IR Quad Cost Estimate Status Marc Kaducak 02-Nov-2012 IR Quad Cost Estimate - M. Kaducak1

Options Considered IR Quad Cost Estimate Kickoff - M. Kaducak2 Case #DescriptionQty. MQXF (Q1, Q2, Q3) # 4m Coils # 6.8m Coils Comment 1 (aka 50%) Q1 AND Q spare = 10 (20 “half length” cold masses) 800Probably requires two labs. 2 (aka 25%) Q1 OR Q spare = 5 (10 “half length” cold masses) 400Possible with one lab. 3 (aka 100%) Q1, Q2, AND Q spare = Probably exceeds budget.

Scope for Case #1 All units are 150mm aperture ~4m length cold masses for Q1/Q3, cold tested and delivered to CERN Two(2) ~4m prototypes (one at each of two labs) Twenty(20) production units (ten at each of two labs) L2 managers included, but no overall project management or project controls. Cost estimates in this presentation do not include mirror, practice coils, short models. These are being prepared separately. IR Quad Cost Estimate Kickoff - M. Kaducak3

Assumptions and Parameters Used FNAL overhead rates used for all except cold mass assembly from LBNL and cable from BNL. FNAL labor rates used for all. CD-3 and production unit start is 01-Mar-2017 LBNL bladder and key design Yield is 8/9, total of 5 prototype and 45 production coils fabricated at each lab. IR Quad Cost Estimate Kickoff - M. Kaducak4

Scheme Two labs producing in parallel, synchronously Single test facility Two(2) reaction ovens at each lab Three(3) sets of winding and reaction/impregnation tools at each lab Additional set of prototype winding/curing and reaction/impregnation tools at each lab First ten(10) production units at each lab take twice as long to fabricate as remaining IR Quad Cost Estimate Kickoff - M. Kaducak5

Basis of Estimate Coil fabrication based on LQ, 11T experience (Ambrosio, Nobrega, Bossert, Yu). Magnet assembly from LBNL (Prestemon, Felice, Cheng, Hafalia). Cable from BNL (Ghosh) Testing from FNAL MTF (Carcagno) IR Quad Cost Estimate Kickoff - M. Kaducak6

Summary Schedule including R&D IR Quad Cost Estimate Kickoff - M. Kaducak7

8 Coil Fabrication Schedule Building Max Production Rate Assume that next coil can start when outer coil curing begins.

Coil Production at Max Rate IR Quad Cost Estimate Kickoff - M. Kaducak9

Learning curve IR Quad Cost Estimate Kickoff - M. Kaducak10 Assumed all activities for first 10 coils took 2x longer than the rest (except for fixed times in ovens) Outcome: First coil starts 01-Mar-2017, last coil finished 16-Oct Even with learning curve this is probably optimistic.

Cost Summary (50% case) IR Quad Cost Estimate Kickoff - M. Kaducak11

M&S Summary (sorry for font) IR Quad Cost Estimate Kickoff - M. Kaducak12

Labor Costs (sorry again for font) IR Quad Cost Estimate Kickoff - M. Kaducak13

FNAL and BNL comparison (based on 02-Jul-2012 BNL estimate) ItemBNLFNAL Mirror, Test CoilsYesNo Yield4/58/9 Total Schedule Start->FinishFY15->FY20FY14->FY21 Production ScheduleFY17->FY20FY17->FY21 Project Management, Controls YesNo Winding, Curing Tooling2 nd Mandrel at each lab3 sets at each lab + prototype tooling Reaction, Impregnation Tooling and Equipment 5 sets at each lab, oven for 5 coils 3 sets at each lab + prototype, one additional oven (clone of existing) Cable cost$208k/UL$277k/UL CM parts$361k$663k IR Quad Cost Estimate Kickoff - M. Kaducak14

25% Option Cost Summary IR Quad Cost Estimate Kickoff - M. Kaducak15

Conclusions Production scheme is aggressive and still requires more study and optimization Despite different approaches and some different boundary conditions, BNL and FNAL estimates are in fair agreement for this phase. IR Quad Cost Estimate Kickoff - M. Kaducak16

Backup IR Quad Cost Estimate Kickoff - M. Kaducak17

CERN 10-y plan LHC baseline plan for the next ten years. In terms of energy of the collisions (upper line) and of luminosity (lower lines). The first long shutdown is to allow design parameters of beam energy and luminosity. The second one, 2018, is for secure luminosity and reliability as well as to upgrade the LHC Injectors. 18 From Lucio Rossi

LHC Dipole Learning Curve (P. Fessia) IR Quad Cost Estimate Kickoff - M. Kaducak19