AIP Magnet Controls Cost Estimates by Kristi Luchini April 23, 2009

April 22, 2009 AIP Magnet Control Cost Estimates 1

AIP Magnet Controls

Cost Estimates

by Kristi Luchini

April 23, 2009

April 22, 2009 AIP Magnet Control Cost Estimates

STATED SCOPE

Scope on April 23, 2009• Add MCOR VME controls in LINAC Sectors 21, 24-29 (AIP Row 19)• Upgrade QE Magnet Controls in LINAC Sectors 21, 24-29 (AIP Row 20)• Update B136 Quad magnet controls in BSY (501B,51AGF) (AIP Row 37)• Upgrade LINAC Sector 21 reversing switch controls for Q21301 (AIP Row 42)• Controls for wigger magnet controls in DL2 for 51/52 WG1 (AIP Row 51)

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Motivation

Motivations on October 31, 2007• Equipment more than 20 years old and at end of useful life. Unreliable, lack of

available parts will affect future LINAC operations• Better short and long-term current stability• Interface with new EPICS-based control system for better diagnostics• Lower line harmonics, noise, power consumption

Motivations on April 9, 2008• Move all LCLS Magnet controls and monitor to EPICS as soon as possible due to

lack of support staff for the VMS controls system.

Motivations on April 23, 2009• Eliminate need for magnet software support in Controls LINAC Upgrade Project • The new fast feedback will be in EPICS which will not use SLC controlled devices,

which includes some LINAC correctors.• Reduce cost for April 2009 AIP Row 25 since PSC-II’s in sectors 21-BSY used by

SLC Magnet Controls will be decommissioned during upgrade.

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April 22, 2009 AIP Magnet Control Cost Estimates 4

1. DOWNTIME LENGTH

Present Understandings and Plan

Downtime 8 weeks

January 4 - March 1,2010

Build plan Refurbish racks and assemble/test in field

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2. TWO TO THREE BULK POWER SUPPLIES

Mode / PS Type SLC LCLS

Bulk 200A 139V 25A 17V

Boost 20A 17V 20A 3.7V

Change in rating and use of 3 bulk PS:

1. Better match of rating to load (225A – 200A or 25A) in SLC and LCLS modes

2. Less expensive, smaller and COTS

December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade

December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 6

THE EXISTING LINAC QE Bulk


THE REVISED BULK PS TOPOLOGY

Bulk power supplies were identified as the critical path item if custom designed – COTS desired


CONTROL OF 3 PS DIAGRAM

Black items are provided by power supply manufacturer\

Red items are provided by SLAC


Network Switchswh-li21-nw02

EPSC (QUAD Boost 401)





EPSC( QUAD Boost 901)



Terminal Serverts-li21-nw01

EPSC (QUAD Bulk)

Ethernet

Network Block Diagram for QE Upgrade (typical sector)

EPICS IOC

MCOR

Bulk

Timingfbck

ca

crate

MCOR Upgrade

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Software 2-day @ $700/day $14001. Database & Displays2. ChannelWatcher, Archiver, SCORE, Alarm Handler ,LEM , Oracle

Hardware1. 3U Elma VME Crate (4-slot) $ 35002. EVR PMC Module $ 25003. MVME6100-0161 CPU $ 40004. Timing Cables (fiber optic - duplex) $ 10005. Intra-rack network cables (Ethernet=3, serial=1) $ 1006. Intra-rack MCOR-to-VME cable mod w/ SCS-2 connector (2) $ 0 (PCD)7. Intra-rack cables (cat6 and mcor to vme) $ 1508. Acromag IP Carrier AVME9670 w/P0 $ 7009. Hytec IP-ADC-8413 +/-10V, 16-bit, 16-chan adc $ 250010. Acromag ip231-16E +/-10V, 16-bit,16-chan dac $ 140011. Acromag Trans 200 Transition module $ 300

– Total M&S: $1515012. ED&I 2-days @ $550/day $ 110013. Labor 1.25 days @ $450/day $ 562.50

Total Hardware: $16812.50 Total Software: $ 1400.00 without Burden and Contingency Total: $18212.50

Contingency 10% of M&S: $ 1515.00 Indirect 8% of M&S: $ 1212.00 Indirect 45% of Labor: $ 883.13

with Burden and Contingency Total: $21822.53

8 Sectors Total without Burden and Contingency: $145,7008 Sectors Total with Burden and Contingency: $174,540

Note: optional use of an mvme3100-1263 CPU and MVME721-101 with transition module will reduce the cost by $1,700.00 per sector, which would reduction the total cost of M&S by $16,100,

Controls LINAC Sectors 21, 24-292009 AIP Cost Estimate for MCOR Upgrade in Row 19

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Controls Cost Estimate for QE Upgrade in LINAC Sectors 21,24-29

2009 AIP Row 20 & 42Software 3-day @ $700/day $2100.00

1. Database & Displays 2. ChannelWatcher, Archiver, SCORE, Alarm Handler ,LEM , Oracle

Hardware1. Ethernet Switch: 10 ports total (9-epsc, 1-terminal server) $ 02. Terminal Server: 9 ports total for epsc $ 1200 3. Intra-rack network cables (cat6) $ 1200

Total M&S: $ 2400

4. ED&I 2-days @ $550/day $ 11005. Labor 3-days @ $450/day $ 1350

Total Hardware: $ 4850 Total Software: $ 2,100

without Burden and Contingency Total: $ 6950

Contingency 10% of M&S: $ 240 Indirect 8% of M&S: $ 192Indirect 45% of Labor: $ 1552.5

with Burden and Contingency: $8934.5

7 Sectors Total without Burden and Contingency: $48,6507 Sectors Total with Burden and Contingency: $62,542

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Controls Cost Estimate for B136 Dipole and Quadrupole Upgrade (50B1/31AGF)

2009 AIP Row 37

Software 1-day @ $700/day $700

1. Database & Displays

2. ChannelWatcher, Archiver, SCORE, Alarm Handler ,LEM , Oracle

Hardware

1. Ethernet Switch: 2 ports total $ 0

2. Terminal Server: 2 ports total $ 0

3. Intra-rack network cables (cat6) $ 200

Total M&S: $ 200

4. ED&I 1-days @ $550/day $ 550

5. Labor 1-days @ $450/day $ 450

Total Hardware: $ 1200

Total Software: $ 700


Contingency 10% of M&S: $ 22

Indirect 8% of M&S: $ 17.6

Indirect 45% of Labor: $ 517.5

with Burden and Contingency Total: $ 2457.1

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Software 1-day @ $700/day $700

1. Database & Displays

2. ChannelWatcher, Archiver, SCORE, Alarm Handler ,LEM , Oracle

Hardware

1. Ethernet Switch: 2 ports total $ 0

2. Terminal Server: 2 ports total $ 0

3. Intra-rack network cables (cat6) $ 200

Total M&S: $ 400

4. ED&I 1-days @ $550/day $ 550

5. Labor 1-days @ $450/day $ 450

Total Hardware: $ 1400

Total Software: $ 700


Contingency 10% of M&S: $ 40

Indirect 8% of M&S: $ 32

Indirect 45% of Labor: $ 517.5

with Burden and Contingency Total: $ 2689.5

Controls Cost Estimate for LCLS Vertical Wigger Magnet in DL2 (51/52 WG1)

2009 AIP Row 51

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Cost Breakdown Summary

Magnet Controls AIP - FY09 (costs in k$)

Item AIP Row 19 (note) AIP Row 20 & 42 AIP Row 37 AIP Row 51 Totals

EDI 8.8k 7.7 0.55 0.55 20.4

MSL 136.9 41.0 1.35 1.55 183.9

Burden 16.76 12.3 0.6 0.55 33.65

Contingency 12k 1.7 0.03 0.04 13.27

Grand Total 176.46 62.7 2.53 2.69 251.22

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Note: AIP Row 19optional use of an mvme3100-1263 CPU and MVME721-101 with transition module will reduce the cost by $1,700.00 per sector, which would reduction the total cost of M&S by $16, 100

Note: AIP Row 20,42,37 and 51The majority of the cost the cost will be in FY09, with a small percentage of labor in FY10 for labor.However, if the downtime is delayed the labor cost can be shifted to FY10


4

3

2

1 Debug Lan1 Lan2 E V R P M C MVME6100

Slot

Front View

VME Crate and I/O

AVME9670

4

3

2

1

Slot

Trans 200Port D Port C Port B Port A

Rear View

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P1

P2

MVME6100

J19

J93

J9

Debug

Lan1

Lan2

J21

J23

J22

J24

Lan2

Lan1

Debug

MVME6100

Front View

Top View

J12

J14

J11

J13

PC

I Me

zzan

ine

PC

I Me

zzan

ine

PM

C1

PM

C2

EVR-PMC

VME I/O CPU with Event (Timing)

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P1

A

B

C

D

A9670 TRANS-200

Acromag IP231-16E

Hytec IP-ADC-8413

P1

VM

E

Bac

kpla

neP2 P2

P0P0

Slot A

Slot B

Slot C

Slot D

Top view Modules

VME I/O For MCOR Control and Monitor

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Documents

AIP Magnet Controls Cost Estimates by Kristi Luchini April 23, 2009