The Cost & Schedule to
Accomplish the Transition
Proposed SLAC Controls Upgrade
December 1, 2010
Ray Larsen
1
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
SLAC Linac Controls Upgrade Proposal 12-01-10
2
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
SLAC Linac Controls Upgrade Proposal 12-01-10
3
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
SLAC Linac Controls Upgrade Proposal 12-01-10
4
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
SLAC Linac Controls Upgrade Proposal 12-01-10
5
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.
5.
6.
7.
Profile Monitor Beam Length (BLEN)
Vacuum gauge controller interface
Vac-ion pump controller interface
Wire scanner movers (Hytek)
• PMC Card AMC Adapter
8. Fast Frame grabber for Profile Monitor
SLAC Linac Controls Upgrade Proposal 12-01-10
6
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.)
SLAC Linac Controls Upgrade Proposal 12-01-10
7
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.
SLAC Linac Controls Upgrade Proposal 12-01-10
8
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
SLAC Linac Controls Upgrade Proposal 12-01-10
9
Controls Upgrade AIP R&D Manpower
7.0
6.0
Oct
5.0
Nov
Dec
4.0
Jan
3.0
Feb
2.0
Mar
1.0
Apr
0.0
Manpower FY11-12
May
Jun
Controls
Total MW
SLAC Linac Controls Upgrade Proposal 12-01-10
10
RF Upgrade AIP Manpower
RF 12 Mo. through Q1-12
SLAC Linac Controls Upgrade Proposal 12-01-10
11
Controls Total, Infrastructure & RTM MW
SLAC Linac Controls Upgrade Proposal 12-01-10
12
Controls AIP Budget Summary
SLAC Linac Controls Upgrade Proposal 12-01-10
13
Budget by FY for 1 RF Station (RA)
Funded In
2009
TOTAL
Costed In
FY 2009
ED&I (Eng., design &
inspection)
Costed In
FY 2010
Costed In
FY2011
Funding
3.1
522
399
924
B&H (Buildings & hardware)
0
105
45
150
Contingency
0
0
305
305
1.3
243
184
428
4
870
933
1,807
Indirect Allocation
TOTALS
14
system
MPS
Timing
RF
network
corrector incl PS
LGPS control
LGPS
solid state subbooster
BCS readout
BCS full system
profile monitors
toroids
wire scanners
modulator PLC+ upgrade
racks
vacuum CAMAC replacement
vacuum rack mounted chassis
PPS
long haul cables
crates
temperatures etc
option
average LI11-20 LI11-20 LI21-30 LI21-30
probability NRE (k$) basic
deluxe basic
deluxe
0
200
200
0
0
0
608
608
608
608
0
2240
2240
2240
2240
0
820
820
50
50
0
608
608
0
0
0
432
432
0
0
0
0
864
0
0
0
0
1440
0
1440
0
50
50
50
50
750
0
750
0
750
150
320
320
0
320
100
80
80
0
0
0
0
0
0
0
0
0
5000
0
4000
0
1512
1512
1512
1512
0
150
150
150
150
100
0
432
0
144
0
0
0
0
0
2048
2048
0
0
1150
1150
1150
1150
300
300
300
300
total
edi_factor
nsector
manmonth_cost
indirect_rate_labor
indirect_rate_MandS
5110
11670
20156
6060
12714
1.6
10
25
52%
9.40%
SLAC Linac Controls Upgrade Proposal 12-01-10
Estimated 10Sector Cost
T. Himel
 Assume LI11-20
Column costs
 Solid state subbooster required
 Modulator PLC
not required
 BCS & Power
Supplies Included
 RF Station Unit
Cost = $28K
15
Infrastructure Work Detail
INFRASTRUCTURE TASKS – CONTROLS + RF (ILC Standards Program)
1.
2.
3.
Hardware Tasks
Task Description
Status
Resources
Crates 6 slot nonredundant Engineering
development units
Crates 12 slot fully
redundant Production
Units
MCH Hub Switches
Bring up crates in lab
2 units w/ Physics
backplane in hand
Q. Yang, SW
Estimated
FTE MW
0
Receive and test
crates from different
vendors
Bring up on Physics
backplane; evaluate
Bring up with Linux
OS, develop EPICS
environment
Receive Tx-Rx unit &
bring up on Physics
backplane; develop Rx
commercial source
3 units on order from
2 vendors for delivery
end November
3 units in hand; 1 to be
delivered
1 unit on hand (NAT),
4 units due November
(Adlink)
Test with commercial
ADC; develop timing &
trigger application
driver
Q. Yang, SW
3
Q. Yang, SW
1
Q. Yang, SW
4
J. Dusatko, HW
12
Q. Yang, SW
12
4.
Crate controllers
(IOCs)
5.
Timing Module (U
Stockholm for XFEL)
Total HW
Total SW
Total Infrastructure
12
20
32 MW
SLAC Linac Controls Upgrade Proposal 12-01-10
16
RTM Work Detail
CONTROLS & RF MTCA RTM TASKS
1.
Generic AMC
4 Ch Fast ADC 16 bit
119 MSPS
Model/Vendor
VAMC511/ Vadatech
port to Physics 2-wide
Applications
Stripline Beam
Position Monitors
(2 types)
Toroid Beam Current
Monitors (2 Types)
Profile Monitor BLen
gated ADC (GADC)
RF feedback controller
and RF interlock
signals
2.
10 Ch fast ADC 16 bit
119 MSPS, 2 DAC Ch at
238 MSPS
Vadatech converted
VAMC511 or Struck
ABA SIS8300
3.
3-Industry-Pack
Adapter w/ RTM
TEWS Model TAMCxxx
Adapted to Physics
Platform
Profile Mon BLEN
Actuate
TEWS IPs
Vacuum gauge
readout; remote
wakeup
Vac-ion pump
controller
Wire scanners –
movers- port xstg dsgn
TEWS IPs
Hytek IPs
4.
PMC Adapter
Total RTM
TEWS, Vadatech
Profile Monitor
Existing designs ported Camera frame grabber
to MTCA Adapter w/
Rear I/O
RTM Model
RTM-1
SMA Coax in Signal
conditioning, filtering
RTM-2 SMA Coax in
Toroids & GADC
RTM-2
Include gating feature
RTM-3
Coax in SMA
Connector adapter
from RF down-mixer
chassis
RTM-4
Generic 3-IP High
density I/O; Port SCSI,
firmware; add IPMI
RTM-4
Resource FTEs- MW
20
RTM-4
8
RTM-4
8
RTM-5
Port firmware, EPCS
from VME, add IPMI,
high bandwidth
16
20
4
4 (1st prototype
cmplt.)
16
12
148 MW
SLAC Linac Controls Upgrade Proposal 12-01-10
17
RF Subsystem Work Detail
RF Subsystem Tasks
1.
2.
Hardware Tasks
RF clock generation &
Down-converter
chassis
3.
Modulator-Klystron
interlock protection
unit & SLED Tuner
Driver, Solenoid PS,
SSSB interface
System Firmware
4.
System Software
5.
Rack & cooling
Description
3-board RF chassis
with water cooled
heat sink; generation
low noise local
oscillator for IF down
mix; sample and DAC
clocks
Design, build standalone chassis with
internal interlock
FPGA; local display &
controls options
Develop firmware for
RF system feedback
Develop software for
complete system incl.
EPICS panels
Develop sealed rack
cooling system LCW
heat exchanger inside
existing rack
Totals HW-FW
Totals SW
Total RF Subsystem
1.
2.
3.
Notes
Standard Type N
cables in, Subminax
out to ADC Rear
Transition Module
Resources
R. Akre, HW, 0.25
B. Hong, HW, 0.75
New HW, 0.75
S. Geng SW, 0.5
Resources FTE MW
13
40
40
24
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
Test board w/ ADCDAC supplied by SLAC
L. Doolittle (LBNL
contract) HW FW
S. Geng, SW, 0.5
8.0
PCD Engr, HW
12
Investigate
engineering & fab to
specs by local
company; field test
24
174
48
222 MW
Assumptions: Following are Separate AIP Projects:
Rack refurbishment including electrical
Solenoid PS replacement
Solid state sub-booster
SLAC Linac Controls Upgrade Proposal 12-01-10
18
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
19
Summary Schedule
SLAC Linac Controls Upgrade Proposal 12-01-10
20
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
SLAC Linac Controls Upgrade Proposal 12-01-10
21
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
SLAC Linac Controls Upgrade Proposal 12-01-10
22