1. Undulator Cost & Schedule Patric Den Hartog, ANL April 24, 2002
Undulator WBS
Costing Methodology
Costing Highlights
Undulator Systems Schedule
Cost Rollup
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

2. Undulator Systems WBS 1.2.3 Undulator Systems WBS 1.2.3
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

3. Undulator Systems Layout
Entrance transition
11 cells
3 3.4 m undulators
Magnetic structure and movers
Vacuum chamber
2 short breaks
Electron beam diagnostics
Focusing and steering
1 long break
X-ray diagnostics
Exit transition
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

4. 1.2.3 Undulator Systems 1.2.3.1 Undulator systems PED
Undulator mechanical
Undulator vacuum
Undulator diagnostics
Undulator power supplies
Undulator electromagnets
Undulator controls
Undulator PPS
Undulator magnetic measurement facility
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

5. Costing Methodology Costs estimated by cognizant engineers/scientists
Ordinal List of components developed from CDR
Costs based on experience with similar systems
Undulator costs estimated two ways
Based on previous procurements of similar devices
Based on cost of LCLS prototype
Contingency
Assigned on the basis of the completeness of the design, comparison with recent comparable components, and knowledge of catalog prices where available
WBS does not include installation
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

6. 1.2.3.1 Undulator System PED Design and prototype systems
Assembly and installation procedures
Prepare bid packages
In particular---
Undulator mechanical system PED
2nd undulator prototype re-using permanent magnets
Undulator vacuum chamber prototyping including short and long breaks
Protoype short and long breaks with diagnostics
High speed CCD imaging software
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

7. 1.2.3.2 Undulator Mechanical 1.2.3.2.1 Undulator module 1.2.3.2.2
33 undulators
Dominates cost of WBS 1.2.3
High precision movers for alignment
33 PM quads and positioners
Undulator supports
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

8. Basis of undulator cost estimate
Two methods compared
Cost estimate based on cost of similar devices
Multiply by ratio for length
Accounts for additional poles and magnets
Adjust for elements that are clearly more expensive
Titanium strongback and machining
Estimate setup cost for vendor for magnetic measurements
472 K$/3.4 meter segment
Cost estimate based on prototype cost
Add up cost of components
Estimate labor for assembly and magnetic measurements
Add in factor for profit and overhead (x2)
474 K$/3.4 meter segment
Too close to be believed!
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

9. 1.2.3.3 Undulator Vacuum Vacuum chamber through undulator
Demanding tolerances on wall outgassing and smoothness
Prototyping required (in )
Difficult engineering to fit focusing, steering , and diagnostics into breaks and maintain smooth transitions
Many standard components are catalog items
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

10. 1.2.3.4 Undulator Diagnostics
Wire scanner
Pulsed current monitor
RFBPM
Cerenkov detector
Alignment laser
OTR diagnostics
X-ray diagnostics
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

11. 1.2.3.5 Undulator Power Supplies
Power supplies for the 35 vertical and 35 horizontal correctors
Standard tolerances
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

12. 1.2.3.6 Undulator Electromagnets
35 horizontal and 35 vertical correctors
Cost based on engineering estimates of similar magnets
Risk based on difficult space constraints
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

13. 1.2.3.7 Undulator Controls Controls based on familiar EPICS platform
Vacuum controls
Motor controls
Diagnostic controls
Power supply controls
EPICS hardware
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

14. 1.2.3.9 Undulator Measurement System
Costs based on system in use at APS
5.5 m granite bench with precision linear encoder
Motion system for Hall probes and coils
Instrumentation
Pulsed wire system
Assembly and shipment to SLAC
Computer system
Installation supervision
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

15. Undulator System Schedule
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

16. Undulator Procurement Plan
Undulator delivery is critical path for project completion
3 yr construction schedule for 33 undulators is a challenge
Permanent magnets, poles, and Ti strongback are long-lead time delivery
If undulators are bid in year 2 so that award can be made as soon as construction funds are available, up to six months can be saved
The required delivery rate may also be reduced through the use of a “Multiple Procurement Option”
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

17. Undulator Schedule - Single Procurement Option
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

18. Undulator Schedule -Multiple Procurement Option
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

19. 1.2.3 Undulator Cost Estimate (FY02 Dollars, Thousands)
Name
PED
Construction
Contingency
Total
% Contingency
1.2.3
Undulator
$ 7,124
$ 31,994
$ 10,831
$ 49,948
28%
$ 2,390
$ 9,514
34%
Mechanical
$ 21,484
$ 5,429
$ 26,914
25%
Vacuum
$ 2,010 $
$ 2,678
33%
Diagnostics
$ 4,559
$ 1,193
$ 5,752
26%
Power Conversion $ $ $
Magnets $ $ $
Controls
$ 2,626 $
$ 3,339
27%
PPS $ $ $
36%
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

20. 1.2.3.2 Undulator Mechanical (FY02 Dollars, Thousands)
Name
PED
Construction
Contingency
Total
Undulator Mechanical
$ ,484
$ 5,429
$ 26,914
Undulator Module
$ ,725
$ 4,931
$ 24,656
Undulator Quadrupole
$ ,052 $
$ 1,408
Undulator Hardware Supports $ $ $
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL

21. 1.2.3.3 Undulator Vacuum (FY02 Dollars, Thousands)
Name
PED
Construction
Contingency
Total
Undulator Vacuum
$ 2,010 - $
$ 2,678
Undulator Vacuum Valve $ $ $
Undulator Pump $ $ $
Undulator Vacuum Gauge $ $ $
Undulator Vacuum Pipe $ $ $
Inter-Undulator Chamber $ $
$ 1,307
Vac,. Plumbing, Flanges, Gaskets, Hardware $ $ $
LCLS DOE Review, April 24, 2002
Patric Den Hartog, ANL