VLCW July Global Design Effort1 Installation Global System Review F. Asiri W. Bialowons, T. Shidara Acknowledgment: C. Hauviller, R. Sugahara C. Corvin, G. Aarons, M. Munro, F. Peters, B. McKee, P. Rodriguez,

VLCW July Global Design Effort 2 Status Prepared WBS to level 5 Obtained all pertinent material on similar installation –PEPII, SSC, SLC, Spear II, APS, Fermi Main Inj, KEKB, LHC –None offer a one-for-one scalable comparison, but collectively they provided a range “ 2% to 12%” an average of 7% Identified “Point of Contact” for each T.S. and A.S. Attempted to obtained components list from T.S. and A. S. managers –The list is lately received and is partially complete –The equipment installation details are not yet confirmed Established subsystem interfaces/Boundaries –Qualitatively and softly defined Established an Installation and costing plan

VLCW July Global Design Effort 3 Compiled, studied and discussed the data obtained for installation cost estimate of other projects –LHC, KEKB, TESLA, NLC, etc Visited CERN and DESY –Discussed and obtained parametric data for LHC installation –Observed installation of Cryomagnets and CMS detector –Participated in the ILC Main Linac cost model meeting in DESY Discussed and obtain data for installation from XFEL presentations Discussed installation issues related to ILC Main Linac Applied RSMeans approach for the equipment installation cost as percentage of total project cost –RSMeans is N. America’s leading supplier of construction cost information and provides accurate and up-to-date cost data –Established a range (5% to 8% ) Installation Cost Estimate Approach

VLCW July Global Design Effort 4 Obtained the detailed WBS for installation cost estimate for USLCSC for cold machine (5% to 7%) –Compared scope, complexity and salient features with the ILC Baseline machine –Used the parametric data available and scaled to match –Discussed the results in numerous meetings and made collective judgment –Results presented in the Installation WBS format and discussed with the other installation co-leader Installation Cost Estimate Approach

VLCW July Global Design Effort 5 Each cryomagnet costs about 1000K MCHF –Procurement and Maintenance: 26 MCHF –Operation: 23 MCHF Due to presence of fragile components, tolerance of the internal parts must maintained with in ±0.1 mm during shipping, handling and installation –Most of the cryomagnets were installed on site, too many handling –Special customized transport system used –Special care in handling, transport an installation became necessary –In tunnel transport maximum speed, 3K/hr It took at least 5 days to complete on site assembly and 5 days for testing prior to installation Installation team consisted of total 70 people (Eng, Tech, Operator) Installation rate: initially 10 cryomagnets per week, now up to 30 working 24 hours a day, 7 days a week Notes from LHC Cryomagnet installation at CERN:

VLCW July Global Design Effort 6 Metric: ~53.50/hour $US, (~79.17/hour $US with Overhead & Profit) ~1676 hours/year Installation Cost Model for Equipment in Tunnels

VLCW July Global Design Effort 7 Installation Cost Model in Tunnels 724 Main Linac HLRF AC-DC Power Units With: Added Tunnel Equipment Handling $104,182,594 Without: Added Tunnel Equipment Handling - $ 95,855,560 $ 8,327,034 Percent added = ~100M $US Level

VLCW July Global Design Effort 8 Overall Project Installation Cost Extension Ranges Installation: Surface & Tunnel Cost Percent added = ~1B $US Level

VLCW July Global Design Effort 9 Installation: Cost Parameters Installation Cost Adders & Scale by Size & Location ~10% ~10M $US Level ~ 11.2 man-years in Tunnels ~ 8% ~100M $US Level ~ 89.2 man-years in Tunnels ~ 6% ~1,000M $US Level ~ 669 man-years in Tunnels & Surface ? 4% ~10,000M $US Level ~ 4461 man-years for ILC Project? Metric: ~1676 ~53.50/hour $US

VLCW July Global Design Effort 10 Level 4 Rollup WBS Installation WBSComponent 173 Installation 1731 General Installation 1 Logistics Management 2 Engineering Support 3 Equipment 4 Vehicles 5 Shipping-Receiving 6 Warehousing 7 Surface Transport 1732 Area System Installation 1 Sources e- Area Installation 2 Sources e+ Area Installation 3 Damping Ring Area Installation 4 RTML Area Installation 5 Main Linac Area Installation 6 Beam Delivery Area Installation

VLCW July Global Design Effort 11 On the surface Installation work WAREHOUSING PICKING SYSTEM RACKS CONVEYORS LIFT TRUCKS DOCKS CUSTOM EQUIPMENT MACHINE TOOLS ELECTRONIC TEST MAGNET MEASUREMENT RF TEST QUALITY CONTROL ASSEMBLY INVENTORY CONTROL MANAGEMENT STAGING MANAGEMENT COST CONTROL VEHICLES TRUCKS PEOPLE MOVERS

VLCW July Global Design Effort 12 In the tunnel Installation work

VLCW July Global Design Effort 13 Plans and Goals Near Term In this workshop meet with each T.S and A.S group –To review scope and content of each T.S. WBS –To understand scope of on site testing –To identify any omission, overlapping, double counting Between this and the Valencia workshop –To define scope of on site deliverable for each subsystem –To define the subsystem installation requirements –To establish subsystem interfaces/Boundaries –To review and continue to refine the parametric installation cost Estimate –To incorporate adjustments and Inputs from Area and Technical Systems as Required and Complete the Installation Portion of the Reference Design Report for Submission at the Valencia GDE Meeting in November, 2006 Franz Peters has joined SLAC Installation group part time (0.5 FTE) M. Munro, B. McKee, P. Rodriquez will provide additional support

VLCW July Global Design Effort 14 Goal: to produce an integrated Installation process for the ILC Baseline in full cooperation with other regions –Set-up and manage an installation data base in FY 07 that can be expanded in a full pledged program through FY 08 and FY 09 toward TDR –Proposed estimated level of effort for the American Region toward TDR FY 07;1.5 FTE and ~ $100K M&S (contract) FY 08; 2 FTE and ~ $200K M&S (contract) FY 09; 2 FTE and ~ $200K M&S (contract) –Needs same level of effort from the other regions to perform a real bottom-up cost estimate Installation G.S Long Term Plan