Geoff Pile LCLS Und. System Fabrication [email protected] FAC 29 th, 30 th & 31 st October 2007 LCLS Undulator System Fabrication Schedule FAC

Geoff Pile

LCLS Und. System Fabrication Schedule [email protected] 29th, 30th& 31st October 2007

LCLS Undulator System Fabrication Schedule

FAC Review

October 30th

2007

Geoff Pile


LCLS Installation and Commissioning Time-LineLCLS Installation and Commissioning Time-Line

linac/BC2 Install linac/BC2 Install

2007200720072007

LTU/Undulator System LTU/Undulator System instalation Check instalation Check

out/Commissioning out/Commissioning

AAAA SSSS OOOO NNNN DDDD JJJJ FFFF MMMM AAAA MMMM JJJJ JJJJ

Inj./Linac/BC2 Inj./Linac/BC2 Commissioning Commissioning

Beneficial Occupancy.Beneficial Occupancy.Und. Installation Und. Installation

LTU/und.LTU/und.hall “Co occupancy.”hall “Co occupancy.”

2008200820082008

“Dirty Install”

Prep for Support Stand Installation

Girder Installation

Starts

Geoff Pile


Major Deliverables& Concern factors scaled to 10 (0-5 schedule 0-5 technical)

1.4.1 Management:

Safety

Quality Assurance

Budget and Schedule

Integration and Installation

Admin. – Procurement, vendor management and documentation.

1.4.2 Controls: 5 (4s -1t)

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.

Geoff Pile


Major Deliverables & Concern factors scaled from 0 to 10

(0-5 schedule 0-5 technical)

1.4.3 Undulator Magnet and Support: 4 (3s+1t)

Undulator Magnet Assemblies

Quad magnets and translation stages

Fixed Supports and Motion Systems

1.4.4 Undulator Vacuum System: 7 (3.5s+ 3.5t)

Aluminum Vacuum chamber + Support and leveling System

Pumping – acquisitions move to SLAC

Bellows

1.4.5 Diagnostics: 8 (5s+3t)

Beam Position Monitors

Beam Loss Monitors

Beam Finder Wire

Geoff Pile


0

5

10

15

20

25

30

35

40

45

Support Motion

Support Motion Est

Quadrupole

Quad Est

Vac Chamber

Vac Chamber Est

Vac Supports

Vac Supports Est

Vac Bellows

Vac Bellows Est

Vac Spools

Vac Spools Est

BFW

BFW Est

BPM

BPM Est

BLM

BLM Est

Tuning

Tuning Est

Girder Assembly

Girder Inst

Current ANL delivery schedulesCo-occupancyUndulator Support StandsCables/Cable Trays

Beneficial OccupancySupport Mover SystemGirders, Control Electronics

Geoff Pile


Tuning Schedule

Activity descriptionBest

EstimateBE

UnitsCRR4

EFCRR4 Units

Tune Undulator - 08 7/2/07 8 7/17/07 8

Tune Undulator - 09 7/18/07 9 7/27/07 9

Tune Undulator - 10 7/25/07 10 8/3/07 10

Tune Undulator - 11 8/2/07 11 8/17/07 11

Tune Undulator - 12 8/10/07 12 8/27/07 12

Tune Undulator - 13 8/22/07 13 9/7/07 13

Tune Undulator - 14 8/30/07 14 9/17/07 14

Tune Undulator - 15 9/10/07 15 9/25/07 15

Tune Undulator - 16 9/18/07 16 10/3/07 16

Tune Undulator - 17 9/28/07 17 10/15/07 17

Tune Undulator - 18 10/8/07 18 10/23/07 18

Tune Undulator - 19 10/16/07 19 10/31/07 19

Tune Undulator - 20 10/24/07 20 11/8/07 20


EstimateBE

UnitsCRR4

EFCRR4 Units

Tune Undulator - 21 11/5/07 21 11/20/07 21

Tune Undulator - 22 11/13/07 22 11/30/07 22

Tune Undulator - 23 11/21/07 23 12/10/07 23

Tune Undulator - 24 12/3/07 24 1/3/08 24

Tune Undulator - 25 12/13/07 25 1/15/08 25

Tune Undulator - 26 1/8/08 26 1/24/08 26

Tune Undulator - 27 1/16/08 27 2/1/08 27

Tune Undulator - 28 1/25/08 28 2/11/08 28

Tune Undulator - 29 2/6/08 29 2/22/08 29

Tune Undulator - 30 2/14/08 30 3/3/08 30

Tune Undulator - 31 2/25/08 31 3/11/08 31

Tune Undulator - 32 3/4/08 32 3/19/08 32

Tune Undulator - 33 3/14/08 33 3/31/08 33

Geoff Pile


Girder Assembly Schedule


EstimateBE

UnitsCRR4

EFCRR4 Units

Assemble Girder - 01 1/25/08 1 2/15/08 1

Assemble Girder - 02 2/8/08 2 3/3/08 2

Assemble Girder - 03 2/25/08 3 3/17/08 3

Assemble Girder - 04 2/28/08 4 3/20/08 4

Assemble Girder - 05 3/4/08 5 3/25/08 5

Assemble Girder - 06 3/7/08 6 3/28/08 6

Assemble Girder - 07 3/12/08 7 4/2/08 7

Assemble Girder - 08 3/17/08 8 4/7/08 8

Assemble Girder - 09 3/20/08 9 4/10/08 9

Assemble Girder - 10 3/25/08 10 4/15/08 10

Assemble Girder - 11 3/28/08 11 4/18/08 11

Assemble Girder - 12 4/2/08 12 4/23/08 12

Assemble Girder - 13 4/7/08 13 4/28/08 13

Assemble Girder - 14 4/10/08 14 5/1/08 14

Assemble Girder - 15 4/15/08 15 5/6/08 15

Assemble Girder - 16 4/18/08 16 5/9/08 16

Assemble Girder - 17 4/23/08 17 5/14/08 17


EstimateBE

UnitsCRR4

EFCRR4 Units

Assemble Girder - 18 4/28/08 18 5/19/08 18

Assemble Girder - 19 5/1/08 19 5/22/08 19

Assemble Girder - 20 5/6/08 20 5/28/08 20

Assemble Girder - 21 5/9/08 21 6/2/08 21

Assemble Girder - 22 5/14/08 22 6/5/08 22

Assemble Girder - 23 5/19/08 23 6/10/08 23

Assemble Girder - 24 5/22/08 24 6/13/08 24

Assemble Girder - 25 5/28/08 25 6/18/08 25

Assemble Girder - 26 6/2/08 26 6/23/08 26

Assemble Girder - 27 6/5/08 27 6/26/08 27

Assemble Girder - 28 6/10/08 28 7/1/08 28

Assemble Girder - 29 6/13/08 29 7/7/08 29

Assemble Girder - 30 6/18/08 30 7/10/08 30

Assemble Girder - 31 6/23/08 31 7/15/08 31

Assemble Girder - 32 6/26/08 32 7/18/08 32

Assemble Girder - 33 7/1/08 33 7/23/08 33

Geoff Pile


Undulator Girder Installation Schedule


EstimateBE

UnitsCRR4

EFCRR4 Units

Install Undulator Girders 1-10 4/16/08 10 4/29/08 10




Geoff Pile


SM System & Quad Production Deliveries

0

5

10

15

20

25

30

35

40

Support Motion

Support MotionEst

Quadrupole

Quad Est

GirderAssembly

Girder Inst

Co-occupancyUndulator Support StandsCables/Cable Trays

Beneficial OccupancySupport Mover SystemGirders, Control Electronics

Geoff Pile


Support Mover System Deliveries

Activity description Best Estimate BE Units CRR4 EF CRR4 Units

Ship 4 S/M to SLAC (#5,6,7,8) 10/24/07 8 10/10/07 8

Ship 4 S/M to SLAC (#9,10,11,12) 11/7/07 13 10/24/07 12

Ship 4 S/M to SLAC (#13,14,15,16) 11/21/07 18 11/7/07 16

Ship 4 S/M to SLAC (#17,18,19,20) 12/7/07 23 11/21/07 20

Ship 4 S/M to SLAC (#21,22,23,24) 12/21/07 28 12/7/07 24

Ship 4 S/M to SLAC (#25,26,27,28) 1/15/08 33 12/21/07 28

Ship 4 S/M to SLAC (#29, 30, 31, 32)

1/23/08 38 1/15/08 32

Ship 1 S/M to SLAC (#33)

1/23/08 33

Geoff Pile


Quadrupole DeliveriesActivity description Best Estimate BE Units CRR4 EF CRR4 Units

Ship to SLAC -Quad Magnet 1st Article (Q1) 10/26/07 1 9/27/07 1

SLAC Ship Rejected Q2R back to ET 11/5/07 1 10/1/07 2

Ship to SLAC - Quad Magnet (Q3) 11/13/07 2 10/1/07 3

Ship to SLAC - Quad Magnet (Q4,Q5) 11/19/07 3 10/11/07 5




Ship to SLAC - Quad Magnet (Q12,Q13,Q14,Q15) 12/19/07 15 11/28/07 15






Ship to SLAC - Quad Magnet (Q36,Q37,2 Coils) 2/25/08 37 2/13/08 37

Geoff Pile


Vacuum Chamber Production Deliveries

0

5

10

15

20

25

30

35

40

45

Vac Chamber

Vac Chamber Est

Vac Supports

Vac Supports Est

Vac Bellows

Vac Bellows Est

Vac Spools

Vac Spools Est

Girder Assembly

Girder Inst

Geoff Pile


Vacuum Chamber Production Deliveries


Chambers 1-5 Depart ANL 2/1/08 5 1/23/08 5





Ship Chamber Supports to SLAC (1) 12/10/07 1 11/5/07 1

Ship Chamber Supports to SLAC (36) 2/4/08 36 2/1/08 36

Package-Ship to SLAC - Bellows(35) 3/25/08 35 2/15/08 35

First Articles 12/1/07 3

Ship Quad Spools (30) 1/31/08 33

Ship Quad Spools (33) 10/25/07 10/31/07 33

Geoff Pile


BFW, BPM, & BLM Production Deliveries

0

5

10

15

20

25

30

35

40

Oct-0

7

Nov-0

7

Dec-0

7

Jan-0

8

Feb-0

8

Mar

-08

Apr-0

8

May

-08

Jun-

08

Jul-0

8

Aug-0

8

BFW

BFW Est

BPM

BPM Est

BLM

BLM Est

Tuning

Tuning Est

Girder Assembly

Girder Inst

Geoff Pile


BFW, BPM, & BLM Production Deliveries


RFI: BFW Lot #1 (3) Beam Finder Wires at SLAC 12/12/07 3 11/29/07 3

RFI: BFW Lot #2 (10) 1/14/08 13 1/14/08 13

RFI: BFW Lot #3 (10) 2/11/08 23 2/11/08 23

RFI: BFW Lot #4 (10) BFWs at SLAC 3/20/08 33 4/7/08 33

RFI: BPM Group A (2) 1/15/08 2 11/27/07 2

RFI: BPM Group B (11) 2/17/08 8 1/23/08 13

RFI: BPM Group C (11) 3/15/08 18 3/5/08 24

RFI: BPM Group D (11) 4/16/08 28 4/16/08 36

RFI: BPM Group E (8) 5/10/08 36

RFI: BLM (34+2)) 36 7/1/08 36

Geoff Pile


The End

The Clock is Ticking…

Additional Notes Follow

and we know it!

Geoff Pile


1.4.3 Magnets and Supports

Undulators

39 Undulators @SLAC 1 Undulator @Argonne

Support Mover System

1 Support & Motion System @Argonne8 Support & Motion Systems @SLAC4 Support & Motion System @Hi-Tech ready to shipRemaining 25 Support & Motion Systems now in production @Hi-Tech/Metalex

Date

Totals SM systems Delivered to SLAC

(current estimate)

10/24/2007 8

11/7/2007 12

11/21/2007 18

12/7/2007 23

12/21/2007 28

1/15/2008 33

1/23/2008 38

Geoff Pile


Quadrupoles

Two 1st articles - marginally low in field

They were rejected and the revised design has 123 laminations instead of 115.

Two new replacement first articles are in production and will be delivered to ANL this week; we have negotiated with ET to speed up the rest of the schedule and bring us back on track.

1 production Quadrupole stage is at Argonne;

the rest were delivered to SLAC.

Date

Totals Delivered to SLAC

(current estimate)

11/5/2007 1

11/13/2007 2

11/19/2007 3

11/29/2007 5

11/29/2007 7

12/4/2007 11

12/19/2007 15

1/9/2008 19

1/18/2008 23

1/30/2008 27

2/8/2008 31

2/19/2008 35

2/25/2008 37

Geoff Pile


The Schedule… The Cost……Event Original Completion

DateUpdated Completion Date

Polishing of all extrusions

12/07/07 11/30/07

Machining of all extrusions

4/21/08

Chamber Processing at ANL

4/23/08

Ship Chambers 1-5 to SLAC

1/23/08 2/1/08 1-6


1/28/08 2/22/08 6-11


3/10/08 3/14/08 11-22


3/26/08 4/4/08 22-33


4/25/08 4/29/08 33-40

Cost Items Updated Estimates and Quotes…Oct 07

Extrusions $11,165.44

Flanges $41,310.00

Polishing Prep $350.00

Polishing $152,819.85

Straightening $15,600.00

Machining $238,400.00

Crating $4,979.60

Surface Sampling $5,040.00

ANL labor ~$220,000

Total $689,664.89

Geoff Pile


Cavity BPM Production Status

Cavity BPM machining contracts placed with parts expected 11/27/07

Two vendors will provide a single machined First Article production BPM for evaluation

Vacuum window first lot delivery 11/12/07

Vendor for brazing BPM pending contract award

Group & # Totals Delivered to

SLAC

Date

RFI: Group A(2) 2 1/15/2008

RFI: Group B (6) 8 2/17/2008

RFI: Group C (10) 18 3/15/2008

RFI: Group D(8) 26 4/16/2008

RFI: Group E(10) 36 5/10/2008

Geoff Pile


1.4.5 Diagnostics

Beam Loss Monitor

Engineering re-design - design is for MPS system and not Diagnostic

PRD complete – This design does not meet PRDCurrent proposal for BLM is only as an MPS input for now

Even in simple form the cost and schedule is still of concern.

Future ANL/SLAC collaboration on upgrade may be viable later?

Geoff Pile


Beam Loss Monitor A Simple MPS/Beam Loss Monitor system for now!

Production design will inhibit beam when beam loss is detected above a pre-determined set-point. Requires limited dynamic range from the detector(s)

Expect to install in undulator tunnel July 08

****************************************************************************************************

A more Sophisticated BLM may be required – no reasonable solution available at present.

Future design will meet PRD requirements. This design will keep track of the total accumulated exposure of the magnets in each Undulator. Helps predict, understand and curtail operational scenarios that may cause long term magnet damage. Requires a large dynamic range for the radiation detector(s) and much more sophisticated electronics and software.

Geoff Pile


Production BLM design

Detector Moves with the Undulator and

protects during undulator roll

out

Documents

Geoff Pile LCLS Und. System Fabrication [email protected] FAC 29 th, 30 th & 31 st October 2007 LCLS Undulator System Fabrication Schedule FAC