Undulator Long-Lead Procurements (LLP) 10 May 2005 Procurement Status Strongbacks Magnets Poles 1st-Article Undulator Assembly and Support/Mover Systems Look-ahead

Undulator Magnets & Supports Team (not all of us are full time) XFD-XFE + ASD-ME Michael Bracken Loretta Cokeley Jeff Collins Alex Didenko Patric Den Hartog* Mark Erdmann Glen Lawrence Tom Powers Sushil Sharma* Emil Trakhtenberg Thomas Barsz (ASD-QA) XFD-MD + ASD-PHY Kurt Boerste Roger Dejus Elizabeth Moog* Shigemi Sasaki Ken Thompson Janet Werner Isaac Vasserman Marion White (CAM) * = Group Leader

LLP – 40 Titanium Strongbacks (1) 3.4-m-long titanium bars: Forged, annealed, rough machined, annealed, precision machined. Original Plan: Competitive bids – Single award FDReview: award to 2 vendors, reduce schedule risk. Bid package: sent to 5 prequalified vendors Vendors can be prequalified on the basis of previous successful work for APS and/or ANL and our familiarity with their facilities, quality of work, and safety. We visited vendors with whom we had never interacted but who responded to our inquiries and appeared capable of successfully performing the job. New vendors were found as a result of intensive web searches by our team, however, FedBizOps advertisements yielded no credible sources thus far.

LLP – 40 Titanium Strongbacks (2) Of the RFQs issued: One no-bid. Cited concerns that they may not locate sufficient titanium in time to meet our schedule. One extremely high bid; concerns about availability and cost of titanium. One very high bid.

LLP – 40 Titanium Strongbacks (3) Two similar bids; we decided they were reasonable for this market. One listed a fixed cost and a variable cost that floated with the cost of as-purchased titanium. The fixed cost bid was significantly higher than the variable. We sent all vendors a request for a variable bid. The same two were responsive, however it took a couple of iterations to find a reasonable way to define a cost basis; raw material cost changes faster than is reflected in the standard indices.

LLP – 40 Titanium Strongbacks (4) Awards to: Metalex [Cincinnati, OH] Dial [Rockford, IL] Total cost is 3.2M$ [budgeted 2.06M$] 95% of titanium is used to make pigment; 5% is made into metal. We now compete with Airbus, Boeing, and military applications. Alas. There is still risk that the cost increases before the vendors purchase all forgings.

LLP - Titanium Strongback 1.04.03.03.01

LLP - Magnet Blocks 1.04.03.03.02 We require 19,200 Neodymium Iron Boron magnet blocks. Magnets will be fabricated by the vendor, ground to final precise dimensions, plated for surface protection, magnetized, labeled, sorted by magnetic field, and divided into undulator-sized lots. The vendor-proposed sorting will be approved by us. We will furnish a spreadsheet to the assembly vendors listing the magnet serial number and orientation for each magnet in each slot.

LLP - Magnet Blocks 1.04.03.03.02 (2) The vendor will measure the magnets and provide data for us to approve. ANL will also choose a subset of magnets to measure and verify.

Magnet award: aaaa-bbbb (Japan) Award - Magnet Blocks 1.04.03.03.02 Magnet award: aaaa-bbbb (Japan) Should happen this week. Winning bid = NNN k$, NN k$ over budget APS has recent, positive experience with this vendor (see next slide, taken last week).

Similar Magnets, but for APS Similar Magnets, but for APS. A stack of 450 LCLS magnets will be 50% taller than pictured. The assembly vendor needs temperature-regulated storage for the many boxes of magnets.

Schedule - Magnet Blocks 1.04.03.03.02 First shipment – enough for the 2 first-article undulators 16 weeks ARO Remainder 25 weeks ARO

We require 19,200 vanadium permendur magnet poles. LLP - Magnet Poles 1.04.03.03.03 We require 19,200 vanadium permendur magnet poles. The material is typically forged into rectangular bars and annealed for ductility, then cut, machined, and ground to our precise dimensions, and annealed for best magnetic performance. 49% cobalt, 49% iron, 2% vanadium Highest flux density of any commercially available strip core alloy.

LLP Scope: Magnet Poles 1.04.03.03.03 (2) Awarded to Hi-Tech Manufacturing, Schiller Park, IL. Awarded for 903k$, 400k$ less than the budgeted amount. Major simplification of the pole design, eliminating titanium wings, $aved a lot. Vendor has recent (this year) highly-relevant experience making similar items for the APS. Understands the job and developed processes for working with this tricky material.

Undulator Assembly LLP′

First Article Undulators Positive response to our proposal at the last DOE review to include first-article undulators with the LLP items this year. Proceeding… Preparing to issue the RFP this month to pre-qualified vendors. Plan: issue awards to two vendors for assembly for better risk mitigation. Do a fly-off for the last units.

Bid Package Assembly drawings, including drawings of all fixtures used by APS in assembling the prototype undulator are essentially complete. The statement of work is written and is being reviewed. Detailed assembly procedures were written to describe how the prototype undulator was assembled, including videos. These will be included as suggestions to the vendors.

Undulator Assembly – QA Philosophy All LLPs are delivered to the AV with travelers; the AV is required to perform verification inspection of 10% of the incoming parts. Verify some of the measurements Go-no-go fixtures Undulator assembly drawings provide magnet slot numbers and assembly information. We verify their installation by receiving their signed certification and by photographic documentation of each undulator showing magnet serial number and undulator slot number provided by the AV. First article acceptance depends on measurements and tunability at the APS magnet measurement facility. The remainder are accepted at SLAC,

Undulator Assembly – QA Philosophy (2) Drawings are based on a successful prototype.  (Probability of failure is lower because we've already made one) Drawings include realistic tolerances and features that can easily be verified both during manufacturing, assembly, and final inspection processes. (Probability of failure is lower because there are methods to check when something is wrong) Detailed assembly procedure includes video and a spreadsheet for the magnet assembly process. (Probability of failure is lower because the assembly vendors can more easily grasp the scope of the work.)

Detail from the assembly procedure – magnet designations and markings XXXXX Magnet Serial Number Orientation – ‘L’ Magnet Serial Number Orientation – ‘R’ INCORRECT! Detail from the assembly procedure – magnet designations and markings

Sample Spreadsheet from APS "O" = numbered face up and "R" = numbered face down. "O", "R" procedure applies for both Top and Bottom Jaw. End magnet strengths are 78% and 28% of full strength, respectively.

Undulator Assembly – QA Philosophy (3) Procurement contracts that require 100% inspection of magnet blocks, poles, and strongbacks. Detailed Acceptance Criteria Listings to verify contractor deliverables. Witnessing of all First Articles by LCLS-APS project personnel followed by continued project surveillance. (Probability of failure is lower because the vendor's first articles will be verified in the presence of LCLS-APS personnel and because vendors will be subjected to regular monitoring and or visits by ANL-LCLS Quality Assurance.) Go/No Go gauges to verify key features (pole gap) are correct prior to shipping to SLAC.

Undulator Assembly – QA Philosophy (4) A vendor selection process based upon prequalification visits, previous ANL or DOE history, 3rd party quality certification such as ISO 9001, and feedback from SNS and APS Quality Assurance personnel.  (Probability of failure is lower because vendors were selected on the basis of proven methods.) Procurements contacts that include highly detailed, approved statements of work featuring clear contractor deliverables and hold points. (Probability of failure is lower because the statements of work have been reviewed by multiple subject matter experts and include multiple opportunities for the LCLS Project to keep the vendors on track.)

Assembly Models and drawings of all assembly fixtures used at APS are provided to the assembly vendors, though they are free to develop their own. This task has been simplified a lot, but is still complicated due to the large number of precision parts that have to be carefully tracked, certified, stored, and assembled. A lot of attention was devoted to prequalification of the vendors, to ensure that they are capable of being successful with a project of this size and complexity; people, facilities, QA, safety, history.

Assembly – short base

Assembly – short base with poles

Assembly – short base - fully assembled with poles, magnets, and clamps

Assembly – short base – fixture for precision positioning of the first poles

Assembly – Use the transfer fixture for precision positioning of the next poles; anchor with four poles

Assembly – continue down the line

Assembly – completed long base

Shipping Shipping will be monitored with a shock and thermal monitoring system during the entire trip from A to B. Similar approaches were taken in monitoring shocks and vibrations during cryomodule transport from JLAB to SNS, and undulator transport from Seattle to Chicago. Collected data were downloaded upon arrival and thoroughly checked. Temperature controlled, low-vibration vehicle, such as air-ride, good shipping crate design, non-stop, no vehicle change en route….

PAC05 UNDULATOR FOR THE LCLS PROJECT – CHANGES IN THE MAGNET STRUCTURE DESIGN* E.Trakhtenberg, M.Erdmann and T.Powers ANL, Argonne, IL 60439, U.S.A. The design modifications of a new hybrid-type undulator with a fixed gap of 6.8 mm, a period of 30 mm and a length of 3.4 m are presented. The prior pole design included side “wings” which were used for precise positioning, and clamps to fasten the poles to the magnet base. This design has been replaced by a more straightforward assembly, where the pole is attached to the magnet structure base using only two screws. Tests were performed on the vanadium permendur pole material to prove that the threaded holes are easy to fabricate and are able to successfully withstand the torque required to hold the pole in place. A fixture was also developed to ensure the precise location of the poles on the base during assembly. In addition to the pole modifications, the magnet-structure base is now manufactured as one piece as opposed to three, which greatly eases assembly. Finally, a small section of the original prototype had these changes successfully implemented, and the test results are presented.

First article support and mover system Engineering design is proceeding. A pre-prototype was constructed, and a measurement plan is under development that will enable us to determine whether the prototype device meets specifications. Measurement instrumentation has been procured as necessary and is being readied for use. Measurement begins after PAC. A Beta version of the motor-driver software exists and has been in use for preliminary testing.

Support/Mover Pre-Prototype Model Cradle Translation Stage CAM Mover

Note on Roles and Responsibilities The APS undulator experts responsible for design, construction, assessment, and value engineering of the prototype undulator, are responsible to oversee the undulator magnet and support procurements. Responsibility for vendor management, vendor oversight and performance, and undulator performance rests with ANL-APS. ANL-APS effort is associated with many of the SLAC activities, in a “Lead, Mentor, Consult” role. Lead – ANL leads; SLAC personnel observe/participate. Mentor – SLAC leads the effort – ANL observes. Consult – ANL personnel are available for questions, troubleshooting, brainstorming.

6-Month Look Ahead Detailed scheduling information will be provided by the LLP vendors, enabling us to refine the schedule. First article LLPs should be available. Undulator assembly vendors will be on board and working hard. A 1st article undulator should be available for tuning. [but at the outer limit of the 6-month period]

Else, this is the end, thank you. A portion of one of the Assembly Videos can be shown at this point - if there is time or interest……… Else, this is the end, thank you.