CD 0.4 Damping Ring. LBL / SLAC collaboration. M. Ross April 25, M. Ross. J. Corlett. J. Rasson. K. Jobe R&D. J. Corlett

Transcription

1 CD 0.4 Damping Ring M. Ross J. Corlett J. Rasson B. McKee D. Atkinson Project/ Systems S. Marks R. Rimmer K. Kennedy Engineering/R&D K. Jobe R&D J. Corlett <tbd> Accelerator Physics G. Koehler N. Hartman R. Lafever Engineering Support LBL / SLAC collaboration M. Ross April 25, 2000

2 must have an optimistic outlook - means valid model and costs deliberately very conservative model - why? the way it ought to be at a research lab - push the envelope Must have much better model, more valid estimate, than 5/99 April 25, 2000 CD 0.4 Damping Ring 2

3 Outline: Requirements and Specifications Cost drivers Critical technologies - Cost & Risk Technology choices Cost estimating methods - sources, confidence, parameters Engineering effort summary WBS summary Design / Cost inconsistencies to be noted! April 25, 2000 CD 0.4 Damping Ring 3

4 Requirements: PARAMETER MDR PPDR UNITS TOLERANCE Particle types e - /e + (e - ) e + (e - ) - - Nominal beam energy GeV - Beam energy range 5 5 % +/ - Particles per bunch 1.6x x10 10 e - /e + max Number of trains (N t ) max Bunch spacing within train (τ b ) ns - Gap for kicker rise/fall (τ k ) ns min Injected x/y-emittance (norm.,rms) (γε o ) <150 <42,000 µm - Extracted x-emittance (norm.,rms) (γε x ) <3. 0 <500 µm - Extracted y-emittance (norm.,rms) (γε y ) <0. 03 <100 µm - Injected energy spread (largest of bunch or train) ± rms % max Extracted energy spread % max Extracted bunch length mm max Throughput efficiency (MDR 1.9 to 1.6, PPDR 2.8 to 1.9) >80 >68 % Shaded entries - special note April 25, 2000 CD 0.4 Damping Ring 4

5 Ring Specification summary - MDR/PPDR: PARAMETER MDR PPDR UNITS TOLERANCE Circumference m - Current Amp max Loss per turn KeV - TME Cell 1B 3Q 4S 1B 4Q 4S - - TME Cell length 6 11 m - Number of TME cells St raight length m - Number of wiggler sections Wiggler section length 4.5 TBD m - Average vacuum pressure 1 10 ntorr max TME quad aperture (diameter) mm min Wiggler magnet gap mm min MDR dynamic aperture design will change TME cell design; require re-optimization Shaded entries - likely to change for CD0.4 April 25, 2000 CD 0.4 Damping Ring 5

6 Cost Summary - CD M$ total + fac 59M$, glo 33M$ 40,000 Cost Drivers: EDI 82 Magnets 99 Vacuum 36 Install. 39 Supports 23 Facilities 59 Global? 33 35,000 30,000 25,000 20,000 15,000 10,000 5,000 0 VACUUM SYSTEMS INSTALL HARDWARE OTHER MAGNET SYSTEMS QUAD SYSTEMS PULSED MAGNET SYSTEMS MAGNET SUPPORTS/GIRDERS MAGNET SYS ACTIVITIES DIPOLE SYSTEMS Mechanical Engr SEXTUPOLE SYSTEMS LASER WIRE SYSTEMS STAND-ALONE BPM SYSTEMS RF STRUCTURES Vacuum Engr Survey & Alignment SR MON SYSTEMS Design Engr INSTALL CABLE PLANT Manufacturing Interface MODULATORS Systems Engr OTHER INSTRUMENTATION WAVEGUIDES Safety & Hazards KLYSTRONS Top 90% $ April 25, 2000 CD 0.4 Damping Ring 6

7 Technology choices- Risk and Cost - CD0.4 Cost Drivers: Magnets 99 EDI 82 Installation 39 Vacuum 36 Supports 23 Facilities 46 Global? 33 Radiation control $ Permanent Magnets Wiggler Aluminum Vacuum Chamber $ Girder movers $ Installation $ Facilities Thermal control Cooling / Power $ Tunnel Electronics April 25, 2000 CD 0.4 Damping Ring 7

8 AcrobatDocument Critical Technical issues - Risk: Radiation dose - activation and exposure Remote handling limits Activation as a function of material: Al - excellent SS/Cu/Fe - SLAC experience Co - ~ 13 x higher Exposure: 50W in 100 lb Fe 0.6 Mrad/hr and 5 x n/s SLAC - 10W 300mRad/hr (30cm) activation (SS,Fe, Cu) NLC intensity table (e10) design max Two loss models: Loss Model (1) SLC transmission % NLC beam losses lost power lost power (W) (W/m) e+ booster linac (*) 2.8 e+ system e- booster linac 2 e- system e+ PPDR 1.9 (2) NLC transmission % e+/e- MDR 1.6 e+ pre Pre-linac 1.6 e+ main * max rating is 4.0 e- system Design MDR for 50 W/m - No electronics in the PPDR April 25, 2000 CD 0.4 Damping Ring 8

9 Cost 81 K$/each Critical Technical issue - cost : TSET recommendations Magnets edr pdr ppdr eltr pltr pxfer ebc1 pbc1 total unit K$ BEND QUAD SEXT CORRECTOR?? SEPTA KICKERS SPIN ROTATORS WIGGLERS Includes: EDI 19% Mgnt 48% Mover 32% PS 19% SLS quads cost 7.1K$ SrFeO radiation damage tests done in BDE - no change (<1%) seen for 50MRad (2x10 11 n/cm 2 ) Radiation damage in ferrite Published data 1.00E+19 n/cm^2 no detectable loss Estimate 2.6E+07 n/cm^2/s^2 50W loss in 100 lb block Time limit 4.38E+06 days before detectable loss 4 kinds of magnets Main Rings No bulk SmCo activation only SrFeO (with SmCo tuners) PPDR/PLTR Electromagnets because of large size BC-1/ PXFER Nominal linac style PM MDR Wiggler Shielded Nd-FeB April 25, 2000 CD 0.4 Damping Ring 9

10 Cost 81 K$/each Critical Technical issue - cost : Magnets (2) Magnet costs by component 0.3 Cost 41 K$/each w/o Wiggler, Kicker, System EDI and girders TOTAL MAGNET COST INCREASE EM --> PM DIPOLES 1469 QUADS 1155 SEXTUPOLES 312 A strong candidate for further cost review! Fractional cost (of 99M$) OTHER MAGNET SYSTEMS QUAD SYSTEMS PULSED MAGNET SYSTEMS MAGNET SUPPORTS/GIRDERS CORRECTOR SYSTEMS MAGNET SYS ACTIVITIES DIPOLE SYSTEMS SEXTUPOLE SYSTEMS SOLENOID SYSTEMS April 25, 2000 CD 0.4 Damping Ring 10

11 Critical Technical issue - risk : Wiggler Cost 222 K$/m Transverse field flatness 1999 SPEAR aperture reduction with BL11 wiggler - Very similar to planned MDR (much shorter) Electromagnet field flatness is limited due to pole saturation ==> use NdFeB (with wider poles) NLC DR Electromagnet BL11 Hybrid (NdFeB) Use collimation to protect NdFeB (sensitive to few Mrad) Not in estimate Cost increase 35% 7M$ April 25, 2000 CD 0.4 Damping Ring 11

12 Critical Technical issue - risk : Vacuum Cost 38 K$/m Required pump speeds due to thermal out-gassing MPS considerations make Al attractive Ring section L cross section surface area Al (SLAC) SS (SLAC) Al (DAFNE) m cm m^2 total pump speed l/s Arc E E E+00 Wiggler E E E+00 Straight E E E-01 Sum E E E+01 Required speed (l/s per meter) Outgassing rate (Torr l/s per cm^2) 5.00E E E-13 DAFNE report excellent performance with Al using fine surface finish machining (10-14 Torr l/s /cm 2 ) Provision for in-situ bake and chamber clearance ~2mm Super-finish not in estimate April 25, 2000 CD 0.4 Damping Ring 12

13 23 M$ total Critical Technical issue - Cost : Movers SLS - Swiss Light Source has similar vertical tolerances (50µm) - successfully mounted on stiff 4 m girders (also ATF) SLS girder (not incl movers) 1 M$ / ring NLC girder/magnet movers 5.1M$ / ring Movers are used for girders only - components are pre-aligned to within the tolerance. Correctors are required Permanent magnets make this easier because of low power dissipation MDR Mover count reduced from 330 to 60 (heavier movers) Not in estimate April 25, 2000 CD 0.4 Damping Ring 13

14 Critical Technical issues - Risk Environmental control (Soleil Light Source CDR) Vertical: 100 µm over 10 m per year 10 µm over 10 m per day 1 µm over 10 m per hour Tunnel temperature = input water temperature= 21 deg +/- 0.1 deg C Active air cooling and circulation low W/meter into air Problems with CD-1 model due to heat from cables Light sources have understood and corrected this problem Not in estimate April 25, 2000 CD 0.4 Damping Ring 14

15 Critical Technical issues - Cost Electronics in Ring Enclosure 50 W/m is 50 times main linac average Shield high rad locations (n shielding) Deep tunnel wall electronics holes (~2m) End of linac Entrance to ring first ring arc following injection ring aperture restrictions (wiggler) No electronics in pre-damping ring Not in estimate April 25, 2000 CD 0.4 Damping Ring 15

16 Installation: Cost Installation Management Controls & instrumentation supervision 315 RF installation supervision 165 Mechanical supervision 165 Vacuum supervision 165 AREA MANAGEMENT & SUPERVISION LOGISTICS 165 AREA MANAGEMENT INSTALL DOWNSTAIRS 165 AREA MANAGEMENT INSTALL UPSTAIRS 165 Power conversion supervision 139 Manage cable plant 121 Pulsed RF manager 110 COORD & SUPERVISION - FACILITIES 82 Alignment supervision 56 CW RF manager 55 Installation coordination meetings and reviews 36 Schedule and cost status and updates 36 RF supervision 35 AREA MANAGEMENT INSTALL PENETRATIONS 33 AREA SYSTEM INSTALLATION MANAGER 33 Mechanical & vacuum supervision 30 RF system installation manager 27 Grand Total 2,100 EMDR example K$ K$ $2,500 $2,000 $1,500 $1,000 $500 $0 Installation Management Pre-installation (Preparation) EMDR Installation per activity Logistics Installation - upstairs gallery... 3 year duration - 7 people avg PM Not in estimate Installation - downstairs tunnel Checkout EDR Documentation April 25, 2000 CD 0.4 Damping Ring 16

17 Critical Technical issues - Cost Facilities 4 primary water loops: Requirements: RF Magnet High Conductivity Radiation Cavity, klystron, Vacuum chamber Power magnets (PPDR, septa) RF loads Collimation, Dumps Expected Load: Area AC Power AC Power Water Water Rad. Water Air RF Mgnts Ops. Load Ops. Load Ops. Load Ops. Load 480V gallery tunnel tunnel tunnel (kva) (kva) (kw) (kw) (kw) (kw) e-dr e+dr e+pdr subtotal, Totals What % is this of total 313 M$+EDI utilities? ( ) April 25, 2000 CD 0.4 Damping Ring 17

18 Summary of model & cost inconsistencieschanges/evaluation expected for CD0.4 Expected cost impact Dynamic aperture optimization + Wiggler field specification + Permanent magnet wiggler + Permanent magnet controls + Magnet / Girder movers / correctors - Tunnel air stabilization + Vacuum system + Installation w/o cables - Tunnel Electronics Enclosure - TSET input (EDI) - Subsystem specification/reliability - April 25, 2000 CD 0.4 Damping Ring 18

19 Cost Estimating Methods Where do the estimates come from? $14,000 $12,000 $12,118 $10,000 $9,637 Source of costs for EDR (95%) $8,000 $6,000 $4,563 $4,000 $2,768 $2,867 $2,000 $1,600 $1,270 $1,184 $1,000 $872 $585 $0 lbl (wiggler) mckee TSET munro (vacuum mech) mfd scaling schwarz (RF) richards (septa) hamner (vac ctl) varion cat. pappas (kicker) smith (BPM) browne (movers) April 25, 2000 CD 0.4 Damping Ring 19

20 Cost Estimating Methods TSET interface Magnet - used costing guidelines provided updated labor rates Magnetic measurement costs General guidance from SLAC MFD Collimation (used 5/99 estimate) Vacuum, Supports, Installation - waiting Parameterization: Cost Systems Engineering Installation Assembly Magnets Engineering Cabling Basis scaled examples detailed Parts count Parts; length Parts Cost sheets (size, weight, guidelines) Parts, length depth April 25, 2000 CD 0.4 Damping Ring 20

21 Cost Methodology - McKee Source Data sheets ~1500 LBL Summaries ~200 (based on McKee s breakdown by task) Success legacy LINK McKee TSET CTL PCD Consolidation by sub-area ACCESS - Injector area coordinator etc April 25, 2000 CD 0.4 Damping Ring 21

22 Costing - EDI EDI in 3 categories: Global (system) 45 Subsystem Component 37 45% 40% 35% 30% 25% 20% 15% 10% 5% 0% VACUUM SYSTEMS INSTALL HARDWARE OTHER MAGNET SYSTEMS QUAD SYSTEMS PULSED MAGNET SYSTEMS MAGNET SUPPORTS/GIRDERS MAGNET SYS ACTIVITIES DIPOLE SYSTEMS SEXTUPOLE SYSTEMS LASER WIRE SYSTEMS STAND-ALONE BPM SYSTEMS RF STRUCTURES SR MON SYSTEMS INSTALL CABLE PLANT MODULATORS OTHER INSTRUMENTATION WAVEGUIDES KLYSTRONS Need TSET definition and savings EDI as a percentage of subsystem (total 31%) April 25, 2000 CD 0.4 Damping Ring 22

23 Costing - EDI $1,600,000 $1,400,000 $1,200,000 Breakdown of EDI by activity $1,000,000 $800,000 $600,000 $400,000 $25,000 $20,000 super $200,000 $0 VACUUM CHAMBERS INSTALLATION DRAWINGS SYSTEM DRAWINGS PARTS & DRAWING MANAGEMENT QUAD MAGNETS SEPTA ( ZDR EST ) KICKERS ( ZDR EST ) DIAGNOSTICS BEND MAGNETS SCHEMATICS SUPPORTS Design Costs per subsystem 1500 to get # drawings ~ 9,000 INTERFACE DRAWINGS AUXILLIARY HARDWARE SYSTEM LAYOUTS SEXT MAGNETS $15,000 $10,000 $5,000 $0 MANUFACTURING AND ASSEMBLY DESIGN ENGINEERING MECHANICAL ENGINEERING dsgn eng insp INSTALLATION AND CHECKOUT VACUUM ENGINEERING ELECTRICAL ENGN/HARDWARE MANAGEMENT & SYSTEMS ENGR SAFETY & HAZARDS April 25, 2000 CD 0.4 Damping Ring 23

24 Costing - Labor Staffing profile used to segregate WBS x.x.x.n Engineering labor per year - 5/99 estimate Annual FTE DESIGNER ENGINEER PHYSICIST K$ Non-engineering Labor by activity 30,000 25,000 20,000 15,000 10,000 5, Year number INSTALL HARD... VACUUM SYSTEMS OTHER MAGNET... MAGNET SUPP... MAGNET SYS ACT... PULSED MAGNE... INSTALL CABLE... SR MON SYSTEMS CD2 CD3 April 25, 2000 CD 0.4 Damping Ring 24

25 Costing confidence - Done Factor Completeness of estimate - Is everything included? Reliability of estimate - where did it come from? (background, source) Risk of the cost number - how much would I pay for this product? Intuition and assessment that the cost will not be exceeded Costing confidence for Manufacturing TOTAL DONE COST $K % factorcertainty SYSTEM $20, % edr $39, % pdr $40, % ppdr $27, % eltr $7, % pltr $9, % pxfer $1, % ebc1 $16, % pbc1 $15, % TOTAL 179, April 25, 2000 CD 0.4 Damping Ring 25

26 WBS LABOR $ M&S $ TOTAL k$ * * Damping Ring Areas 135, , , * Damping Ring Areas Conceptual Design 9, , * Damping Ring Areas R&D 9, , * Damping Ring Areas Design 21, , * Damping Ring Areas Sustaining Engineering 15, , * Damping Ring Areas Acquisition 35, , , * Damping Ring Areas Installation, Integration & Testing 42,539 2,090 44, LABOR K$ M&S K$ TOTAL k$ * 2 Magnet Systems 45,356 64, , * 1 Vacuum Systems 13,876 30,675 44, * 4 Instrumentation Systems 18,736 14,292 33, * 3 RF Systems 14,989 10,575 25,564 April 25, 2000 CD 0.4 Damping Ring 26

27 NLC CD 0.4 tradeoff consideration - Fall 1999 Accepted items: Rejected items: Strung power supplies -26,872 Installation of pre-assembled girders not individual magnets -22,231 Updated cost estimates - ED&I and B&H -18,471 Removed blanket 'System Area Management' -16,435 Reduced power supply sizes -11,573 Reduced length of transfer line -12,204 Conventional - per draft from Clay -7,528 Reduced magnet fabrication labor rates to $30 per hour. -7,276 Detailed girder assembly -3,828 Reduced cable and cable trays -3,349 Corrected errors -2,052 Updated magnet specifications -1,286 Eliminated bypass line installation -760 Modified TME cell to 3 quad configuration -700 Eliminated combined function dipoles -629 Reduced number of prototypes -550 Higher energy operation Delete redundant power supplies Permanent bend magnets 720º bend main rings Stack rings Permanent magnet sextupoles (main rings only) Low emittance injector Power supply string - rings and transport lines Delete movers Reduce corrector count Re-visit tradeoffs with new costs April 25, 2000 CD 0.4 Damping Ring 27