Cost estimation for production & Cost estimation for production & installation of Calorimeter Systeminstallation of Calorimeter System

V. Issakov

Physics Department, Yale University, New Haven, CT 06511Physics Department, Yale University, New Haven, CT 06511

12/01/200412/01/2004

Contributors of the cost/schedule estimation:Contributors of the cost/schedule estimation:V. Issakov (50%) – Subsystem manager, physicist, Yale UniversityV. Issakov (50%) – Subsystem manager, physicist, Yale UniversityA. Soldatov (10%) – Leader group, Deputy director, IHEP, RussiaA. Soldatov (10%) – Leader group, Deputy director, IHEP, RussiaS. Chernichenko (20%) – Chief of Scintillator facility, IHEP, Russia S. Chernichenko (20%) – Chief of Scintillator facility, IHEP, Russia

Photon Calorimeter for KOPIOPhoton Calorimeter for KOPIO

The requirements to the KOPIO Photon Calorimeter:• Energy resolution 3.5[%]/E.• Time resolution 100[psec]/E.• Photon detection inefficiency (due to holes-cracks) 10-4.• Granularity 1111 cm2.• Active area 5.5 5.5 m2 • Radiation length 16X0

(18X0 including Preradiator).• Physical length 60 cm.

The Shashlyk technique with the APD photo-readout satisfies the KOPIO requirements.

All sizes are All sizes are millimetersmillimeters

Calorimeter SystemCalorimeter System

Calorimeter System includes:I. Mockup of Calorimeter System - the complete-equipped prototype of

Calorimeter system (168 modules), to study the performance parameters of the Calorimeter & Preradiator/Calorimeter systems and to develop the pattern recognition algorithms.

II. Photon Calorimeter – the matrix of the 5252 APD-instrumented modules with a beam hole of 182 modules , Calorimeter mechanics (including two mobile halves of Calorimeter frame, Calorimeter railways and Calorimeter installation/service equipment) & Calorimeter cooling system.

III. Instrumentation of Photon Calorimeter - Calorimeter High-Voltage control system, Calorimeter LV power supply system, Calorimeter “cosmic-ray” Pre-calibration System, Calorimeter Monitoring/Calibration System, Calorimeter WFD-readout System.

IV. The cable system of Photon Calorimeter – 3,172 signal cables, 2704 HV control cables & 2704 3 LV power supply cables.

Cost estimation for Calorimeter SystemCost estimation for Calorimeter System WBS # Description Sub. Mat. EDIA Lab. Tot.

1.2.3

Cost of Calorimeter System (CS) 1,227 3,249 2,593* 2,209 9,278YALE Contribution (DOE) 0 0 1,030 0 1,030IHEP Contribution** (RUSSIA) 0 0 375 5 380KOPIO Contribution (NSF) 1,227 3,249 1,188 2,204 7,868

1.2.3.1 Mockup of the CS (The complete-equipped matrix of 128-modules to study the Performance Parameters of CS) 38 188 42 92 360

1.2.3.2 Photon Calorimeter (2704 APD-instrumented modules, Calorimeter mechanics & Cooling system) 60 2,480 113 1,759 4,412

1.2.3.3 Instrumentation of Photon Calorimeter (2704 channels of HV-control, monitoring, calibration & WFD-readout electronics) 779 491 46 109 1,425

1.2.3.4 Shipping of Photon Calorimeter (Shipping formula: 600 mod. 3, Mechanics, 904 mod.) 100 0 0 0 100

1.2.3.5 Assembly & Test of the delivered modules (APD/mod. assembly, mech. & optical tests, a “cosmic-ray” calibration) 60 30 135 67 292

1.2.3.6 Installation of Photon Calorimeter (modules into frames, monitoring-calibration system, readout electronics) 0 0 66 120 186

1.2.3.7 Cabling of Photon Calorimeter (Production and installation of cables) 70 60 18 57 205

1.2.3.8 Commission of CS (The mechanical & “cosmic-ray” tests of the full-loaded CS) 0 0 35 0 35

1.2.3.9Scientific-technical coordination & management,Travel

120 0 733 0 853

*) Support of the FTE eng./scientists: KOPIO - $1,188k, IHEP - $375k, YALE - $1,030k.**) IHEP contribution in past: Scintillator factory (~$3,000k), Test facility (~$200k).

Calorimeter-mockup productionCalorimeter-mockup production WBS # Description Sub. Mat. EDIA Lab. Tot.

1.2.3.1 Mockup of the CS (The complete-equipped matrix of 128-modules to study the Performance Parameters of CS) 38 188 42 92 360*

1.2.3.1.1 Fabrication of 100 “mass-production” modules 0 34 0 41 75

1.2.3.1.2Instrumentation of 100 “mass-production” modules by APD units (APD, preamplifier, LV-HV converter)

0 112 0 11 123

1.2.3.1.3Production of the mockup mechanics

(Frame & Rotating lift-platform) 0 13 3 13 29

1.2.3.1.4Prototype of the cooling system(Refrigerating-circulator & Heat-exchanger) 0 7 2 5 14

1.2.3.1.5Prototype of the HV control system(D-A converters for control of APD HV-chips) 0 16 0 0 16

1.2.3.1.6Prototype of the “cosmic-ray” pre-calibration system(LTD & Trigger logic, CAMAC) 0 0 5 5 10

1.2.3.1.7Prototype of the monitoring-calibration system (LED-flash system & Fiber optics) 0 6 0 7 13

1.2.3.1.8Production of the readout system prototype (10-bit & 250 MHz WFDs, VXI or VME) 23 0 0 0 23

1.2.3.1.9 Shipping of the Calorimeter mockup 10 0 0 0 101.2.3.1.10 Test & Study of Calorimeter mockup performance 5 0 32 10 47

*) Production cost of Calorimeter mockup is $360k. Support of the FTE scientists for study of Calorimeter mockup performance is $187k (Yale – $145k, KOPIO – $42k).

Photon Calorimeter productionPhoton Calorimeter production

WBS # Description Sub. Mat. EDIA Lab. Tot.

1.2.3.2 Photon Calorimeter (2704 APD-instrumented modules, Calorimeter mechanics & Cooling system) 60 2,480 113* 1,759 4,412

1.2.3.2.1Design of Photon Calorimeter(Conceptual design & detailed drawings)

0 0 42 0 42

1.2.3.2.2 Modification of test-equipment & the production tool for the mass-production cycle 60 25 0 17 102

1.2.3.2.3 Fabrication of 2672 “regular” Calorimeter modules 0 697 0 1111 1,808

1.2.3.2.4 Instrumentation of 2672 “regular” Calorimeter modules by APD units (APD, preamplifier, LV-HV converter) 0 1,575 0 290 1,865

1.2.3.2.5 “Cosmic ray” test of 2672 instrumented “regular” Calorimeter modules 0 0 0 24 24

1.2.3.2.6The production of “special” Beam-Liner modules(32 APD-instrumented modules)

0 63 6 27 96

1.2.3.2.7Photon Calorimeter mechanics(Frame, cooling & railway systems, service-equipment, etc.)

0 120 65 290 475

*) Additional IHEP support of the FTE scientists for supervision and tests of modules, APD-units & APD-instrumented modules is $330k.

Cost of the module productionCost of the module production

Materials, Labor Cost Materials $259.581. 300 scintillator tiles $36.532. 300 lead tiles $65,553. Assembling parts $37,004. 108 m of WLS fiber

(Kuraray Y11-200MS-1mm)$108.00

5. Packing box $12.50Labor $245.401. Molding of the scintillator tiles $108.002. Stamping of the lead tiles $122.403. Formation of the WLS fibers $15.00Assembling & Testing $171.001. Assembling of module $126.00

2. Test of module $36.00

3. Packing of module $9.00

Total $675.98

Module’s production rate is 6 modules/shift

The module’s design includes 15 assembling details

Cost of the module instrumentationCost of the module instrumentation

Materials, Labor Cost

Materials $563.00

1. A 16 mm diameter, blue, windowless APD

$425.00

2. A charge-sensitive preamplifier $25.00

3. A LV-HV converter, capacitors and resistors $94.00

4. Assembling parts $19,00Labor $45.001. HV PC-board $5.002. Preamplifier PC-board $5.003. APD’s PC-board $5.004. Mechanic of APD cage $30.00Assembling & Testing $63.001. Assembling of the APD unit $54.00

2. Test of the APD unit $4.503. Packing of the APD unit $4.50

Total $671.00

Cost of the module’s instrumentation (APD)

Module’s instrumentation rate is 6 units/shift

AP

DA

PD

LV - HVLV - HV

PreampPreamp

Quoted price of the LV-HV Model: C20Quantity: 2,500Unit Price: $ 79.00John Bianchi EMCO High Voltage Corp.11126 Ridge RoadSutter Creek, CA 95685, USAPhone: (209) 223-3626www.emcohighvoltage.com

Quoted price of APDModel: SD630-70-74-510Quantity: 3,000Unit Price: $ 425.00Paul Sharman Advanced Photonix, Inc.1240 Avenida AcasoCamarillo, CA 93012, USAPhone: (805) 987-0146www.advancedphotonix.com

Cost of the module instrumentationCost of the module instrumentation

Materials, Labor Cost Materials $476.001. A 30 mm diameter, green-extended PMT & PMT socket $198.00

2. A charge-sensitive preamplifier $25.00

3. A LV-HV converter, PMT base, capacitors and resistors $124.00

4. Assembling parts, including antimagnetic shielding $129,00

Labor $45.001. HV PC-board $5.002. Preamplifier PC-board $5.003. APD’s PC-board $5.004. Mechanic of APD cage $30.00Assembling & Testing $63.001. Assembling of the APD unit $54.002. Test of the APD unit $4.50

3. Packing of the APD unit $4.50Total $584.00

Cost of the module’s instrumentation (PMT)

Module’s instrumentation rate is 6 units/shift

Requirement for the PMT instrumentation is the low magnetic field (< 100 Gauss) into the PMT-location volume. Cost economy is $230k (~ 3% of total Calorimeter system cost) Energy resolution will be 3.5%/E, instead 3.0%/E

Calorimeter instrumentationCalorimeter instrumentation WBS # Description Sub. Mat. EDIA Lab. Tot.

1.2.3.3 Instrumentation of Photon Calorimeter (2704 channels of HV-control, monitoring, calibration & WFD-readout electronics) 779 491 46 109 1,425

1.2.3.3.1 Calorimeter HV control system(2740 D-A converters for control of APD HV-units) 0 196 0 0 196

1.2.3.3.2 Calorimeter “cosmic-ray” pre-calibration system(LTD & Trigger logic, VME/VXI) 0 187 0 0 187

1.2.3.3.3 Calorimeter monitoring-calibration system(2740 channels of LED-flash system) 0 51 10 109 170

1.2.3.3.4 Calorimeter readout electronics(10-bit & 250 MHz WFDs, PCI or VXI) 779 0 36 0 815

1.2.3.3.5 Calorimeter LV power supply & Racks for Electronics 0 57 0 0 57

HV control system for control of APD HV-units. System includes 2704 programmable D-A VME converters. A base unit is a commercial 12-bits D/A converter (XIP-TVME200/XIP-5220, produced by Xycom Automation Inc.).The production cost per channel is ~ $72.“Cosmic-ray” pre-calibration system for adjustment of APD HV, the Calorimeter pre-calibration (accuracy better than 4%) and online long-term monitoring of the APD gain (accuracy better than 1%). System is based on detection of signals from the “cosmic-ray muons”, vertically traversing Calorimeter modules, and includes 468 programmable Low-Threshold Discriminator & Trigger Programmable Logic. A base units are the commercial LTD & TPL (V814 & V495, produced by CAEN).The production cost per channel is ~ $69.Monitoring-calibration system for online short-term monitoring of the APD gain & timing. System is based on the "ultrabright LED-lamps" with an electronic method of stabilization of the light output and includes 44 special LED modules. The similar system has been developed and tested for LHCb project. We propose to adapt the LHCb system for our project.The production cost per channel is ~ $63.Calorimeter readout electronics include 176 WFDs boards and 12 crate-collector boards.The production cost per channel is ~ $301.

Assembly & test of the delivered modulesAssembly & test of the delivered modules

WBS # Description Sub. Mat. EDIA Lab. Tot.

1.2.3.5 Assembly & Test of the delivered modules (APD/mod. assembly, mech. & optical tests, a “cosmic-ray” calibration) 60 30 135* 67 292

1.2.3.5.1Complete assembling, mechanical/optical test of the delivered modules

60 20 66 33 179

1.2.3.5.2 “Cosmic ray” test & pre-calibration of the delivered modules 0 10 69 34 113

“Cosmic ray” test & pre-calibration of the delivered module Procedure includes the accumulation of data-base for APD-instrumented Calorimeter modules

*) Additional YALE support of the FTE scientists for supervision and tests of modules, APD-units &

APD-instrumented modules is $370k.

Installation of Calorimeter SystemInstallation of Calorimeter System

WBS # Description Sub. Mat. EDIA Lab. Tot.

1.2.3.6 Installation of Photon Calorimeter (modules into frames, monitoring-calibration system, readout electronics) 0 0 66* 120 186

1.2.3.6.1 Installation of modules into Calorimeter frame 0 0 24 37 61

1.2.3.6.2Installation and testing of monitoring and calibration system(44 LED boards & LV power supply, 2704 optical cables) 0 0 24 18 42

1.2.3.6.3Installation and testing of 2704 readout-electronics channels(12 mainframes & controllers, 12 collector boards & 176 readout boards)

0 0 18 65 83

WBS # Description Sub. Mat. EDIA Lab. Tot.1.2.3.6.3 Installation of Railway and Cabling systems 0 0 0 27 27

1.2.3.6.4 Installation of Calorimeter support frame 0 0 0 81 81

1.2.3.6.5 Installation of Assembling and Service system 0 0 0 13 13

1.2.3.6.6 Installation of the power supply on the Calorimeter top 0 0 0 10 101.2.3.6.7 Installation of the electronic racks on the Calorimeter top 0 0 0 10 10

Installation of The Calorimeter Mechanics (for R. Brown)

*) Additional YALE support of the FTE engineer & scientists for supervision and tests is $179k.

Cost Evolution for Calorimeter SystemCost Evolution for Calorimeter System

1. The old base cost for the Calorimeter System has been estimated for TDR-2001 as $4,698k

2. The new base cost for the Calorimeter system (NSF Contribution) has been estimated for WBS-2004 as $7,868k

3. The Calorimeter cost has risen due to: a) The increasing of the Calorimeter size

(5252 modules instead of 4848 modules)$673k

b) The input of the new additional expenses for: Mockup of Calorimeter System (the former R&D program)

$360k

The Wave-Form-Digitizing readout electronics (the former item - 2.11.2.1)

$815k

Management & Supervision of Subsystem (a new required item)

$733k

Support of IHEP group at BNL (a new required item)

$469k

Travel support (a new required item)

$120k

NSF Contribution

Risk & Contingency analysis for CS Risk & Contingency analysis for CS WBS # Description Maximal risk factor Max. weight factor Base Cont Total

Tech Cost Sched. Design Tech Cost S/D k$ % k$

1.2.3 Calorimeter System (CS) 7,868 24.0 9,755

1.2.3.1 Mockup of CS 4WFD

10Ship

4Test

4WFD

4WFD

2Ship 1 360 18.0 425

1.2.3.2 Photon Calorimeter 4APD

10APD

8APD

15Liner

4APD

2APD 1 4,412 25.1 5,521

1.2.3.3 Calorimeter Instrumentation 4WFD

4WFD

8HV

4WFD

2WFD

2WFD 1 1,425 22.7 1,748

1.2.3.4 Shipping of Photon Calorimeter 0 10 4 0 0 2 1 100 24.0 1241.2.3.5 Pre-installation test of modules 0 10 4 0 0 2 1 292 24.0 3621.2.3.6 Installation of CS 2 4 8 0 2 2 1 186 20.0 2241.2.3.7 Cabling of CS 2 4 8 0 2 2 1 205 20.0 2461.2.3.8 Commissioning CS 2 4 8 0 2 2 1 53 20.0 421.2.3.9 Scientific & tech. support of CS 0 10 2 0 0 2 1 853 22.0 1,041

The complete risk-factor of CS is “low-middle” (Well-approved technology)The complete contingency of Calorimeter system is 24%. Maximal technical risk factor is 4 (New design, nothing exotic) Maximal cost risk factor is 10 (Top-down estimate from analogous program) Maximal schedule risk factor is 10 (Delays completion of critical path item) Maximal design risk factor is 15 (Concept only)

Calorimeter System scheduleCalorimeter System schedule

Calorimeter-system spending-profileCalorimeter-system spending-profile

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2005 2006 2007 2008 2009 2010

Mockup

Calorimeter

Instrumentation

Shipping

Pre-inst. Test

Intallation

Commission

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Total

Calorimeter-system spending-profileCalorimeter-system spending-profile

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500

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1500

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2005 2006 2007 2008 2009 2010

Mockup

Calorimeter

Instrumentation

Shipping

Pre-inst. Test

Intallation

Commission

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Total