1. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 1 IR Quadrupole Cost and Schedule Marc Kaducak LARP Review June 10, 2013

2. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 2 Outline Scope Recap Summary Schedule Cost and Schedule Assumptions Cost and Schedule Estimate Methodology Cost Breakdowns Labor and Cost Time Phased Profiles Summary

3. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 3 Scope Recap Prototyping SQXF 6 coils in US, 12 at CERN (6 RRP, 6 PIT) 2 Mirrors, SQXF1, 1b, 2, 2b magnets LQXF 16 coils LQXF1, 1b, 2, 3(w/new structure), 3b magnets Production US would provide cold masses for Q1 and Q3. Total of twenty(20) cold masses, including two(2) “pre-series”, two(2) spares. Tested in US. CERN will integrate into cryostats. With a yield of 8/9, ninety(90) coils would be fabricated.

4. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 4 High Level Schedule

5. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 5 Production Cost and Schedule Assumptions 1.CD-3 in FY2017. CD-0,1,2 schedule unclear, but assume that CD-like readiness is required on timeline consistent with CD-3 2.Production window is FY2017-2021 a)Goal is >1 year schedule contingency relative to CERN schedule. Deliver production cold masses by end of FY21 for 10/2022- 3/2023 installation in LHC. 3.Funds for SC wire purchase available in FY2015. Up front payment of 13% required, with another 27% less than one year later. Overhead only applied to first $2M (based on current BNL policy) 4.CERN Hi-Lumi TDR is complete in 2015. 5.FNAL and BNL each produce coils -> cold masses. LBNL performs cabling and structure sub-assembly. 6.Coil yield is 8/9. 7.Test facility upgrades complete in time for production.

6. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 6 Cost Estimate Methodology 1.Bottom up estimate. Lots of supporting documentation available (master spreadsheet with 25+ tabs) 2.No Resource Loaded Schedule, but time phased with escalation, overheads. 3.For Production - Overall contingency of 35%. 4.For FNAL test Facility Upgrade – Overall Contingency of 30%. 5.For Prototype magnets – Contingency is Scope. 6.Labor rates from official FNAL database, BNL average rates. ItemBasis of EstimateEstimator(s) Conductor, CableOxford discussionsA. Ghosh Coil Parts, Tooling, Equipment LHQM. Anerella, R. Bossert, A. Nobrega, J. Schmalzle, M. Yu Coil LaborLHQ, 11 Tesla experienceM. Anerella, R. Bossert, A. Nobrega, J. Schmalzle, M. Yu Structure LaborLQD. Cheng TestingMTF experienceR. Carcagno & team Prototyping phaseLARP Experience to dateG. Ambrosio, G.L. Sabbi

7. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 7 Production M&S Costs

8. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 8 Production Labor Profile FTEs (1768 hrs/yr) during Production Across All Labs Only ½ year of coil production Output is 24 coils Output is 32 Coils, 4 Cold Masses Output is 34 Coils, 8 Cold Masses Output is 8 Cold Masses

9. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 9 Prototyping, Production Combined Cost Profile Cost Profile ($AY, w/o contingency) No Contingency in these columns (see next slide)

10. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 10 Funding Types and Profile Funding Profile ($AY) Contingency included (spread uniformly by %)

11. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 11 Summary  No formal CD-0,1,2 schedule yet. The goal has been to prepare a reasonable and achievable plan that meets the CERN Hi-Lumi schedule with sufficient fidelity in the cost and schedule estimates.  Plans are not final and estimates are still estimates, but they have bases primarily in experience, scale-ups, vendor discussions. Lots of supporting documentation available.  Advance project funding is required for SC wire (CD-3 minus 2 years), tooling and equipment (CD-3 minus 1 year) production procurements, and also to complete the prototype program.

12. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 12 Backup

13. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 13 Guide to Cost Spreadsheets – Production Material Production Material All cost estimate spreadsheets included in file “IR_Quad_CostEstimate23-May-2013.xlsx” First four sheets are probably of most interest: “Summary” – roll up of R&D, construction “RandD” – SQXF and LQXF “Material” – M&S for production cold masses (MQXF) “Labor” – labor for production cold masses (MQXF) The rest are details supporting sheets

14. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 14 Guide to Cost Spreadsheets – Production Labor

15. LARP Review, June 10, 2013Magnet Cost and Schedule – M. Kaducak 15 Major Cost Elements 1.20,790 meters strand 2.4 sets of reaction tooling, 8 sets of impregnation tooling 3.2 new reaction ovens. 4.Parts for 16 LQXF coils, 90 production coils. 5.Production tech labor (~30 techs at peak production). 6.Test facility upgrades. ItemPrototyping Estimate Construction Estimate GARD Contribution First sets of toolingX Duplicate toolingX LQXF conductor/cableX MQXF conductor/cableX New ovensX FNAL Test Facility UpgradeXX