Costing Methodology for Injector and Linac Components

1. Methodology, 1.2.1+1.2.2 Costs/ScheduleVinod Bharadwaj, SLACApril 24, 2002 • Costing Methodology • Injector Costs (WBS 1.2.1) • Linac Costs (WBS 1.2.2) • Schedule Vinod Bharadwaj, SLAC

2. COSTING METHODOLOGY – Overview • Define Work Breakdown Structure (WBS) • Generate Parts Lists, Parts Counts • Generate Cost Collection Input Forms for Parts • Collect costs, input into database • Generate project and major sub-system costs • Generate resource requirements • Generate and refine time phasing, milestones and schedule Vinod Bharadwaj, SLAC

3. Work Breakdown Structure (WBS) • The WBS is 6 levels deep .. • Level 1 – Funding type e.g. Total Estimated Cost (TEC) • Level 2 – Major area of the machine e.g. Beam Generation • Level 3 – Major subsystem e.g. Injector – all equipment associated with the injector • Level 4 – Class of component e.g. Magnets • Level 5 – Identifiable component in that class e.g. Bend Magnets – Bend Magnet – 5D7.1 • Level 6 –Piece parts or operations required to fabricate the Level 5 component e.g. Magnet Coil Winding Vinod Bharadwaj, SLAC

4. LCLS Project Level 3 WBS • 1 LCLS TEC • 1.1 PROJECT PLANNING, MANAGEMENT AND ADMINISTRATION • 1.1.1 Environment, Safety and Health • 1.1.2 Project supervision and coordination • 1.2 BEAM GENERATION • 1.2.1 Injector • 1.2.2 Accelerator • 1.2.3 Undulator • 1.2.4 Installation & Alignment • 1.3 PHOTON BEAM HANDLING AND SYSTEMS • 1.3.1 X-ray transport and diagnostics • 1.3.2 X-ray end station systems • 1.3.3 Installation and Alignment • 1.4 CONVENTIONAL CONSTRUCTION • 1.4.1 Injector facilities • 1.4.2 Linac facilities • 1.4.3 Undulator facilities • 1.4.4 Near Hall • 1.4.5 Tunnel • 1.4.6 Far Hall Vinod Bharadwaj, SLAC

5. 1.2.1 Injector 1.2.1.1 PED 1.2.1.2 Mechanical 1.2.1.3 Vacuum 1.2.1.4 Diagnostics 1.2.1.5 Power Conversion 1.2.1.6 Magnets 1.2.1.7 Controls 1.2.1.8 PPS 1.2.1.9 RF 1.2.1.10 Lasers 1.2.2 Accelerator 1.2.2.1 PED 1.2.2.2 Mechanical 1.2.2.3 Vacuum 1.2.2.4 Diagnostics 1.2.2.5 Power Conversion 1.2.2.6 Magnets 1.2.2.7 Controls 1.2.2.8 PPS 1.2.2.9 RF Injector 1.2.1 & Accelerator 1.2.2 Level 4 WBS Level 4 WBS – Class of Components Vinod Bharadwaj, SLAC

6. Ordinal Parts List example • Make an “ordinal parts list” of components that the beam sees • Start of injector ordinal parts list (lists attached to the end of this talk) Injector Section/Part NameLocation (cm) Quantity RF Gun to L0-1 Section cathode load lock -30 1 cathode/RF Gun 0 1 Gun solenoid, S1 25 1 Toroid, CM1 50 1 x-y corrector, SC1 50 1 On-axis alignment laser 75 1 Faraday Cup w/ YAG Screen, FC1 75 1 Electro-optic diagnostic, EO1 75 1 Gun E-Spectrometer Dipole 100 1 Faraday Cup w/ YAG Screen, FC2 along bend angle 1 Beam Position Monitor, BPM1 125 1 L0 Section Start of L0-1 Acc Section 142 1 x-y corrector, SC2 150 1 LINAC SOLENOID, S2 170 1 x-y corrector, SC3 435 1 End of L0-1 Acc Section 446.4 Vinod Bharadwaj, SLAC

7. Parts Lists, Parts Counts • Start with ordinal parts list • Add other needed components, resources • Make summaries of needed components, resources • Associate parts with WBS numbering .. 1.2.1.6 Magnets 1.2.1.6.1 Bend Magnets - 5D7.1 0 1.2.1.6.1.1 Magnet Materials 1.2.1.6.1.2 Magnet Machining 1.2.1.6.1.3 Mag Coil Winding 1.2.1.6.1.4 Magnet Assembly 1.2.1.6.1.5 Fiducialization 1.2.1.6.1.6 Mag Measure 1.2.1.6.2 Quadrupoles - 1Q5.6 0 1.2.1.6.2.1 Magnet Materials 1.2.1.6.2.2 Magnet Machining 1.2.1.6.2.3 Mag Coil Winding Vinod Bharadwaj, SLAC

8. Cost Collection Input Form • Standardized Form • Knowledge of labor rates, overheads, escalation .. • Common definitions of risk, estimate origin etc. • Time phasing Vinod Bharadwaj, SLAC

9. Cost Collection Input Form – time and labor Vinod Bharadwaj, SLAC

10. COST DATA BASE • Engineers are supplied with the ordinal parts list • Engineers fill out the Standardized Form • PED is broken out • M&S and time & labor type • Preliminary schedule for funding • Engineers maintain backup information for their input data • SLAC experience in accelerator systems put to good use • Sheets are collected and input into Microsoft Project database • Data can be sliced in any required way • Microsoft Project can generate summaries, reports, etc. of the cost information Vinod Bharadwaj, SLAC

11. Injector & Accelerator Costs • The Injector is defined as from the Gun to the Input of L1 • The Accelerator is defined as from the input of L1 to the end of DL2 + the electron dumpline • The Injector and Accelerator have many components in common. We use the following rules to deal with this • PED for common components is included in the Injector costs • Diagnostics – Wire scanners, profile monitors, toroids, BPMs, transverse RF BLM • Magnets – 5D7.1, QE quads, correctors • RF Controls and Distribution • Timing system • Any PED for minor modifications to a common component is added in the Accelerator costs • The component costs are added to both costs according to the count Vinod Bharadwaj, SLAC

12. Injector Costs – 1.2.1 WBS – Summary Parts list Vinod Bharadwaj, SLAC

13. 1.2.1 Injector Cost Estimate (FY02 Dollars, Thousands) Vinod Bharadwaj, SLAC

14. 1.2.1.7 Injector Cost Estimate (FY02 Dollars, Thousands) Vinod Bharadwaj, SLAC

15. 1.2.1.7.5 Injector Cost Estimate (FY02 Dollars) Vinod Bharadwaj, SLAC

16. Accelerator Costs – 1.2.2 WBS – Summary Parts list Vinod Bharadwaj, SLAC

17. 1.2.2 LCLS Linac Cost Estimate(FY02 Dollars, Thousands) Vinod Bharadwaj, SLAC

18. 1.2.2.6 LCLS Linac Cost Estimate(FY02 Dollars, Thousands) Vinod Bharadwaj, SLAC

19. 1.2.2.6.8 LCLS Linac Cost Estimate(FY02 Dollars, Thousands) Vinod Bharadwaj, SLAC

20. 1.2.1 Schedule Milestones WBS 1.2.1 Injector Milestones Send out bid packages, order parts Oct 2004 Begin fabrication of gun, load-lock, magnets, supports Oct 2004 Laser room with components installed Jun 2005 Begin installation beam line components Jun 2005 Begin installation racks and components, cable trays, power supplies, system wiring Jun 2005 Pump down vacuum system Oct 2005 Checkout basic laser system Oct 2005 Begin checkout beamline components, power supplies, diagnostics Oct 2005 Install new protection systems Oct 2005 Begin commissioning injector Feb 2006 First rf, first photoelectrons Feb 2006 Accelerate beam through injector Feb 2006 Vinod Bharadwaj, SLAC

21. 1.2.2 Schedule Milestones • 1.2.2 LCLS Accelerator milestones – Cu Magnets to bid Oct 2004 SC magnet to bid Oct 2004 BC-1 Cu Magnets award Jan 2005 SC magnet award Jul 2005 Start of BC-1 shutdown Oct 2005 BC-1 Cu Magnets rec'd Dec 2005 X-band installed Jan 2006 BC-1 installed Jan 2006 First beam to BC-1 Mar 2006 SC magnet rec'd May 2006 Start BC-2/BSY shutdown Oct 2007 BC-2 installed Jan 2008 BSY modifications complete Jan 2008 Start BC-2 commissioning Mar 2008 Vinod Bharadwaj, SLAC

22. INJECTOR PED MILESTONES FY03 • December 2002 • Gun laser specifications and preliminary design • Preliminary beamline layout • March 2003 • RF gun specifications and preliminary design • Laser oscillator bid package • June 2003 • Load lock specifications and preliminary design • September 2003 • E-O diagnostic specifications and preliminary design • Design of timing/rf distribution • Specifications and preliminary design of controls software • Power supply specifications Vinod Bharadwaj, SLAC

23. INJECTOR PED MILESTONES FY04 • December 2003 • Beamline detailed layout • Load lock engineering design • March 2004 • RF gun engineering design • Laser pump bid package • June 2004 • Detailed layout all controls hardware • September 2004 • E-O diagnostic engineering design • Laser uv conversion and transport to cathode design • Design low level rf system Engineering design of all components to be manufactured COMPLETED and all bid packages prepared by end September 2004 Vinod Bharadwaj, SLAC

24. Accelerator PED Milestones in FY2003 • December 2002 • Dipole magnet modelling finished • March 2003 • Quadrupole magnet modelling finished • Fast bunch length monitor design complete • June 2003 • X-band structure design complete • September 2003 • SC wiggler magnet specs finished • BC1 magnet design, vacuum and articulation finished • High resolution BPM electronics designed Vinod Bharadwaj, SLAC

25. Accelerator PED Milestones in FY2004 • December 2003 • Magnet power supplies defined • March 2004 • BC2 magnet, vacuum chamber and articulation design complete • Fast bunch length monitor prototype testing complete • June 2004 • Vacuum system design complete • High resolution BPM electronics prototyping finished • Magnet and wiggler design complete • RF systems design complete • September 2004 • Designs finished & reviewed • Bid packages for all systems ready Vinod Bharadwaj, SLAC

26. CONCLUSIONS • System for collecting LCLS costs setup • Ordinal parts list • Parts count • Standard cost input form • Database to collect cost information and generate reports • Costs for 1.2.1 Injector & 1.2.2 Accelerator well understood • Total PED for Injector is 6,505 K$ • Total PED for Accelerator is 8,222 K$ • Total cost for Injector is 20,411 K$ • Total cost for Accelerator is 23,052 K$ • Ready for PED funds Vinod Bharadwaj, SLAC