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LCLS Undulator System Status

LCLS Undulator System Status. Lehman Review July 10 th -12 th 2007. Undulator System - Argonne WBS Responsibility. 1.4.1 Management 1.4.2 Controls 1.4.3 Magnets & Supports 1.4.4 Vacuum Systems 1.4.5 Diagnostics. Major Deliverables. 1.4.1 Management: Safety Quality Assurance

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LCLS Undulator System Status

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  1. LCLS Undulator System Status Lehman Review July 10th-12th 2007

  2. Undulator System - Argonne WBS Responsibility • 1.4.1 Management • 1.4.2 Controls • 1.4.3 Magnets & Supports • 1.4.4 Vacuum Systems • 1.4.5 Diagnostics

  3. Major Deliverables • 1.4.1 Management: Safety Quality Assurance Budget and Schedule Integration and Installation Admin. – Procurement, vendor management and documentation. • 1.4.2 Controls: Cables (tunnel and inter-undulator): cable trays, and racks. Motion controls: sub micron leveling, control algorithms and software. Ancillaries: Thermal monitoring, undulator limit switches etc. Vacuum controls: Interface integration only – some limit protection. Diagnostic controls: Beam Finder Wire, Beam Position Monitor, Beam Loss monitor etc. Integration of Wire Position Monitor (SLAC component) Communications: Integrated Tunnel Electronics Rack with on board IOC etc. EPICs programming.

  4. Major Deliverables • 1.4.3 Undulator Magnet and Support: Undulator Magnet Assemblies [40 complete, final delivery this week] Quadrupole Magnets, including Stages & Stands Support and Motion Systems, including Fixed Supports • 1.4.4 Undulator Vacuum System: Chamber – (Stainless steel on Hold) Alternatives under consideration Support and leveling System Pumping – acquisitions move to SLAC Bellows • 1.4.5Diagnostics: Beam Position Monitors Beam Loss Monitors –(on Hold) Beam Finder Wire

  5. 1.4.1 LCLS Management at ANL • Change in ANL Project Director since last Lehman Review • Milton leaves to become director for Fermi project at Elettra Feb 1st 07 • Pile – new ANL/LCLS project director Jan 8th 07 • ANL/LCLS project retains direct link in org chart to ANL ALD • Efim Gluskin becomes ANL/LCLS Scientific Advisor • ANL/LCLS gets more support from ASD and ESD

  6. ANL-APS Organization Chart

  7. 1.4.1 Management • ANL is committed to delivering a well documented, well engineered, high quality Undulator System • We have improved & standardized our documentation • We have increased the level of QA effort • We have added an engineering design checker • We have renegotiated appropriate level of effort to complete the project (from ANL divisions)

  8. 1.4.1 Management • Organization and Responsibilities • ANL is now mainly in the procurement and delivery stages of the project • ASK procurement and delivery system software deployed May1st 07 - Information updated on continual basis • SLAC also granted remote access to ANL ICMS document system • Equipment has started to arrive at SLAC. Minor Integration and design issues are being seen in MMF and CMM during assembly • We are working with SLAC to develop standard processes to handle changes. Early resolution of these issues now will avoid delays during the assembly bottleneck in FY08

  9. Required Effort - Summary to ANL • The LCLS Undulator System requires ~15 APS FTEs (+ 5 “others”) of effort for FY07 • ANL is fully committed to LCLS through delivery. Begin ANL effort reduction during installation. Further effort reduction during commissioning. We plan to be finished and off the LCLS project by the end of FY08. • APS Group Leaders now own their Staff’s part of the schedule for the LCLS project • Roughly 50 different people are required, distributed in 16 Groups • This is an estimate - we will still need to meet our commitment even if our estimate isn’t perfect

  10. 50 matrixed workers = ~ 20 FTEs

  11. ANL LCLS Major Effort Issues 1.4.1 Management: Need toHire Integration Engineer (replacement for Pile) – Was difficult but it’s imminent. Hired additional .5 FTE for experienced QA oversight – Yeldez Amer Will need to replace Engineer for QA/ASK support ~ end of 07 Will need to replace Engineer for Progress, Task Coordination & Documentation ~end of 07 1.4.2 Controls: Ramped up effort in last six months – much improved CPI and SPI against optimized working schedule. Utilizing additional 2.5 Engineers + 1 technician from ESD to catch up. 1.4.3 Undulator Magnet and Support: Currently replacing ANL Vendor manager/contract specialist. Hired 50% design FTE for checking drawings and SOWs. (Have used for Controls, Vac & Diag.) Sufficient Effort from ME groups - continued support required. 1.4.4 Undulator Vacuum System: Sufficient Effort from NE and ME groups until May – Serious design issues in June 07 Cost and Schedule under review – ANL & SLAC will provide additional support for parallel design efforts. See Technical talks 1.4.5Diagnostics: BPM – Re-directed additional 50% of NE mechanical engineer effort for BPM production Utilizing almost 1 combined extra FTE from Diagnostics group for 3 BPM tests

  12. FY 07 Financial Situation and Effects of the Continuing Resolution The FY07 Technical Addendum to ANL MOU states that ANL will receive ~ $15M. • Early September 06 - Advanced payment of $2M for FY07 undulator assemblies • Oct 07 – ANL uses carry over funds -CR is an issue but Vacuum and Support Mover Systems could do with more R&D and Production Engineering • Stainless Vs Aluminum Vac chamber effort created – (was good strategy to confirm processes before production) • January 07 - CR Now becomes a major issue • Mid-January • Enough funding left for 6 weeks of effort only • Put all procurements on hold • Planned core team disaster scenario

  13. FY07 and the CR • Received additional $2M 2/6/07 • February 07 prioritized procurements – zero funded >$50K procurements for vendor responses. • planned to release only low-value long lead items but had “undulator assembly commitments” issue • Received additional $2M 3/16/07 • March 07 released low-value long lead items • Received $6M end of March 07 • April 07 – routing funded requisitions for re-approvals • SM vendor evaluations in progress at ANL – Vac system component orders routed for approvals. • May 07 – Awarded Support Mover contract • Received remaining $3m May 07

  14. Month_Year Undulator SPA Report • April 2007 Actual Cost of Work Performed (ACWP) negative variance due to: • Spares were purchased together with production units in a cost saving exercise. (As agreed with SLAC) • Cost of spares was backed out of April ACWP. Actual cost will be posted to project as spares are used. Spares were budgeted in FY09.

  15. 1.4.2. Controls: Latest Working Schedule • Undulator Control Module • FDR July,2007 (will slip) • Award Blade IOC contract August, 2007 • Award First article UCMI November, 2007 • Receive final UCMI February, 2008 • Populated racks ready for ship to SLAC March, 2008 • Intra-undulator cable contract • Award contact July, 2007 • Receive final shipment September, 2007 • Electronics Interface Assembly • Receive final delivery September, 2007 • Software • Support Motion and System monitoring March 2008 • SLAC Installation • Begins March 2008

  16. 1.4.3 Magnets and Supports • All forty undulator assemblies are complete. • One first Article is at ANL • Final shipment to SLAC this week (total 39 units) • Final Design pre-production support stands and girder were delivered to ANL • The support installation and girder assembly process is a “work in progress” –see LTT slides

  17. 1.4.3 Magnets & Supports • Support Motion System. • Production contract awarded to Hi tech (w/Metalex) end of May • 10 week delivery for 4 first Articles – progress made so far – well on track with no show stoppers expected

  18. LCLS Undulator Quadrupole 1st Article • Working with Everson -TESLA. First Articles in test and evaluation. Production delivery schedule is very tight. No tests yet on corrector effects – no power planned for correctors. Argonne and SLAC will each extensively test the first articles. • Quad production support/translation stages complete.

  19. Long Term Test • The re-designed support and motion system stands were tested in the Long Term Test area. • The installation technique proved successful. The supports deflected less than 1.5 microns during an 80mm roll out of a 1000lb weight (simulating the undulator).

  20. Long Term Test

  21. 1.4.4 Vacuum System since last Lehman • October 06 – Risk reduction required due to uncertainties in design, production and schedule of Stainless Chambers • Started parallel effort and construction of Aluminum Clamshell Vs Stainless prototype Chambers • Progress review and decision tree applied to both systems March 07 – neither system mitigates all risks • Reviewers choose Stainless Chamber and Aluminum Clamshell effort is dropped • June 07 Permeability testing - appears to be a show stopper for Stainless Chamber.

  22. Vacuum System Chamber/Undulator magnetics • Magnetic measurements of a short section of Stainless Steel Chamber in an Undulator - • Permeability effects are much higher than expected • Too much risk with too many difficult questions to answer • Is a uniform 8 gauss OK? • What are the issues with the end field? • What is the variability in the permeability/material inconsistencies along a full chamber? • What's the variability chamber to chamber?

  23. Meeting all current Specifications is very hard.What is an alternative Chamber? Re-evaluate specs, designs, cost and schedule • Time is of the essence. Correct path to pursue is paramount. Management + expert advise = Decision Matrix. • Parallel efforts are ongoing to obtain input to the decision Matrix. Design & production plans, including cost & schedule are being developed. Three options will be prototyped: • Al extrusion chamber • Results of the extrusion development effort are very promising, and it is now the preferred option. • Cu Chamber – original baseline, requires minimal development • Al Clamshell – requires development

  24. LCLS Undulator Vacuum Chamber Matrix/Down-select Process: We aren’t starting again – The project could accept a lower performance chamber than the ultimate one we’ve been striving for.

  25. Stainless Steel Vacuum System ScheduleFeb 07

  26. AL Extrusion Production Schedule Estimate V’s Existing SS Vac Chamber Schedule: Detailed plan in Undulator Vacuum break-out section • SS Vacuum Chamber Lot (A ) 10/26/07 12/26/07 (4) Ship to SLAC 1/2/08 • AL Vacuum Chamber Lot (A ) (5) Ship to SLAC 1/10/08 • SS Vacuum Chamber Lot (B ) 11/28/07 1/07/08 (7) Ship to SLAC 1/14/08 • AL Vacuum Chamber Lot (B ) (5) Ship to SLAC 1/21/08 • SS Vacuum Chamber Lot (C ) 1/02/08 1/31/08 (7) Ship to SLAC 2/7/08 • AL Vacuum Chamber Lot (C) (12) Ship to SLAC 2/19/08 • SS Vacuum Chamber Lot (D) 1/31/08 3/03/08 (7) Ship to SLAC 3/11/08 • AL Vacuum Chamber Lot (D ) (12) Ship to SLAC 3/26/08 34 Available • SS Vacuum Chamber Lot (E) 3/03/08 3/31/08 (8) Ship to SLAC 4/2/0833 Available • AL Vacuum Chamber Lot (E ) (12) Ship to SLAC 4/16/08 AL Spares • SS Vacuum Chamber Lot (S) 3/19/08 4/09/08 (4) Ship to SLAC 4/16/08 SS Spares

  27. LCLS Installation and Commissioning Time-Line Drive-Laser Commissioning LTU/und. Install LTU/und. hall “ready” Drive-Laser Installed Controls Checkout First Spont. Light A S O N D J F M A M J J A S O N D J F M A M J J 2006 2007 2008 Gun/Inj./BC1 Install (8/21 – 2/20) Gun/Inj./BC1 Commissioning Inj./Linac/BC2 Commissioning linac/BC2 Install LTU/und. Commissioning

  28. Co-occupancy Undulator Support Stands Cables/Cable Trays Beneficial Occupancy Support Mover System Girders, Control Electronics Systems First Light: July 2008 ANL Delivery Schedules

  29. Component Delivery Schedule – 7/10/07 Actual Plan

  30. Working Schedules http://www.lcls.aps.anl.gov/Project_Page/index.html

  31. 1.4.5 Diagnostics • RF BPM • Four RF BPMs produced for 3 BPM and evaluation testing • Vendor problems during development of brazing fixtures – first brazed bpm delivery delayed two months • Production schedule for BPMs is of concern – Prototype brazing took much longer than planned. Current production estimates push us to critical path – We know we have to do everything we can to pull dates back • 3 BPM Test • Very promising results so far – Production design almost complete • Major components for BPM procurement routed for approvals. • See R. Lill’s talk for details

  32. Prototype BPMs for 3-BPM test

  33. LEUTL 3-BPM Test • PC gun installed and LEUTL tunnel commissioned • PC gun beam 325 MeV (400 pC) to dump • 33 Hor. and 23 Vert. micron normalized emittance • Compressed beam 1 ps bunch length • Testing ongoing

  34. 1.4.5 Diagnostics • Beam Finder Wire • Weldment, Machined Parts, Chamber, Catalog Items and all Hardware Design and Procurement Documents are complete and are either in procurement or out for manufacture • Wire Card is currently under final design. • Fixture designs are complete. • Alignment and Assembly Procedures are almost complete • Schedule for production looks tight and will require good vendor management to keep on target

  35. 1.4.5 Diagnostics BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode Potentiometer (Out Position) Electrical Connectors (Down Position) Internal Return Spring (Expanded Position) Internal Kinematic Stop Plates (Open Position) Pneumatic Solenoid Valve (Cylinder Vent Position) Lower Limit Switch (Actuated Position) Bellows Seal (Compressed Position) Wire card (Down Position) BEAM From J. Bailey et al.

  36. 1.4.5 Diagnostics • Beam Loss Monitor • Engineering Begun but design is in flux • PRD is not complete – is BLM a diagnostic or a binary MPS input? • Cost is a major issue • Conceptual designs were in good shape but are they fit for purpose? • Multi-tiered to cover a very large dynamic range • Appeared too expensive to take chances • Simulations In Process • Determination of distribution and dose

  37. Hot spots Vacuum Chamber 3 design options Extrusion Copper tube clamshell Which design can meet requirements? Is it possible to hold cost and schedule Quadrupoles Schedule – watch closely Hysteresis measurements Manufacturers QA Beam Loss Monitor Requirements doc needed Completion of design Final Large Procurements Undulator Control Module Support Motion System Vacuum system components Schedule concerns Vacuum Chambers RF BPM Beam Finder Wire Card Beam Loss Monitor Summary - Good progress in many areas

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