1. Americas KlyCluster Cost Analysis Overview
Tom Lackowski
RF & Sum reported by Peter H. Garbincius
Nov. 17, ILC08
Global Design Effort

2. 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
Nov. 17, ILC08
Global Design Effort

3. 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
Nov. 17, ILC08
Global Design Effort

4. Bullet List
Subtractions, Changes, and additions were identified for each WBS of the Main Linac estimate.
Nov. 17, ILC08
Global Design Effort

5. 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.
Nov. 17, ILC08
Global Design Effort

6. Main Linac Configuration
Four shafts added for RF Waveguides.
Nov. 17, ILC08
Global Design Effort

7. The cost estimate was the lowest level of the RDR estimate, using the same back-up pricing details.
Nov. 17, ILC08
Global Design Effort

8. 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)
Nov. 17, ILC08
Global Design Effort

9. Revised Tunnel Cross Section
Nov. 17, ILC08
Global Design Effort

10. RF Building Layout
Nov. 17, ILC08
Global Design Effort

11. Life Safety Analysis
NFPA (Subterranean Spaces) Prescribes 2 paths of travel to an exit or refuge area. The travel distance to be less than 610 meters.
Nov. 17, ILC08
Global Design Effort

12. 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.
Nov. 17, ILC08
Global Design Effort

13. Area of Refuge
Nov. 17, ILC08
Global Design Effort

14. 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
Nov. 17, ILC08
Global Design Effort

15. Process Water Plants
Nov. 17, ILC08
Global Design Effort

16. Kly Cluster Scheme Process Water System
RF in surface
68.6 KW per 48F DT
(C.A. 7/21/08)
Rough Costing of Kly Cluster Aug
Per RF Heat Load=Used loads & DT from C.A. s
Placeholder on the Kly distribution
Terminate with valve to RF pipe
Negligible 1KW heat load to air from rack ( J.C. 8/13/08)=No air cooling in tunnel
All air cooling in surface (see Lee’s air treatment)
RF Pipe in Shaft
30 KW 21.6F DT
(C.A. 7/21/08)
RF Pipe
4 21.6F DT
(C.A. 7/21/08)
Loads/Circulators
38KW per 36F DT
(C.A. 7/29/08)
Nov. 17, ILC08
Global Design Effort

17. Surface RF Loads Used for Costing
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Global Design Effort

18. Surface RF Loads (updated)
Nov. 17, ILC08
Nov. 17, ILC08
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19. Overall Main Linac Air Flow
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20. Tunnel Air Flow Normal air flow and fire air flow below
Nov. 17, ILC08
Global Design Effort

21. 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.
Nov. 17, ILC08
Global Design Effort

22. 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
Nov. 17, ILC08
Global Design Effort

23. 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 % wrt ILC est
Summing CFS + RF =>
- 4.4 % savings wrt to Americas’ ILC RDR est.
Nov. 17, ILC08
Global Design Effort

24. Peter’s final comments:
Similar considerations apply to the RTML CF&S and RF components => %
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
Nov. 17, ILC08
Global Design Effort

25. Thank-You for your attention.
Nov. 17, ILC08
Global Design Effort