Geoff Pile FAC Review - Undulator 12 November 2008 LCLS Undulator System Overview and Fabrication Geoff Pile

FAC Review - Undulator 12 November 2008 Safety Minute FY09 - SLAC steps up it’s Work Planning and Control even further My personal views and experiences: Work Planning and Control is an Integral part of good Integrated Safety Management In most facilities, implementation of ES&H requirements and work control processes at the activity level has not been effective for non-experimental work activities. By complying with DOE Work Planning & Control: ALL work in “Research & Development, Operations, Maintenance & Construction/Destruction should be reviewed”. APS holds effective weekly pre-project and pre-task briefings associated with Operations and Shut downs - work planning and control is discussed and approved in principle. “Operations Group” requires formal approved work requests prior to work starting Feedback and lessons learned during task close out. Usual attendance of reps and interested parties

Geoff Pile FAC Review - Undulator 12 November 2008 Second Safety Minute Make time for WP&C - Group Leaders should schedule seperate mandatory 1 to 2 hours weekly WPC meetings. Plan least two weeks work for workers every week. Work Planner describes plan to workers involved Documentation: Written assignments with work, safety check lists, referenced procedures, work request and/or permit numbers and feed back discussions. Schedule 1 hour weekly mandatory cross training – 1 staff to up to 10 trainees Practical – perform approved group procedures and make sure they work Theory - explanations of relevant components, systems and how system works with LCLS 10 years of weekly cross training helps both staff and trainees Share the load, plan the work and don’t carry the can yourself!

Geoff Pile FAC Review - Undulator 12 November 2008 Overview of Undulator Component Fabrication Topics What has and hasn’t been delivered to SLAC as of November 12 th 2008? What has been… or appear problem areas now? What is ANL doing in FY09

Geoff Pile FAC Review - Undulator 12 November 2008 Controls

Geoff Pile FAC Review - Undulator 12 November 2008 Controls Status and Schedule ALL Controls delivered I month ahead of schedule (23 rd June 2008) September work deferred due to funding issues. ANL Under estimated contingency effort required to support and complete installation. PROBLEMS: EPICS Programming Support and Motion positioning system not functioning properly. SLAC doesn’t get same results as ANL’s SUT, LTT or LAB View results – Suspect software Stein and Shaof working on LTT with APS metrology group – checking software programming and version #’s, IOC versions - cam calibration etc. LTT still looks good - Exploring basics first, expect resolution this week. Voogd has been helping out at SLAC during installation and turn on Stein will be at SLAC after thanksgiving to help with controls integration

Geoff Pile FAC Review - Undulator 12 November 2008 Magnets and Supports

Geoff Pile FAC Review - Undulator 12 November 2008 Problem: ( discussed at last FAC) Obtaining X Translation Limits & Stops for mm over travel - required redesign Solution: 69 production units delivered to SLAC on 6 /20/08

Geoff Pile FAC Review - Undulator 12 November 2008 Vacuum

Geoff Pile FAC Review - Undulator 12 November 2008 Diagnostics

Geoff Pile FAC Review - Undulator 12 November 2008 Diagnostics Status and Schedule BPM Mechanical – Deliveries complete Problems – brazing BPM window went well until the last 7 units. 33 brazed production Units 7 units were Indium/tin soldered. BPM Electrical – 36 Production Units complete 4 spare units very late due to parts shortage at Miteq ALL parts at Vendors – delivery rescheduled to ANL Nov 21 ANL complete by Nov 28 th - Ship to SLAC following week

Geoff Pile FAC Review - Undulator 12 November 2008 Diagnostics (Contd)

Geoff Pile FAC Review - Undulator 12 November 2008 Beam Loss Monitor Initially five BLMs will be used to protect the undulators by inhibiting beam bunches following an “above-threshold” radiation event. 30 production BLMs may be built in FY09 if R&D is successful Scheduled delivery to SLAC – Berg to install 5 units - 18th of November 2008 Aggressive schedule – Vendor dates slip - may need few extra days to assemble/checkout – plastic radiator backup solution available for 18 th. Electronics are done First Article detector fitted well – vendor approved to proceed Still some components at vendors Anodizing completed this week Quartz Promised to ANL Friday 14 th

Geoff Pile FAC Review - Undulator 12 November 2008 Undulator Inserted Position

Geoff Pile FAC Review - Undulator 12 November 2008 BLM Detector and Electronic Interface Z Integration of Detector Head

Geoff Pile FAC Review - Undulator 12 November 2008 Long Term Test Does LTT match SUT?  LTT testing was put on hold at the end of August  ANL approved to finish more comprehensive and comparative results Requires matrixed staff for:  Alignment, mechanical and electrical assembly, Controls and data acquisition etc. Task management, work planning and control.  The effort is not insignificant ($30 - $40K) but was in MW’s original budget and it is essential

Geoff Pile FAC Review - Undulator 12 November 2008 Status and Schedule Undulator System Management and Integration CPR & Costs to go – Generally in good shape. Some unplanned effort has been required in the last two months to solve problems and meet installation schedules. ANL Controls CPR for October with positive $200K variance Some of it will solve integration problems ( a month or two of Voogd, Shoaf and Steins’ effort) Most spares costs were moved to OPC in September. SLAC has funded essential ANL work in FY09 MOU

Geoff Pile FAC Review - Undulator 12 November 2008 Summary Almost all work related to installation will be completed by late November/ early December 2008 – Production BLMs? TBD (2009) Argonne Construction team started rolling off the project in July – mainly documentation and LTT effort is required to wrap things up. September was a tough month – a few essential people now catching up with outstanding work FY09 – the original small budget included for installation and commissioning support has been increased to allow better integration and problem resolution