranes1 124 Control Racks538420 Total67494135192 35% 26%21%18% Number of Modules (~ Number of Racks)

9. System with Special Modules or Special Attention ATLAS –MDT (extra work partly covered by ATLAS) –TRT (extra work covered by ATLAS) –TGC n-pentane supply and recovery CMS: –Non ALICE: –TRD (some extra development) LHCb: –2 x RICH’s (will need extra development) –OT (??) Extra Physicist Needed These special units are included in the baseline, but they consume more manpower.

10. Today’s Status (on baseline production) ALICE TPC system is completed and currently under test in Bldg. 167. –First tests of PLC + PVSS software are done successfully CMS distribution modules are completed (22 racks). Mixer production is ongoing (40-50%)

11. Extra’s and Auxiliary Systems ATLAS –TRT cooling system –Inner Detector Purge Systems TOTEM –2 systems We have many requests for temporary installations or test systems: in particular from ATLAS and CMS, but we have no resources to satisfy this needs (since 2002). Work Package proposal from ATLAS No Work Package yet No Packages defined.

12. Problem Areas

13. Ageing risk: –Induces bottlenecks for the Component validation.. –Multiplies iterations for all decisions of the project. Schedules: 1.Delays bco holdups in components validation. 2.High overlap and early delivery dates. 3.Progress monitoring is not very transparent. 4.Work order: so far first come first served. Additional Work: –ATLAS inner Tracker –TOTEM – ….

14. Ageing Risk Three systems which are believed to be very sensitive. (ALTLAS TRT, MDT, and LHCb OT) We have set up a Quality plan that is agreed with the experiments, which should cover these risks. Nonetheless, numerous iterations for many decisions. (BTW: How long it takes depends very much on the people.) All resource evaluations underestimate this problem!

15. Schedule Current Bottlenecks: –Decision making –Component ordering is slow –Component dismantling and cleaning –Technical problems with some components after cleaning Delivery delays long due to special cleaning, overheads due to QC procedures, dismantling extra cleaning, etc. No or little stock in CERN store…. Large overlaps in schedules between experiments. –20 projects all priority “1”,… too many things worked on in parallel. –Delivery dates between 2005 and 2006. –So far: first come first served, this causes some frustration now. We need some priorities from the experiments. Bottlenecks have to be solved to increase construction capacity

16. New Work Packages ATLAS Tracker purge and cooling systems. Proposed by ATLAS approx. 1-2 m-y’s (of type B plus x type A) TOTEM ( no work package yet) Guesstimate:1 m-y of type “B” Temporary installations ( should be done by experiments)

17. Manpower

18. Manpower (2 types) Type A: Engineering and Management labor: These are project managers and engineers: Supervision, logistic and management of construction; conducting tests; problem solving etc. Scales with: complexity of project, novelty of the work, technical difficulties, etc. These are: Staff, fellows, PJAS, etc. Type B: Construction and installation labor: These are people that assemble the racks: Scales with: Number of racks to make. These are: FSU, Institute labor (ATLAS) (not available as staff) To be paid by Experiments

19. Manpower Type “A” Initial Estimate for construction Period (2003 to 2007): 60 FTE’s over 5 years Activities with general interest are covered by TA1: guess 75%, so 45 FTE’s Specialized work for individual sub-detectors: should be covered by experiments: guess 25%, so 15 FTE’s. For Baseline Systems Only.

20. Type “A” Manpower versus Time 200 3 2004200520062007Total Staff Physicists 2222210 Staff Technician s 6654425 Fellows Experimen ts 000000 PJAS’s Experimen ts 111104 Total: 9987639 33313 76631 12.5129.552 Current situation and updates TA1 and Experiments In Red: includes 1 extra physicists and 1 extra technician plus the current vacancy for TA1-GS (117) (as discussed with V.V.) 1.52.00.54

21. Type A Manpower versus Project ExperimentPercent FTE’s (TA 1) FTE’s (Experiments ) ATLAS35%164 CMS25%110 ALICE20%92 LHCb20%82 Total100%448 Guesstimate  52 +9 Extra

22. Type “B” Manpower versus Project Manpower Estimate [man-years] Work completed [man-years] Remaining Work [man-years] ATLAS 12.5 (Muon+TRT gas) 0.312.2 CMS83.54.5 ALICE7.52.15.4 LHCb7.30.17.2 Total35.36.029.3 We need ~3 years. For Baseline Systems Only.

23. Manpower Type “B” versus Time 20032004200520062007 Total (2003-2007) FSU35553.623 Industry (external) 00.30.60.301 ATLAS Protvino 0.42.5441.612.5 Total 3.48.89.69.36.635.5 Total of Remaining Total (remaining) 16.1 1 10.8 29.3 Due to delays, efficiency is dropping: Example ATLAS : Remaining work is 12.2 m-y’s, remaining manpower planned is 10.8 m-y’s. For Baseline Systems Only.

24. Schedule

25. Experiment’s Schedules (Milestones) Most items must be installed until early 2006 80 %100 %

26. Construction Schedule Installation not included (10.3 m-y’s)

27. Comments to Schedule The construction of all the baseline systems will go on until the end of 2006. Installation is likely to continue in 2007. It is absolutely important that similar modules are constructed in series. (The experiments have to adopt to our construction schedule.) Side activities have to be reduced. Focus efforts on essentials for 2007.

28. Conclusions

29. Conclusion as of Today Present Commitments: –Baseline –If Extra’s to be added WP’s need to be completed urgently Manpower Situation: –Type A: increase from 39 to 52 FTE’s (initial estimate was 60). Extra: PH +9 FTE’s; Experiments +4 FTE’s –Type B: 35 m-y’s efficiency must be monitored (1/6 months). Schedule: –Extends to 2007 (What could be delivered after 2006 ?) –Bottlenecks must be improved Work order: –list of critical deliverables for 2007