1. C75 Review 21Jan2016 Cost Estimate
McEwen - Rev. 14

2. 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

3. 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

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

5. C50 Costs – scaling to FY16

6. General Cost assumptions for C50
C50R (# 11) Transfer Sept. 2013
Based on C50 # 11 + escalation
C 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

7. 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 C 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

8. C100 Costs – scaling to FY16

9. General Assumptions for C100
Ten (10) of C100 were built from
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 …….

10. 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 ) x (~ 3% for Fy2016)
1.5 X 12 GeV Procurements due to small lot sizes
JLAB Tooling deleted (existing can be re-used)

11. Summary : C100 Cryomodule in FY16
Cost Book FY
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

12. C75 Costs – scaling to FY16

13. 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
C 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

14. 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

15. 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

16. Thank you for your attention

17. 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

18. Back Up – Appendix

19. 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

20. Appendix & Back up C50/C75

21. 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
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
Field Emission Mitigation (SRFFEM)
Un Funded
$147,995
$30,000
$177,995
C50 R&D - Magnetic Hygiene - C75HY
26.0
$76,543
$10,000
$86,543

22. 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

23. 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

24. 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 $
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

25. 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 $
Electrical Work
RF Power Commissioning
$ 1,000.00
LLRF Commissioning
Total (weeks) 5 18 39
18.8
80.8

26. 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

27. CEBAF C20 upgrade to C50 C20 CEBAF 42.25 Cryomodules 1987-1993
Supports CEBAF
C20 CEBAF Cryomodules
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

28. Appendix & Back up C100

29. 12 GeV Procurement Breakdown
All costs in DIRECT Dollars
12 GeV Procurements SCALED /16
1.12
1.5
Procurements (from Cost Book as of 12/16/2011)
Cost Book -10 CMs
Divide by 10 CMs
X Inflation
X factor-small lots
Cavity String Procurements & tools
Exp. & M.Shop
$215,019
$21,502
$24,140
$36,210
< 50K
$283,226
$28,323
$31,798
$47,697
Cavity String Procurements & tools >50K
> 50K
$7,517,408
$751,741
$843,979
$1,265,969
Space Frame Procurements
$56,442
$5,644
$6,337
$9,505
$364,216
$36,422
$40,891
$61,336
Space Frame Procurements >50K
$1,122,748
$112,275
$126,051
$189,076
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
Installation Assembly Tooling
$392,101
$12,386
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
Cavity String < 50K
$274,000
$27,400
$30,762
$46,143
Cavity String > 50K
>50K
$37,000
$3,700
$4,154
$6,231
Cryomodule Assembly
<50K
$345,000
$34,500
$38,733
$58,100
Acceptance Test
$82,000
$8,200
$9,206
$13,809
Cryomodule Install
$26,000
$2,600
$2,919
$4,379
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 ) x 1.03 (escalation for FY16) x 1.5 for small lots

30. Enhanced capabilities
12 GeV Cryomodules
Supports CEBAF
Design, procure, process, assemble, test, commission 10 new cryomodules
providing MV each (eight 19.2 MV/m, 0.7 m cavities each), < 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