1 the cost & schedule to accomplish the transition proposed slac controls upgrade december 1,...

1

The Cost & Schedule to Accomplish the Transition

Proposed SLAC Controls Upgrade

December 1, 2010

Ray Larsen

2SLAC Linac Controls Upgrade Proposal 12-01-10

Outline

• Cost Model Strategy– COTS plus limited In-House development– Industry support - physics applications modules

• Resources– Hardware-Software-Firmware engineering; ARD xTCA

program support; M&S• Budgets

– Controls; RF• Schedule Development

– MTCA infrastructure, IOC & Timing, Controls subsystems, RF Subsystem


Telecom Industry Strategy

• Platform developed as open Telecom standard by group of strong competitors – Major change in philosophy of all company

products proprietary and non-interchangeable• Why? Better for company and customer to

have products guaranteed to work together• Company focuses resources on unique

payload products, shorter time to market, lower development costs


Physics Cost Model Strategy

• Base our standard on new platform adding improved I/O, timing features for physics– Benefit from industry technical assistance and

building prototypes at their expense to launch, quicker learning curve for users

– Physics package attracting Telecom, Industrial Control manufacturers

– With market growth should benefit from multiple vendors and price competition


Hardware Design Time/Cost Savings

• Dual Module Simplifies Design– Develop COTS solutions for complex AMCs– We plan to use no in-house AMC designs – Leverage COTS designs to multiple applications

with minimum RTM engineering time/cost– Complex AMCs cost 1-2 Py @$300K/Yr


Adapting Controls Subsystems

• Port existing front end interfaces onto RTMs• 4 & 10 Ch Fast ADCs w/DAC RTM adapters:

1. Stripline BPMs (2 types)

2. Toroids (2 types, Linac & Beam Containment), Profile Monitor Gated ADC (Same as above)

3. RF Feedback

• 3-Industry Pack RTM Adapters: 4. Profile Monitor Beam Length (BLEN)

5. Vacuum gauge controller interface

6. Vac-ion pump controller interface

7. Wire scanner movers (Hytek)

• PMC Card AMC Adapter8. Fast Frame grabber for Profile Monitor


Budget Cost Analysis

• Resource Cost Estimates– All tasks detailed – Resources identified – Discussed details w/ resources for estimates– Summed resources vs. draft schedule– Performed similar exercise for RF (already

approved AIP)– Totaled all manpower costs vs. time (24 mo.)


Hardware Cost Estimates

• MTCA Infrastructure– COTS based on actual quotes or vendor

budgetary quotes– Includes crate, power modules, Hub Controller,

Processor IOC, Timing Module– Timing module not yet a commercial item but

base cost on similar commercial products– Assumed infrastructure partly shared w/ RF AIP– First articles procured on ARD ILC R&D budget.


Hardware Costs 2

• Applications Modules– AMCs: ADC-DAC, 3-IP, PMC adapter

• ADC-DAC: Vendor quotes, DESY target (Strück); Vadatech quote pending

• 3-IP: quote in hand (TEWS)• PMC: Quotes pending (Vadatech,TEWS)

– US 2nd sources:• Buying first articles to specification, compatible RTM

– Timing • Source is Stockholm U., working to develop vendors

10

Controls Upgrade AIP R&D Manpower

Manpower FY11-120.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

Oct NovDec JanFeb MarApr MayJun JulAug SeptOct2 Nov2Dec2 Jan2Feb2 Mar2Apr2 May2Jun2 Jul2Aug2 Sept2

ControlsTotal MW

SLAC Linac Controls Upgrade Proposal 12-01-10


RF Upgrade AIP Manpower

RF 12 Mo. through Q1-12


Controls Total, Infrastructure & RTM MW


Controls AIP Budget Summary

14

Budget by FY for 1 RF Station (RA)

Funded In 2009 TOTAL

Costed In Costed In Costed In

FY 2009 FY 2010 FY2011 Funding

ED&I (Eng., design & inspection) 3.1 522 399 924

B&H (Buildings & hardware) 0 105 45 150

Contingency 0 0 305 305

Indirect Allocation 1.3 243 184 428

TOTALS 4 870 933 1,807


Estimated 10-Sector Cost

T. Himel

systemoption probability

average NRE (k$)

LI11-20 basic

LI11-20 deluxe

LI21-30 basic

LI21-30 deluxe

MPS 0 200 200 0 0Timing 0 608 608 608 608RF 0 2240 2240 2240 2240network 0 820 820 50 50corrector incl PS 0 608 608 0 0LGPS control 0 432 432 0 0LGPS 0 0 864 0 0solid state subbooster 0 0 1440 0 1440BCS readout 0 50 50 50 50BCS full system 750 0 750 0 750profile monitors 150 320 320 0 320toroids 100 80 80 0 0wire scanners 0 0 0 0 0modulator PLC+ upgrade 0 0 5000 0 4000racks 0 1512 1512 1512 1512vacuum CAMAC replacement 0 150 150 150 150vacuum rack mounted chassis 100 0 432 0 144PPS 0 0 0 0 0long haul cables 2048 2048 0 0crates 1150 1150 1150 1150temperatures etc 300 300 300 300

total 5110 11670 20156 6060 12714

edi_factor 1.6nsector 10manmonth_cost 25indirect_rate_labor 52%indirect_rate_MandS 9.40%

Assume LI11-20 Column costs

Solid state sub-booster required

Modulator PLC not required

BCS & Power Supplies Included

RF Station Unit Cost = $28K


Infrastructure Work Detail

INFRASTRUCTURE TASKS – CONTROLS + RF (ILC Standards Program) Hardware Tasks Task Description Status Resources Estimated

FTE MW 1. Crates 6 slot non-

redundant Engineering development units

Bring up crates in lab 2 units w/ Physics backplane in hand

Q. Yang, SW 0

2. Crates 12 slot fully redundant Production Units

Receive and test crates from different vendors

3 units on order from 2 vendors for delivery end November

Q. Yang, SW 3

3. MCH Hub Switches Bring up on Physics backplane; evaluate

3 units in hand; 1 to be delivered

Q. Yang, SW 1

4. Crate controllers (IOCs)

Bring up with Linux OS, develop EPICS environment

1 unit on hand (NAT), 4 units due November (Adlink)

Q. Yang, SW 4

5. Timing Module (U Stockholm for XFEL)

Receive Tx-Rx unit & bring up on Physics backplane; develop Rx commercial source

Test with commercial ADC; develop timing & trigger application driver

J. Dusatko, HW Q. Yang, SW

12 12

Total HW 12 Total SW 20 Total Infrastructure 32 MW


RTM Work Detail CONTROLS & RF MTCA RTM TASKS Generic AMC Model/Vendor Applications RTM Model Resource FTEs- MW 1. 4 Ch Fast ADC 16 bit

119 MSPS VAMC511/ Vadatech port to Physics 2-wide

Stripline Beam Position Monitors (2 types)

RTM-1 SMA Coax in Signal conditioning, filtering

20

Toroid Beam Current Monitors (2 Types)

RTM-2 SMA Coax in Toroids & GADC

20

Profile Monitor BLen gated ADC (GADC)

RTM-2 Include gating feature

4

2. 10 Ch fast ADC 16 bit 119 MSPS, 2 DAC Ch at 238 MSPS

Vadatech converted VAMC511 or Struck ABA SIS8300

RF feedback controller and RF interlock signals

RTM-3 Coax in SMA Connector adapter from RF down-mixer chassis

4 (1st prototype cmplt.)

3. 3-Industry-Pack Adapter w/ RTM

TEWS Model TAMCxxx Adapted to Physics Platform

Profile Mon BLEN Actuate

RTM-4 Generic 3-IP High density I/O; Port SCSI, firmware; add IPMI

16

TEWS IPs Vacuum gauge readout; remote wakeup

RTM-4

12

TEWS IPs Vac-ion pump controller

RTM-4 8

Hytek IPs Wire scanners – movers- port xstg dsgn

RTM-4 8

4. PMC Adapter TEWS, Vadatech

Existing designs ported to MTCA Adapter w/ Rear I/O

Profile Monitor Camera frame grabber

RTM-5 Port firmware, EPCS from VME, add IPMI, high bandwidth

16

Total RTM 148 MW


RF Subsystem Work Detail RF Subsystem Tasks

Hardware Tasks Description Notes Resources Resources FTE MW 1. RF clock generation &

Down-converter chassis

3-board RF chassis with water cooled heat sink; generation low noise local oscillator for IF down mix; sample and DAC clocks

Standard Type N cables in, Subminax out to ADC Rear Transition Module

R. Akre, HW, 0.25 B. Hong, HW, 0.75 New HW, 0.75 S. Geng SW, 0.5

13 40 40 24

2. Modulator-Klystron interlock protection unit & SLED Tuner Driver, Solenoid PS, SSSB interface

Design, build stand-alone chassis with internal interlock FPGA; local display & controls options

Adapt existing I/O cables to rear panel stand-alone chassis (solution in hand)

J. Olsen, HW-FW, 0.6 S. Zheng, HW, 0.5 A. Young, HW, 0.1

30 25 6

3. System Firmware Develop firmware for RF system feedback

Test board w/ ADC-DAC supplied by SLAC

L. Doolittle (LBNL contract) HW FW

8.0

4. System Software Develop software for complete system incl. EPICS panels

S. Geng, SW, 0.5 24

5. Rack & cooling Develop sealed rack cooling system LCW heat exchanger inside existing rack

Investigate engineering & fab to specs by local company; field test

PCD Engr, HW 12

Totals HW-FW 174 Totals SW 48 Total RF Subsystem 222 MW Assumptions: Following are Separate AIP Projects: 1. Rack refurbishment including electrical 2. Solenoid PS replacement 3. Solid state sub-booster

19

Upgrade Schedule Development

• Three components– MTCA Infrastructure Support (ARD program)– RF Station Demo (Approved AIP in progress)– Control Station Demo (AIP Proposal)

• Integrated draft schedule– Shows all relationships & milestones– Resource loading needs further work but first

order matches available staff plus 3 new– Full Preliminary will be posted; top summary

next slide

LCLS RF Upgrade AIP Proposal 10/20/2010


Summary Schedule


Conclusions

• RF subsystem critical path – Low-noise component evaluations for best

possible phase stability ~10fs – Firmware & software

• Controls critical path– Hardware development of RTMs for 8 Apps– Firmware & software

• Both schedules needs adjustment– Some early items shown are behind schedule


Conclusions 2

• Resources & Budgets• RF:

– Estimate 1 additional FTE HW, SW– Budget & resource analysis still in progress

• Controls:– Estimate 2 additional FTEs at 1 HW, 1 SW– Included in proposed budget

• Management – Needs to be in both budgets but is not yet

1 the cost & schedule to accomplish the transition proposed slac controls upgrade december 1,...

Documents

controls upgrade ai

cost schedule

base cost

linac beam containment

hardware costs

estimatessummed resources

multiple applications

vendor quotes