Undulator Cost & Schedule Patric Den Hartog, ANL April 24, 2002

1. Undulator Cost & SchedulePatric Den Hartog, ANLApril 24, 2002 • Undulator WBS • Costing Methodology • Costing Highlights • Undulator Systems Schedule • Cost Rollup Patric Den Hartog, ANL

2. Undulator Systems WBS 1.2.3 Undulator Systems WBS 1.2.3 Patric Den Hartog, ANL

3. Undulator Systems Layout • Entrance transition • 11 cells • 3 3.4 m undulators • Magnetic structure and movers • Vacuum chamber • 2 short breaks • Electron beam diagnostics • Focusing and steering • 1 long break • X-ray diagnostics • Electron beam diagnostics • Focusing and steering • Exit transition Patric Den Hartog, ANL

4. 1.2.3 Undulator Systems • 1.2.3.1 Undulator systems PED • 1.2.3.2 Undulator mechanical • 1.2.3.3 Undulator vacuum • 1.2.3.4 Undulator diagnostics • 1.2.3.5 Undulator power supplies • 1.2.3.6 Undulator electromagnets • 1.2.3.7 Undulator controls • 1.2.3.8 Undulator PPS • 1.2.3.9 Undulator magnetic measurement facility Patric Den Hartog, ANL

5. Costing Methodology • Costs estimated by cognizant engineers/scientists • Ordinal List of components developed from CDR • Costs based on experience with similar systems • Undulator costs estimated two ways • Based on previous procurements of similar devices • Based on cost of LCLS prototype • Contingency • Assigned on the basis of the completeness of the design, comparison with recent comparable components, and knowledge of catalog prices where available • WBS 1.2.3. does not include installation Patric Den Hartog, ANL

6. 1.2.3.1 Undulator System PED • Design and prototype systems • Assembly and installation procedures • Prepare bid packages • In particular--- • 1.2.3.1.2 Undulator mechanical system PED • 2nd undulator prototype re-using permanent magnets • 1.2.3.1.3 • Undulator vacuum chamber prototyping including short and long breaks • 1.2.3.1.4 • Protoype short and long breaks with diagnostics • 1.2.3.1.7 • High speed CCD imaging software Patric Den Hartog, ANL

7. 1.2.3.2 Undulator Mechanical • 1.2.3.2.1 Undulator module • 33 undulators • Dominates cost of WBS 1.2.3 • High precision movers for alignment • 1.2.3.2.2 • 33 PM quads and positioners • 1.2.3.2.3 • Undulator supports Patric Den Hartog, ANL

8. Basis of undulator cost estimate • Two methods compared • Cost estimate based on cost of similar devices • Multiply by ratio for length • Accounts for additional poles and magnets • Adjust for elements that are clearly more expensive • Titanium strongback and machining • Estimate setup cost for vendor for magnetic measurements • 472 K$/3.4 meter segment • Cost estimate based on prototype cost • Add up cost of components • Estimate labor for assembly and magnetic measurements • Add in factor for profit and overhead (x2) • 474 K$/3.4 meter segment • Too close to be believed! Patric Den Hartog, ANL

9. 1.2.3.3 Undulator Vacuum • Vacuum chamber through undulator • Demanding tolerances on wall outgassing and smoothness • Prototyping required (in 1.2.3.1.3) • Difficult engineering to fit focusing, steering , and diagnostics into breaks and maintain smooth transitions • Many standard components are catalog items Patric Den Hartog, ANL

10. 1.2.3.4 Undulator Diagnostics • Wire scanner • Pulsed current monitor • RFBPM • Cerenkov detector • Alignment laser • OTR diagnostics • X-ray diagnostics Patric Den Hartog, ANL

11. 1.2.3.5 Undulator Power Supplies • Power supplies for the 35 vertical and 35 horizontal correctors • Standard tolerances Patric Den Hartog, ANL

12. 1.2.3.6 Undulator Electromagnets • 35 horizontal and 35 vertical correctors • Cost based on engineering estimates of similar magnets • Risk based on difficult space constraints Patric Den Hartog, ANL

13. 1.2.3.7 Undulator Controls • Controls based on familiar EPICS platform • Vacuum controls • Motor controls • Diagnostic controls • Power supply controls • EPICS hardware Patric Den Hartog, ANL

14. 1.2.3.9 Undulator Measurement System • Costs based on system in use at APS • 5.5 m granite bench with precision linear encoder • Motion system for Hall probes and coils • Instrumentation • Pulsed wire system • Assembly and shipment to SLAC • Computer system • Installation supervision Patric Den Hartog, ANL

15. Undulator System Schedule Patric Den Hartog, ANL

16. Undulator Procurement Plan • Undulator delivery is critical path for project completion • 3 yr construction schedule for 33 undulators is a challenge • Permanent magnets, poles, and Ti strongback are long-lead time delivery • If undulators are bid in year 2 so that award can be made as soon as construction funds are available, up to six months can be saved • The required delivery rate may also be reduced through the use of a “Multiple Procurement Option” Patric Den Hartog, ANL

17. Undulator Schedule - Single Procurement Option Patric Den Hartog, ANL

18. Undulator Schedule -Multiple Procurement Option Patric Den Hartog, ANL

19. 1.2.3 Undulator Cost Estimate (FY02 Dollars, Thousands) Patric Den Hartog, ANL

20. 1.2.3.2 Undulator Mechanical (FY02 Dollars, Thousands) Patric Den Hartog, ANL

21. 1.2.3.3 Undulator Vacuum (FY02 Dollars, Thousands) Patric Den Hartog, ANL