C75 Review 21Jan2016 Cost Estimate McEwen - Rev. 14

Overview of Costs Summary of Costs (also in Bob’s Slides ) From the Charge questions : Are the Requirements and goals for the C75 CM understood, well specified and realistic ? Summary of Costs (also in Bob’s Slides ) Timeline (also in Bob’s Slides) Details of each option listed C50 Basis of estimate C100 Basis of estimate C75 Basis of Estimate One time costs , R&D, Wave Guides Appendix & back up slides

CEBAF Energy Maintenance options All costs in FY16 DIRECT Dollars   From Accelerator "STAY Treat" July2015) - see Slide 6 # Cav cells /cav cav length m Active Length m fill factor % MV volts /cav (MV) gradient (MV/m) klystron power unit cost (FY16 M$ Direct) RF Cost Total Cost FY16 Direct MV (gain) V(gain) /$ C50 8 5 0.5 4 48.1 50 6.25 12.5 6 1.51 20 13.3 C75† 75 9.4 18.8‡ 1.91 45 23.6 C100‡ 7 0.7 5.6 64.4 100 17.9‡ 13 4.77 70 14.7 Update - January 2016 *RF Cost 1.23 16.3 1.73 0.77 2.50 18.0 4.30 1.56 5.85 12.0 †New cells or new processing required to achieve higher Q’s and gradients ‡Digital LLRF required What changed from August 2015 to January 2016 ? Addition of RF to C100 & C75 (assumes C50 still usable) Updated Rates (Budget Office ) & change TDIII to TD II (match AWP) Improved estimate for Fabrication and other costs What is not included ? One time R&D costs Wave Guide Vendor Development + 8 Wave Guides Details in slides that follow

C75 Timeline now stretching into FY17 For comparison – all costs have been kept in FY16 Direct Dollars

C50 Costs – scaling to FY16

General Cost assumptions for C50 C50R (# 11) Transfer Sept. 2013 Based on C50 # 11 + escalation C50 -11 Build in FY13-FY14 Rates adjusted to FY2016 New Labor Rates from Budget Office Nov2015 Next C50 might have the following added costs if old RF & Wave Guides are not reusable New Wave Guide supplier + 8 WG procured ($360K) New digital RF may be needed ($280K Direct) C50 String All costs in FY16 DIRECT Dollars

FY 13 Ave Labor Rates + escalation Conversion of C50-11* to FY16 We use the average labor rates because the actual rates are confidential Steps to convert from C50-11* to C50 in FY16 1. Used C50 Actual $$ from Cost Point from FY13-FY15 Drilled down to Identify Labor types and # man weeks 2. Apply average Cost rates for JLAB for the current year FY16 3. Escalate Material to FY16 C50-11 actual cost (from Cost Point) C50-11 using Model C50 in FY16 Summary Direct Cost FY13 FY14 FY15 Total C50-11 FY 13 Ave Labor Rates + escalation Escalate to FY16 escalation assumed included two years x.03 used FY16 labor rates + M&Sx.03x.03 man weeks 380 25 4 409 wks Labor cost - incl Sat, Fringe $762,249 $74,154 $13,023 $849,426 $890,260 $957,550 Non-Labor $258,551 $6,908   $265,459 $279,335 Total - $ DIRECT $1,114,885 $1,155,719 $1,236,885 * C50-11 used for BOE because C50 -12 is not complete (C50-12 also included special tasks such as Plasma) ** Not included in costs above potential risk that FPC- Wave Guides and/or RF might be unusable New Wave Guide supplier + 8 WG procured ($360K), C50/C75 Zone ($249K) All costs in DIRECT Dollars

C100 Costs – scaling to FY16

General Assumptions for C100 Ten (10) of C100 were built from 2010-2012 What would it cost for ONE in today’s dollars ? Additional costs : Inflation on Procurements from 2010 to today’s dollars We use the same labor types , applying today’s rates (similar to C50/75) Fabrication Labor would be less efficient for only one as opposed to 10 (no ramp up/down ) Procurement Labor increase in total (one CM takes ~ same effort as 10 ) total would be less due to the learning curve from 12 GEV, BUT the same total labor would be applied to only one CM instead of 10 Factor for cost of procurements due to only procuring one set (as opposed to 10 sets ) Cost savings : - Can delete any tooling that can be reused - Will not need PMO oversight for only one CM Application to C100 follow on the next slide …….

Scaling Factors based on 12 GeV Basis of estimate: 12 GEV Cost Book escalated to FY16 Procurements taken from the Cost Book Labor Types , Org. & Man weeks from Cost Point Scaling factors for one CM per Joe Preble as follows Procurement Labor : Scaling factor by Labor type /Org ranges 0 to 50% of total 12 GeV Construction Labor Scaling Factor x 1.5 of one 12 GeV CM Procurement Costs (example in back up slides) Escalation from 2010 to 2016 X 1.09 (CPI from 2010-2015) x (~ 3% for Fy2016) 1.5 X 12 GeV Procurements due to small lot sizes JLAB Tooling deleted (existing can be re-used)

Summary : C100 Cryomodule in FY16 Cost Book FY2010-2012 FY2016 13 kW RF Zone Summary in Direct Cost Total C100 (10 CMs) C100 divide by 10 one C100 scaled for C100 one C100+RF Man weeks Procurement 1,843 184 260   Man weeks Construction 1,960 196 294 Total Labor (Man weeks) 3,802 wks 380 wks 554 wks 107 wks 661 wks Labor cost - incl Sat, Fringe $8,262 $826 $1,484 $250 $1,733 Non-Labor $17,611 $1,761 $2,813 $1,305 $4,118 Total - K $ DIRECT $25,873 $2,587 $4,296 $1,555 $5,851 More detail in back up slides All costs in DIRECT Dollars

C75 Costs – scaling to FY16

C75 – FY16 Direct Costs Steps to build Cost of C75 All costs in DIRECT Dollars Steps to build Cost of C75 Based on C50 # 11 + escalation C50 -11 Build in FY13-FY14, Rates adjusted to FY2016 2. Added Fabrication & material for 8 Cavities and Tuners (8 set) 3. Added 8kW RF Zone costs Summary Direct Cost C75 Prod'n C50 in FY16 8 Cavity/Tuner RF Zone 8kW Total C75 Prod'n man weeks 409 59 81 549 Labor cost - incl Sat, Fringe $949 $158 $192 $1,300 Non-Labor $278 $344 $582 $1,204 Total - K $ DIRECT $1,227 $503 $774 $2,504 Not included in costs above - Does not include C75 R&D ($785K) – Critical path ! - Next C50/75 might have added costs if Wave Guides are not reusable New Wave Guide supplier + 8 WG procured ($360K) More detail in back up slides

C75 RF - Detailed Cost Breakdown RF Cost Breakdown & Options 5kW (C50-75) 8kW (C75) 13 kW (C100) Field Control Chassis (8) $60,000 Stepper Controls $10,000 PZT $7,500 Heater Chassis $5,000 Interlock Chassis HPA Controller Cabling (Probe, stepper, interlocks etc) $8,500 Network Modifications $6,000 Software Modifications Klystrons/Stands/Electronics $360,000 $704,620 Circulator $80,000 $120,000 Power Supply $30,000 $148,200 Solenoid (PS) $14,400 HPA Interlocks $2,500 Waveguide $196,342 Heliax (Fwd/Refl/Drive) $2,400 HPA/Waveguide Installation $400 Electrical Work RF Power Commissioning $1,000 LLRF Commissioning Total Procurements $109,400 $581,900 $1,305,362 Labor with Stat & Fringe $139,598 $192,493 $249,739 Man weeks 58.8 80.8 107.1 Total DIRECT RF Cost $248,998 $774,393 $1,555,101 C75 8 kW Lead times LLRF - 4 months to procure and manufacture LLRF HPA/Wvgd – 8-12 months to procure 8 kW klystrons Comm - 2 weeks Courtesy of Curt Hovator All costs in DIRECT Dollars

C75 R&D – Critical Path ON HOLD All costs in DIRECT Dollars Proj Abrev one time DIRECT cost (FY16 M$) Status Total C50/75 R&D –Roll up $ 0.79 C75- Develop 2 Proto cavities C75DEV Rimmer & Daly $0.52 ON HOLD Field Emission Mitigation SRFFEM R. Geng $0.18 Unfunded C50 R&D - Magnetic Hygiene C75HY G. Ciovati 0.09 See Bob Rimmer’s Presentation

Thank you for your attention

Acknowledgements Special Thanks to my colleagues at JLAB who provided data & feedback in preparation of this presentation Bob Rimmer, Tony Reilly , Ed Daly, Joe Preble , Gigi Ciovati, Rongli Geng, Curt Hovator , Larry Turlington & many others and the JLab Budget Office including Kelly Webster, Annie (Tran) Ungaro & Chris Hayes

Back Up – Appendix

Charge Are the requirements and goals for the C75 cryomodule understood, well specified, and realistic? Is the preliminary design conceptually complete, and likely to lead to an operating cryomodule with the desired characteristics? Will the design be flexible enough to take full advantage of ongoing R&D? Is the C75 cryomodule planned adequately and “ready to go” for refurbishing activity to commence starting toward the end of 2016? If not, should refurbishments as C50 continue until outstanding issues are resolved, or should other paths (e.g., full C100 replacement) be pursued? E. Daly, JLab Cryomodule Pressure Systems 03FEB2014

Appendix & Back up C50/C75

C75 R&D Cost Details 1.04.09.009 - C75 R&D person Wk Direct Labor Cost   person Wk Direct Labor Cost Direct M&S Total Direct Cost 1.04.09.009.001 C75 Dev. Design & Fab two R&D Cavities ON HOLD 111.6 $399,562 $121,200 $520,762 RF & Nb Material for 2 cavities 20.7 $74,563 $0 HOM s- design, fab & test 4 new units 17.1 $66,038 $40,000 $106,038 TUNER - Design & Fab 26.2 $89,190 $25,000 $114,190 FPC 7.7 $28,008 Fabrication & Test of 2 cavities 40.0 $141,763 $56,200 $197,963 1.04.09.009.002 Field Emission Mitigation (SRFFEM) Un Funded $147,995 $30,000 $177,995 1.04.09.009.003 C50 R&D - Magnetic Hygiene - C75HY 26.0 $76,543 $10,000 $86,543

Risk : C50/75 FPC reuse – NO SPARES All costs in DIRECT Dollars Today re-using old coper plated wave guides from C50 However : we have NO SPARES Eventually we expect new WG will be needed for C50 (or C75) Risk and potential Cost impact is $360K Thermal analysis Design & Fab 10 WG Development of a new supplier Technical details in the presentation of Ed Daly & Tony Reilly Wave Guide Vendor Development +8WGs Direct Cost (FY16-$M) C50 $ 0.36 M C75 $ 0.36M C100 included

C75 Detailed Costs All costs in DIRECT Dollars person Wk Direct Labor Cost Direct M&S Total Direct Cost Disassy-SRF C75-01   28.9 $61,225 $1,273 $62,499 CompProc&Assy-SRF C75-01 186.2 $406,222 $245,280 $651,502 CavProc&Assy-SRF C75-01 47.1 $158,221 $8,805 $167,026 Cryomod Assy-SRF C75-01 98.4 $200,214 $22,600 $222,814 CMTF-Test SRF C75-01 0.0 $0 Install&Comm-SRF C75-01 1.3 $3,346 Install/ComOps/RF C75-01 8.1 $19,610 C75 QA/Doc Ctrl/Insp&CMM 39.5 $99,839 C75 Cavity Fabrication 59.0 $158,355 $219,400 $377,755 Tuners Fabrication $125,000 Total C75 (assumes FY16) 468.4 $1,107,033 $622,359 $1,729,391

C75 5KW RF Zone detail Courtesy of Curt Hovator C75 5 kW Zone Task/Milestone   SE EE/CS ET ED PHY Labor Total Materials Work Planning 1 2 Zone Prep (Cable/Chassis/Wvgd removal) 0.4 4 Field Control Chassis (8) 0.2 6 $ 60,000.00 Stepper Controls $ 10,000.00 PZT Interlock Chassis $ 5,000.00 Heater Chassis HPA Controller Cabling (Probe, stepper, interlocks etc) 0.6 $ 8,500.00 Network Modifications $ 6,000.00 Software Modifications 8 kW Klystrons Power Supply HPA Interlocks Waveguide Heliax (Fwd/Refl/Drive) HPA/Waveguide Installation $ 400.00 Electrical Work $ 2,500.00 RF Power Commissioning 0.45 $ 1,000.00 LLRF Commissioning Total (weeks) 3.2 13.8 27 14.8 58.8

C75 8KW Zone RF Detail Courtesy of Curt Hovator C75 8 kW Zone Task/Milestone   SE EE/CS ET ED PHY Labor Total Materials Work Planning 1 2 Zone Prep (Cable/Chassis/Wvgd removal) 0.4 4 Field Control Chassis (8) 0.2 6 $ 60,000.00 Stepper Controls $ 10,000.00 PZT Interlock Chassis $ 5,000.00 Heater Chassis HPA Controller Cabling (Probe, stepper, interlocks etc) 0.6 $ 8,500.00 Network Modifications $ 6,000.00 Software Modifications 8 kW Klystrons $ 360,000.00 8 kW Circulators $ 80,000.00 Power Supply 3 $ 30,000.00 HPA Interlocks $ 2,500.00 Waveguide Heliax (Fwd/Refl/Drive) HPA/Waveguide Installation $ 400.00 Electrical Work RF Power Commissioning $ 1,000.00 LLRF Commissioning Total (weeks) 5 18 39 18.8 80.8

C100 13 KW RF Zone RF Detail Courtesy of Curt Hovator C100 Task/Milestone   SE EE/CS ET ED PHY Labor Total Materials Work Planning 1 2 Zone Prep (Cable/Chassis/Wvgd removal) 0.4 4 Field Control Chassis (8) 0.2 6 $ 60,000.00 Stepper Controls $ 10,000.00 PZT $ 7,500.00 Heater Chassis $ 5,000.00 Interlock Chassis HPA Controller Cabling (Probe, stepper, interlocks etc.) 0.6 $ 8,500.00 Network Modifications $ 6,000.00 Software Modifications Klystrons/Stands/Electronics 12 704,620.00 Circulator 120,000.00 Power Supply 148,200.00 Solenoid (PS) 1.5 14,400.00 HPA Interlocks $ 2,500.00 Waveguide 196,342.00 Heliax (Fwd/Refl/Drive) 2,400.00 HPA/Waveguide Installation 400.00 Electrical Work RF Power Commissioning $ 1,000.00 LLRF Commissioning Total (weeks) 4.8 24 56.5 21.8 107.1

CEBAF C20 upgrade to C50 C20 CEBAF 42.25 Cryomodules 1987-1993 Supports CEBAF C20 CEBAF 42.25 Cryomodules 1987-1993 40 Cryomodules plus Injector Injector includes 2 Cryomodules + one Cryo-unit ) 338 Five (5) cell cavities. During peak Production 2 Cyromodules per month for 18 months, with final test in the accelerator C20 refurbished to C50 started 2006 Refurbishment of CEBAF with improved processes C20 (20MV/m) to C50 (50MV/m) 11 reworked modules installed to support higher-current lower trip rate for remaining experiments Successfully reached 6 GeV operation for the first time. Resumed after 12 GeV to maintain capability Ongoing investigation of C50 Qo drop in modules CEBAF Cryo-unit Results of First 10 Refurbished C50 Cryomodule Courtesy C. Reece, JLab C50 String C50R (# 11) Transfer Sept. 2013

Appendix & Back up C100

12 GeV Procurement Breakdown All costs in DIRECT Dollars 12 GeV Procurements SCALED 2010-2015/16 1.12 1.5 Procurements (from Cost Book 1.03.001.001 as of 12/16/2011) Cost Book -10 CMs Divide by 10 CMs X Inflation X factor-small lots 1.03.001.001.001 Cavity String Procurements & tools Exp. & M.Shop $215,019 $21,502 $24,140 $36,210 < 50K $283,226 $28,323 $31,798 $47,697 1.03.001.001.001 Cavity String Procurements & tools >50K > 50K $7,517,408 $751,741 $843,979 $1,265,969 1.03.001.001.002 Space Frame Procurements $56,442 $5,644 $6,337 $9,505 $364,216 $36,422 $40,891 $61,336 1.03.001.001.002 Space Frame Procurements >50K $1,122,748 $112,275 $126,051 $189,076 1.03.001.001.003 CM Procurements (Vac Ves & end cans etc ) $1,448,131 $144,813 $162,582 $243,872 $748,403 $74,840 $84,023 $126,035 $4,142,640 $414,264 $465,094 $697,641 1.03.001.001.004 Installation Assembly Tooling $392,101 $12,386 1.03.001.001.004 Installation Assembly Tooling (>50K) $38,835   16,341,556 $1,589,823 $1,784,895 $2,677,342 444 Procurements (from Cost Book for Construction Phase 1.03.001.002-.006 1.03.001.002 Cavity String < 50K $274,000 $27,400 $30,762 $46,143 1.03.001.002 Cavity String > 50K >50K $37,000 $3,700 $4,154 $6,231 1.03.001.003 Cryomodule Assembly <50K $345,000 $34,500 $38,733 $58,100 1.03.001.004 Acceptance Test $82,000 $8,200 $9,206 $13,809 1.03.001.005 Cryomodule Install $26,000 $2,600 $2,919 $4,379 1.03.001.006 Microphonics $40,000 $4,000 $4,491 $6,736 $804,000 $80,400 $90,265 $135,398 Total Procurement Cost for One Cryomodule $1,670,223 $1,875,160 $2,812,740 based on 10 (FY2010) based on 10 (FY2015) for reduced Qty Divide 12GeV by 10 x 1.09 (CPI 2010-2015) x 1.03 (escalation for FY16) x 1.5 for small lots

Enhanced capabilities 12 GeV Cryomodules 2010-2013 Supports CEBAF Design, procure, process, assemble, test, commission 10 new cryomodules providing 107.5 MV each (eight 19.2 MV/m, 0.7 m cavities each), < 300 W @ 2.07 K, new designs included: New 7 Cell Cavity design “Low Loss” New tuner, HOM couplers, HOM probe feedthroughs New RF window design New cavity processing methods Cavity New Hall Add arc Enhanced capabilities in existing Halls Add 5 cryomodules 20 cryomodules 12 GeV Cryomodule