the cost & schedule to accomplish the transition
DESCRIPTION
The Cost & Schedule to Accomplish the Transition. Proposed SLAC Controls Upgrade December 1, 2010 Ray Larsen. Outline. Cost Model Strategy COTS plus limited In-House development Industry support - physics applications modules Resources - PowerPoint PPT PresentationTRANSCRIPT
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The Cost & Schedule to Accomplish the Transition
Proposed SLAC Controls UpgradeDecember 1, 2010
Ray Larsen
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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
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3SLAC Linac Controls Upgrade Proposal 12-01-10
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
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4SLAC Linac Controls Upgrade Proposal 12-01-10
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
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5SLAC Linac Controls Upgrade Proposal 12-01-10
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
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6SLAC Linac Controls Upgrade Proposal 12-01-10
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 interface6. Vac-ion pump controller interface7. Wire scanner movers (Hytek)
• PMC Card AMC Adapter8. Fast Frame grabber for Profile Monitor
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7SLAC Linac Controls Upgrade Proposal 12-01-10
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.)
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8SLAC Linac Controls Upgrade Proposal 12-01-10
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.
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9SLAC Linac Controls Upgrade Proposal 12-01-10
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
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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
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11SLAC Linac Controls Upgrade Proposal 12-01-10
RF Upgrade AIP Manpower
RF 12 Mo. through Q1-12
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12SLAC Linac Controls Upgrade Proposal 12-01-10
Controls Total, Infrastructure & RTM MW
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13SLAC Linac Controls Upgrade Proposal 12-01-10
Controls AIP Budget Summary
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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
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15SLAC Linac Controls Upgrade Proposal 12-01-10
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
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16SLAC Linac Controls Upgrade Proposal 12-01-10
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
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17SLAC Linac Controls Upgrade Proposal 12-01-10
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
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18SLAC Linac Controls Upgrade Proposal 12-01-10
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
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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 slideLCLS RF Upgrade AIP Proposal 10/20/2010
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20SLAC Linac Controls Upgrade Proposal 12-01-10
Summary Schedule
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21SLAC Linac Controls Upgrade Proposal 12-01-10
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
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22SLAC Linac Controls Upgrade Proposal 12-01-10
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