1. LCLS Klystron Modulator AIP Sec 28 AIP Review Feb 2010
Briant Lam and Ben Morris

2. Project Description
Refurbish Sector 28 klystron modulators to demonstrate improvements to the safety and reliability of the 6575s that will enhance LCLS
Safety:
Segregate electrically hazardous circuits
Control electronics in “touch safe” enclosures
Reliability:
Replacing obsolete and problematic relay logic control system with a modern PLC
Redesign high failure components
Internal voltage regulation, alternative to VVS

3. Prototype Status Construction completed
Testing began with water load in B015 in November, continuing today

4. B015 Testing Status Run at 21.5kV & 30Hz, several hours of operation
Validate higher rep rate (limited power)
Finalize documentation

5. Prototype: – April 2010 Production: May – Sept. 2010 Schedule
Complete B015 testing: 3/19
Install at 28-1: 3/30
Design validation (full power testing): 4/30
Production: May – Sept. 2010
Contingent upon completion of documentation and finishing validation of prototype unit: 5/3
No contingency to order long lead parts: now
Modulator production rate: 3 weeks/modulator
Sector 28 complete: 9/30 (22 weeks)

6. Cost Project Budget: $441k Cost to Date (-1/10) Cost to Complete
$362k for ED&I and B&H
ED&I cost overrun
Cost to Complete
Prototype & documentation (ED&I): $20k
Production (B&H)
Seven modulators
M&S: $20k/modulator (8% G&A assumed)
Labor: $12.5k/modulator (53% G&A assumed)
Total: $227k
Total cost-to-complete: $247k

7. Cost Budget Actual ED&I 2010-Jan $272k Cost to complete $20k Total
B&H
$90k
$227k
$230k
$317k ($87)
Contingency
$88k
Total Cost
$441k
$609k ($168)

8. Budget Overruns Issues ED&I B&H Contingency: enough for B&H overruns
Assumed very little engineering development when in reality considerably more was needed
B&H
PLC costs: $1k estimate vs. $10k actual (EPICS)
Contingency: enough for B&H overruns

9. Change Scope Increase Funding Potential Solutions
Existing funding sufficient to complete prototype and two production units
Limited statistical sample to evaluate efficacy of improvements with only 3 units in operation
Increase Funding
Additional $168k allocation in FY10
Complete S28 by end of FY10
Defer additional $168k allocation until FY11
Finish prototype, build remaining 2 in FY 2010
Complete remaining 5 units during FY11-Q1
Limited delay in amassing operational data