Linac Coherent Light Source Status Overview

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Linac Coherent Light SourceStatus Overview

• John N. Galayda
• Director of LCLS Construction

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Construction 26 complete Contingency 29 of
Estimate to Complete
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PROJECT INJURY EXPERIENCE TO DATE
Lost Time Injury Rate

• SubContractors
• 39 K Hours worked (05/31/2006))
• Zero Injuries
• LCLS Collaboration
• 518 K Hours worked (05/31/2006)
• Shoulder back strain
• 24 Days Worked Without Injuries (05/11/2006)

Note Injury rates based on 200 K hours (100 man
years) of effort.
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LCLS Project Organization (Mar06)

• Feb06 Lehman committee recommended strengthening
  Project Office
• APD Engr
• APD Civil
• Procurement
• Continued strengthening of Conv Facilities
• LCLS PMOG functioning

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Injector and Linac

• Injector 61 complete
• Gun fabrication at SLAC- Hot test in ASTA bunker,
  August
• Laser delivery in July 2006
• Linac BC-1
• Articulated vacuum chamber received
• installation in Fall shutdown
• Injector installation schedule runs into
  2006/2007 shutdown
• Shutdown schedule 21 August 2006 to 5 January
  2007
• In-tunnel work (BC-1) must have priority
• Pursue all prudent means to speed schedule and
  preemptively mitigate schedule problems
• Add design staff
• Off-site fabrication, sources for rigging etc.
• Commissioning start January 2007
• Commissioning applications software will be
  rudimentary at start

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Installation Schedule
6 MeV
250 MeV
4.30 GeV
13.6 GeV
135 MeV
Linac-X L 0.6 m
Linac-0 L 6 m
rf gun
L0-a,b
Linac-1 L ?9 m
Linac-2 L ?330 m
Linac-3 L ?550 m
25-1a 30-8c
21-3b 24-6d
...existing linac
21-1 b,c,d
undulator L 130 m
X
BC2 L ?22 m
BC1 L ?6 m
Wall region
DL2 L 275 m
Injector, 2006 down
Linac, 2007 down
SLAC linac tunnel
research yard
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Status of Gun Fabrication and Testing

• Gun machining and brazing in progress
• Gun will be furnace baked after final tuning
• Final braze of power splitter complete
• Gun solenoid received, magnetic measurement plan
  completed
• Test plan reviewed
• Mechanical design of gun solenoid supports
  approved

Gun Solenoids
Dual Feed Full-Cell
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Gun Fabrication in Progress
Cathode Plate (rear)
Dual-Feed Waveguide
Cathode Cell
Cathode Cell
Dual-Feed Full Cell
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Readying Components for 2006 Down
Gun Solenoid
Injector Quadrupoles Shortened
Accelerator Sections
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Commissioning
Begins after all components have previously been
installed, aligned, connected, and verified by
installers

• Commissioning
• Pre-Beam Checkout
• Final component verification, made mostly in
  tunnel by system physicist (e.g., polarities,
  motion-control, etc.)
• Systems validation (e.g., power supplies,
  software applications, etc.)
• Beam Commissioning
• Component and system verification/calibration
  with beam (hardware and software e.g., BPM
  tests)
• Optimization of beam transport and tuning (e.g.,
  steering)
• Characterization of beam quality (e.g., emittance
  meas.)

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Commissioning Plans - Preparation

• Plan development assigned to each system team
• Drive Laser (White, Gilevich)
• Gun Injector (Dowell, Limborg, Schmerge)
• Linac (Emma, Wu)
• Undulator (Nuhn, Welch)
• FEL (Welch, Nuhn)
• XTOD/XES (Arthur, Möller, Stefan, Tompkins)
• Each developed an MS-Project file detailing both
  schedule and strategy
• Goal was to force early development of tuning
  strategy (what to measure, what to tune, in what
  order simulations encouraged now)
• Files now merged into master file and time-frame
  locked to project schedule (thanks to Jim Welch)

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Machine Commissioning Plans

• Schedule developed in MS-Project
• One file/manager per system
• Link to milestones and events in Master file

V\LCLS\Group\Commissioning\Commissioning
Schedule\Commissioning_Master.mpp
Injector-BC1
BC2
LTU-und.
install
install
Nov. 07
Dec. 05
Aug. 07
Mar. 08
Dec. 06
Aug. 06
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SLAC-Wide Effort on LCLS Safety Assessment
Document
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• Preparations for Accelerator Readiness Review
• Integrated with design review process
• Component and System PDRs and FDRs are being
  conducted following LCLS guidelines.
• Safety aspects are a normal part of the technical
  requirements.
• Working to report safety analyses in a uniform
  way to facilitate future assessments.
• SLAC Citizens Committees participate in the
  review process, following normal SLAC practice.
• Citizens Committees involvement specified
  through the SLAC Safety Oversight Committee.
• Need to ensure that all aspects of the project
  are reviewed, and that the completeness is
  presentable in a coherent way.

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• Accelerator Readiness Review
• LCLS ARR for Injector Commissioning will take
  place Sept.- Nov. 2006, once Citizen Committees
  reviews are complete and the SOC is satisfied.
• Working with the DOE SSO to ensure that the
  review process outlined here will be appropriate.

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Undulator Systems

• Undulator production underway
• Prototype at SLAC for measurement
• Chamber finish tests underway
• Single Undulator Tests ongoing
• RFBPM fabrication test encouraging
• Undulator Measurements at SLAC
• MMF startup in August

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Undulator Systems

• First Article Delivered to SLAC

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Photon Beam Systems

• John Arthur is staffing up
• Deputy Hal Tompkins
• X-ray Transport/Optics/Diagnostics
• XTOD Liaison physicist- Peter Stefan
• Prototype gas attenuator assembled, vac. tested
• Design reviews for XRT vacuum, collimators
• End Station Systems
• Staffing up- Layout of experiments is settled
  down
• AMO Liaison physicist John Bozek
• Detector Liaison physicist - Niels van Bakel

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X-Ray Transport/Optics/Diagnostics

• Prototype gas attenuator cell tested at LLNL

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NEH
AMO
X-ray pump-probe
SXR
soft x-ray line
hard x-ray line
Flipper Mirrors
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FEH
XPCS
Coherent x-ray imaging
High energy density science
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Sector 20

• Beneficial Occupancy 21 April
• Installation underway in vault
• tray
• supports
• floor

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Magnet Measurement Facility Beneficial Occupancy
14 April 2006
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Final Focus Test Beam Cleanout

• Phase 1 completed 28 April
• preservation of technical components
• Phase 2 began 1 May
• removal of shielding blocks completed 2 June
• Removal of cabling will be completed 16 June
• Phase 3
• Soils preparation for new Beam Transport Hall
• Completion in July

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Project Highlights and Key Considerations

• Conventional Facilities
• Architectural design _at_ 100
• Drawings for construction in hand
• 2- and 3- floor CLOC plans in hand
• CM evaluating bids
• Bids for first major packages in hand
• Second group of bids due 21 June
• Bid process for CLOC being accelerated

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Cost Estimates for Civil Construction

• Project budget based on three estimates of the
  T-II (60) design
• Jacobs
• Turner
• Wightman (tunneling) Davis-Langdon(excl. tunnel
• WBS unchanged when Jacobs/Turner 100 received
• Bid process had started- wait/see real bids

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Results of Estimates
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Contingency Analysis from 7 February Lehman Review
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First Bid Group Entire Beam Path
Bid Group 1 represents 68 of total hard cost
of LCLS CF. LCLS WBS Budget for total hard cost
of LCLS CF 67.3M Jacobs/LCLS estimate for
group 1 46M
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Bid Group 1 Comparison to Turner 100 Estimate

• Tunneling 194K (1) over estimate
• Bid based on unit pricing
• Estimates more transparent
• Homework paid off
• Survey, site utilities close to estimate
• Fire protection 35(215K) above estimate
• Earthwork 25 (1.2M) over estimate
• Award these five packages ASAP

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Bid Group 1 Comparison to Turner 100 Estimate

• Concrete 6.1M (55) above estimate
• Only two bids, 2nd bid nearly 10M higher
• Relatively small number of companies have the
  capability to bid this kind of task (thick
  shielding)
• Cost of concrete accounts for 500K
• Bidder claims labor shortage, overtime
  inefficiency, higher qty. rebar than estimated,
  blah blah blah
• Third quote competitive with lowest bid, but not
  bonded
• Alternatives for re-bid under consideration
• No low-risk path to re-bid has been identified
• 2nd bid problematic
• Turner team reluctance is evident
• estimate 3 months to re-bid, 3 months added to
  construction

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Bid Group 1 Comparison to Turner 100 Estimate

• HVAC 4.2M (93) over estimate
• Only 2 bidders, 2nd bid 3.1M higher
• High effort assumed in bid (gt2X estimate)
• Electrical 3.5M (48) over estimate
• Only 2 bidders, 2nd bid very close
• Cost of materials a factor
• Labor hours estimate very high (as above)

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Bid Group 1 Comparison to Turner 100 Estimate

• Plumbing 2.0M (103) above estimate
• Only 2 bids
• Bid breakdown includes 3X estimated labor
• 2nd bid 0.8M higher

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Projection for All Awards
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Actions Taken by LCLS and SLAC

• Demand bid analysis by Turner, proposal of viable
  re-bid options
• Appeal to Turners president was necessary
• Lump-sum bids an accepted practice but details of
  cost estimate are difficult to extract
• Demand conversion of Turner contract to make
  Turner execution of the CLOC an option for SLAC
• Bring CLOC options to DOE status review

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Turner Response

• Options considered and pursued in parallel
• Negotiate with responsive bidders
• Quickly explore value-engineering ideas with goal
  to win back 5M-6M
• Enlist Jacobs help in fast turn-around of ideas
• Break-up of Concrete, Mech/Elec/Plumbing tasks to
  attract smaller firms
• Breakout of retaining walls is straightforward
• Propose a guaranteed-maximum price approach to
  CLOC

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LCLS Recommended Path Forward

• Keep Beam Path (electron beam, undulator hall,
  front end, Near Hall, XR tunnel, Far Hall) moving
  ahead as quickly as possible
• Award Tunnel, Survey, Site Utilities, Earthwork,
  Fire Protection ASAP
• Attempt to negotiate with low bidders-
• Minimum recovery of 2M is expected
• 6M is high end of realistic-
• Do not consider re-bid unless strategy is clearly
  developed and believable

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CLOC

• Set budget target based on real bid information
• Bid Group 2 due next week (partial response- 40
  higher than estimate)
• Three options for acquisition of CLOC
• Get bids for packages 34 ASAP (August?)
• Turner considering a guaranteed-maximum price
  (GMP) contract to build the (2-floor) CLOC
• Proposal from Turner by mid-July
• Bid the CLOC competitively for results in
  September
• Prepare for design-build-to-cost, reflecting the
  realities of LCLS budget as of September 2006

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LCLS Project Options for CLOC

• Today, options are heavily dependent on how one
  extrapolates from bid group 1
• Continue targeting a 2-floor CLOC
• Based on
• 51 increase over estimate for Packages other
  than tunneling
• 15 to go forward from award
• 22 contingency for technical systems ETC
  2007-2009

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Revised Estimate Based on Bid Package 1

• For 2-story CLOC, 105.8M at award
• Based on low bids in bid package 1 and
  proportional (51) growth in follow-on packages

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Contingency Analysis, 2-Story CLOC
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Design-to-Cost CLOC

• Draconian economies required to maintain TEC
• Delay start of CLOC until Spring 2007
• Limits financial risk
• Limits CLOC capability
• 2-3 labs? severely limited office space
• Preserves full performance of FEL

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Design-to-Cost CLOC
Compare to 32.7M estimate contingency for
2-floor CLOC
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Summary

• Injector and Bunch Compressor 1 will be ready for
  commissioning in January
• Preparations for commissioning the injector
• Address engineering, physics, operations, safety
• Undulator Systems Coming Together
• X-Ray Front End design maturing
• NO COMPROMISE to capability of FEL

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Summary

• Facing a very tough decision on CLOC scope
• Financial impact versus CLOC functionality
• Civil Construction organized, prepared to start
• DOE/SLAC/LCLS must rapidly choose a course of
  action for CLOC construction

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End of Presentation