[Halld-pid-upgrade] focusing box budget estimate

[Michael Williams]

Hi all,

Below you can find an outline of the full focusing box budget.   I have more details (per item prices, etc) but for the TDR this is probably the right level of detail I think.  

Notes:
* Some of the costs scale linearly with the box length.  Below I assume two 1-m-long boxes.  We should choose a fixed length as nominal so our PMT and box prices are "consistent".  
* All labor costs are fully loaded (i.e. include all indirect costs).  Some of this could possibly be done by students at zero cost to the project.  
* All material costs are based on vendor quotes and/or experience from recent similar projects completed at Bates.
* All costs include conservative contingency (some of which is detailed below).  


Box ($50k total):
* stainless steel  $13k
* bolts $1k
* fused-silica windows $12k
* machining (paid service) $14k
* labor (welding + assembly) $10k


Mirror Supports ($25k total):
* Material $14k
* Labor (assembly + alignment) $11k


Mirrors (only one will be used in the final design):
* Glass + Al backing  $77k total (this assumes we also need to apply our own coating, i.e. that the commercial one is not sufficient)
* Polished Al $150k total (this takes our vendor quotes on the pieces we've made, and applies conservative scaling up to the full project, e.g., for polishing we assume we must use the vendor in Chicago that can only polish up to a about 1/3 m long pieces and then we need to pay a per-piece price; same for the coating where a per-piece price is used).


Water system ($17k total):
* Parts $2k
* Labor (assembly) $7k
* Instruments $2k
* Labor (install + test instruments) $6k


Additional engineering $75k (until we fix the mirror design, we need to allow for 10 weeks x 1 FTE in case we need to use a totally different mirror strategy … this also includes the remaining engineering on the seal, etc).


Grand total (assuming more expensive mirror option) $317k or $300k without the water system (depending on if we want to factor out the water system).   

* We will, of course, try and get better deals on the mirrors once we choose a technology.  ATM our scaling the project up *increases* the cost per area compared to our prototypes rather than decreasing as so far we've used small-scale vendors (and include contingency in all estimates).   With larger orders, we may find larger vendors or may get better deals from the current ones.   The numbers in the TDR ATM just scale up the test samples with area to the full box, and are a factor of ~3 lower than the estimates used here.  

* From the 317k total about 110k is labor at Bates (most is contingent engineering).  

* I'm not sure how much of the water system we can scrounge and how much of the assembly, etc, could be done by students, but this may be an area where savings could be found.

* We don't include the PMT shielding here, but if it's just an extension of the stainless steel box (on a hinge or similar to allow easy access) then you can guestimate that based on the $13k stainless steel price for the boxes.   I suspect the $10k number in the TDR ATM is not far off.  



Cheers,

Mike