LCLS Klystron Modulator AIP Sec 28 AIP Review Feb 2010

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Presentation transcript:

LCLS Klystron Modulator AIP Sec 28 AIP Review Feb 2010 Briant Lam and Ben Morris

Project Description Refurbish Sector 28 klystron modulators to demonstrate improvements to the safety and reliability of the 6575s that will enhance LCLS Safety: Segregate electrically hazardous circuits Control electronics in “touch safe” enclosures Reliability: Replacing obsolete and problematic relay logic control system with a modern PLC Redesign high failure components Internal voltage regulation, alternative to VVS

Prototype Status Construction completed Testing began with water load in B015 in November, continuing today

B015 Testing Status Run at 21.5kV & 30Hz, several hours of operation Validate higher rep rate (limited power) Finalize documentation

Prototype: – April 2010 Production: May – Sept. 2010 Schedule Complete B015 testing: 3/19 Install at 28-1: 3/30 Design validation (full power testing): 4/30 Production: May – Sept. 2010 Contingent upon completion of documentation and finishing validation of prototype unit: 5/3 No contingency to order long lead parts: now Modulator production rate: 3 weeks/modulator Sector 28 complete: 9/30 (22 weeks)

Cost Project Budget: $441k Cost to Date (-1/10) Cost to Complete $362k for ED&I and B&H ED&I cost overrun Cost to Complete Prototype & documentation (ED&I): $20k Production (B&H) Seven modulators M&S: $20k/modulator (8% G&A assumed) Labor: $12.5k/modulator (53% G&A assumed) Total: $227k Total cost-to-complete: $247k

Cost Budget Actual ED&I 2010-Jan $272k Cost to complete $20k Total B&H $90k $227k $230k $317k ($87) Contingency $88k Total Cost $441k $609k ($168)

Budget Overruns Issues ED&I B&H Contingency: enough for B&H overruns Assumed very little engineering development when in reality considerably more was needed B&H PLC costs: $1k estimate vs. $10k actual (EPICS) Contingency: enough for B&H overruns

Change Scope Increase Funding Potential Solutions Existing funding sufficient to complete prototype and two production units Limited statistical sample to evaluate efficacy of improvements with only 3 units in operation Increase Funding Additional $168k allocation in FY10 Complete S28 by end of FY10 Defer additional $168k allocation until FY11 Finish prototype, build remaining 2 in FY 2010 Complete remaining 5 units during FY11-Q1 Limited delay in amassing operational data