Nov. 17, 2008 ILC08 Global Design Effort 1 Americas KlyCluster Cost Analysis Overview Tom Lackowski...

Nov. 17, 2008 ILC08 Global Design Effort 1

Americas KlyCluster Cost Analysis Overview

Tom Lackowski

RF & Sum reported by Peter H. Garbincius

Agenda• Afternoon Sessions - Klystron Cluster Design• • Session Description: This session will be used to review the Klystron

Cluster alternative for HLRF equipment distribution and its impact on CFS regional design options. Current work to date will be presented. It is intended that representatives from Working Group 1 as well as representatives of the HLRF and LLRF efforts will participate in this session.

• Session Objective: Establish an understanding within the technical groups of the CFS design and cost savings associated with this Klystron Cluster alternative.

• 13:30 – 14:15 Overview from FNAL (T. Lackowski)• 14;15 – 15:00 Overview from KEK (A. Enomoto)• 15:00 – 15:45 Overview of HVAC for Single Tunnel (L. Hammond)• 15:45 – 17:00 Overview of Cost Impact (P. Garbincius)• 17:00 – 18:00 Discussion


• August ‘08 we were introduced to the KlyCluster concept of RF distribution.

• September ’08 we were requested to develop a cost analysis of KlyCluster compared to the RDR cost.– Cost Analysis addressed only the Main Linac– Employed the tools developed for the RDR

cost estimating to make the analysis.– Used Americas Basis of estimate


Bullet List

• Subtractions, Changes, and additions were identified for each WBS of the Main Linac estimate.


• Cost Comparison Methodology and Scope– The Americas RDR Main Linac Estimate was

used as the basis for the comparison.– The site independent WBS sections (Electrical,

Safety, Handling Equipment, and Survey and Alignment) are included and have been considered.

– The RDR unit costs used in the comparison estimate.


Main Linac Configuration

• Four shafts added for RF Waveguides.



• The cost estimate was revised @ the lowest level of the RDR estimate, using the same back-up pricing details.

Major Civil Changes

• Civil cost reduced by 28% (relative to Main Linac)

• + Added four; 3 meter diameter shafts• + Added four (4) sites• +Added eight (8) full and 2 half buildings for

housing KLY Cluster and rack equipment.• - Eliminated Service Tunnel: Maintained 4.5

meter tunnel Diameter– + Added 28 Refuge Areas

• - Reduced caverns volumes by 25% (comparison made using a corrected excavated volume for caverns)


Revised Tunnel Cross Section


RF Building Layout


Life Safety Analysis

• NFPA 520-2005 (Subterranean Spaces) Prescribes 2 paths of travel to an exit or refuge area. The travel distance to be less than 610 meters.


Areas of Refuge

• Using the new shafts needed for the RF as exits, one area of refuge is required between shafts. Additional alcoves included for electrical switchgear, transformers and racks.


Area of Refuge


Air Treatment and Process Water

• Air Treatment increased by 25%• + Added HVAC for the 4 additional shafts• - Eliminated tunnel fan coils• Process Water decreased by 54%• - Eliminated chilled water• + Reduced diameter of tunnel process piping

but used stainless to distribute LCW • -- Eliminated tunnel LCW Skids


Process Water Plants



Kly Cluster Scheme Process Water System

Rough Costing of Kly Cluster Aug 15 -21 2008• Per RF Heat Load=Used

loads & DT from C.A. emails• Placeholder on the Kly

distribution• Terminate with valve to RF

pipe• Negligible 1KW heat load to

air from rack (email J.C. 8/13/08)=No air cooling in tunnel

• All air cooling in surface (see Lee’s air treatment)

RF Pipe4 KW @ 21.6F DT(C.A. Email 7/21/08)

Loads/Circulators38KW per RF@ 36F DT(C.A. Email 7/29/08)

RF Pipe in Shaft30 KW ea@ 21.6F DT(C.A. Email 7/21/08)

RF in surface68.6 KW per RF@ 48F DT(C.A. Email 7/21/08)

Global Design Effort

Surface RF Loads Used for Costing

Nov. 17, 2008 ILC08 17

Surface RF Loads (updated)

Nov. 17, 2008 ILC08 Global Design Effort 18Nov. 17, 2008 ILC08

Overall Main Linac Air Flow


Tunnel Air Flow• Normal air flow and fire air flow below


Other Areas

• Electrical reduced by 25% - Judgment used, reasoning that the electrical distribution reduced with KLY cluster scheme; elimination of Service Tunnel electrical distribution.

• Piped Utilities increased by 370% due to automatic fire suppression in Beam Tunnel (NFPA 520 requirements for single tunnel)

• Reduced Safety Equipment by 20% - Eliminate potable fire suppression units.


Summary

• Functional Requirements used in the RDR have been maintained.

• Life Safety further study.• Changes in the costs are a reflection of the

KLY Cluster scheme only; potential savings from other value engineering ideas have not be incorporated.

• corresponds to -4.9% savings wrt ILC RDR est


RF System Modifications

• Estimates from Chris Adolphsen, July 28, 2008• 300 MW RF pipe: 1,370 meter per 30 RF units

(PHG geometric guess) – scale to 560 RF units

adds + 0.4% wrt total ILC RDR estimate• Coaxial RF Couplers: scale to 560 RF units

adds + 0.2% wrt total ILC RDR estimate• Subtract: 22 m WR 650 waveguide per RF unit

Ray Larsen: subtracts - 0.05% wrt ILC est• Summing CFS + RF =>

- 4.4 % savings wrt to Americas’ ILC RDR est.


Peter’s final comments:

• Similar considerations apply to the RTML CF&S and RF components => - 4.6 %

• Need better estimates for the RF pipe and coaxial couplers

• If ILC can live with single tunnel for ML,

ILC can probably live with single tunnel almost everywhere

• This is example of a “what-if” feasibility study providing an order of magnitude impact

in order to decide whether proof-of-principle R&D is worth potential savings


• Thank-You for your attention.


Nov. 17, 2008 ILC08 Global Design Effort 1 Americas KlyCluster Cost Analysis Overview Tom Lackowski...

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