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

Geoff Pile

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

LCLS Undulator System Update

FAC Review

October 29th(30th&31

2007

Geoff Pile


ANL/LCLS Undulator Project Management Chart

Bill Berg

Lori Cesario

Geoff Pile


ANL/LCLS Undulator System Integration Engineer

BERG, WILLIAM Argonne National Laboratory

9700 S. Cass, IL 60439

Extension:2-6929

BLDG 401-B2199

Radio Page:4-1882

E-mail Page:[email protected]

E-mail Address:[email protected]

Geoff Pile


ANL/LCLS Undulator System Program Control Management System (PCMS)

Fran Clark retired in September 07 – STA advisor when required

Lori Cesario now ANL PCMS main point of contact

Lori CesarioArgonne National Laboratory

9700 S. Cass, IL 60439

Extension:2-7389

BLDG 362 C169

E-mail Address: [email protected]

Geoff Pile


ANL LCLS Major Effort Covered for FY08

09/07 – Completed FY08 Agreement sheet estimates for ANL/LCLS workers

10/07 - ANL management agree LCLS effort profiles for FY08

1.4.1 Management:

Hired Integration Engineer (replacement for Pile)

Secured 2 QA Engineers/Reps(~ 1 FTE) thru Sept 08

Secured 2 QC coordinators for Progress, Task Coordination & Documentation ~ thru July08

Added part-time secretarial assistance

1.4.2 Controls:

Sufficient Effort available - continued support required

1.4.3 Undulator Magnet and Support:

Sufficient Effort available - continued support required

1.4.4 Undulator Vacuum System:

Sufficient Effort available - huge effort is required to meet schedule

1.4.5 Diagnostics:

BPM - Additional engineering and technician help added for BPM production

BLM - Sufficient Effort available - Using almost one extra FTE from Diagnostics group

- huge effort is required to meet schedule for both BPM and BLM

Geoff Pile


ANL LCLS Effort Profile/Plan FY08/09

ANL production engineering effort drops off significantly in March/April 08ANL production engineering effort drops off significantly in March/April 08

April through July 08 technical leads and key players left to help with delivery and April through July 08 technical leads and key players left to help with delivery and installation issuesinstallation issues

Documentation hand over will be covered through September 08Documentation hand over will be covered through September 08

July 08 through September 08 only key 1.4.1 management left. All management effort is July 08 through September 08 only key 1.4.1 management left. All management effort is reduced by 50% reduced by 50%

End of September 08 – ANL plans to be off the projectEnd of September 08 – ANL plans to be off the project

FY09 ANL has small budget to contribute to Undulator CommissioningFY09 ANL has small budget to contribute to Undulator Commissioning

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


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


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


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


Long Term Test Update

Final Design 1st Article support stands and girder delivered to ANL – installed QA accepted in September 07.

The support motion and girder assembly installation process is a “work in progress” – see LTT slides

The pre-production girder has been cut in half. We are using it with the two pre-production supports to create the short and long break sections too.

Geoff Pile


1.4.4 Vacuum System

Un-resolvable questions with Stainless Chambers -Decision made in September 07 to build production

Extruded Vacuum chambers

Two full sized Aluminum prototypes have been built.

All planned fabrication steps have been performed.

The chambers have been baked and their measured out-gassing rate is lower than the specification

Many preparations for production are in-process or in place.

Geoff Pile


Aluminum Extrusion

Prototype Conclusions…

The extrusion can be manufactured and machined with wall thickness and straightness required to meet final installation tolerances. The full length chamber can be produced within all acceptable dimensional tolerances.

Uniform 0.5 mm nominal wall thickness and vacuum integrity required to maintain the specified average pressure was achieved.

Average surface finish achieved in testing - meets current PRD spec.

The polishing process improves the surface finish without introducing contaminants

Geoff Pile


1.4.4 Vacuum System

ANL will be the “General Contractor” for manufacture of the Aluminum Extruded Vacuum Chambers

Extrusions (in House)Explosion bonded C-fix Flanges (on order)Extrusion Polishing in process (outside Vendor)Extrusion Machining in process (outside vendors)Ready for flange welding and vacuum processing (in House) Significant in house Engineering and QA oversight required

Outstanding progress so far on very demanding schedule (almost parallels SS working schedule) but experienced group fully committed to meet it.

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


BPM Status

X-Band Cavity BPMDevelopment phase complete Production procurement in placeFirst machined production units expected in November

Receiver Electronics4 First article prototypes assembled and tested with good results3-BPM testing prototypes incorporate receiver, local oscillator and filter first article packagingProduction procurement ongoing -10 units at SLAC 1/4/08, 20 units by 1/5/08, 30 units by 1/6/08, 40 units by 1/7/08

Test QualificationSuccessful collaborative effort testing and qualifying BPM system Qualified system with the same ADC (PAD) as SLAC LINAC BPM upgrade to minimize risk of integration

Geoff Pile


Comprehensive BPM Test Program

1 m Resolution spec met: (09/27/07) < 0.6mLong term drift spec for 1 hour spec metGain stability spec met1 hour temperature stability spec met24 hour temperature stability spec met electronics with simulated beam

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 DiagnosticsBeam Finder Wire

Weldment, Machined Parts, Chamber, Catalog Items and all Hardware Design and Procurement Documents are complete and are in the procurement and production phase.Wire Card is currently under final design at SLAC.Alignment and Assembly Procedures are 90% completeSchedule for production looks tight and will require good vendor management to keep on target

• Lot #1 ( 3) 12/12/2007 Beam Finder Wires at SLAC • Lot #2 (10) 1/14/2008• Lot #3 (10) 2/11/2008• Lot #4 10) 3/20/2008

Geoff Pile


BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode

Wire card(Down Position)

Lower Limit Switch(Actuated Position)

Pneumatic Solenoid Valve(Cylinder Vent Position)

Internal Return Spring(Expanded Position)

Electrical Connectors(Down Position)

Internal Kinematic Stop Plates

(Open Position)

Bellows Seal(Compressed Position)

BEAM

Potentiometer (Out Position)

From J. Bailey et al.

1.4.5 Diagnostics

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

Geoff Pile


SummaryGood progress is being made in all areasHot spots

QuadrupolesSchedule – close attention req.

Vacuum Flanges Very finicky – “first time” sealing <100% Good QA, inspection and careful handling required

Vacuum ChamberProduction quality, surface finish, straightening and machining all require careful oversight

BPM moves into ProductionLots of oversight required

Beam Loss MonitorCompletion of design

Final Large Procurements Vacuum Chamber Machining BPM body manufacturing, BPM electronics manufacturing

Schedule ConcernsRF BPMVacuum ChambersBeam Finder Wire CardBeam Loss Monitor