Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Undulator Prototype Status and Measurement System Marion M. White ANL-ASD-LCLS

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Outline Scope Plans and Procurement Philosophy Status Design Improvements Technical Risk Mitigation Schedule Risk Mitigation Measurement Requirements Summary

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Scope 33 (+7) Precision magnetic arrays with canted poles 33 (+7) Support/alignment systems including Cradle that supports the undulator, BPM, and electromagnetic quadrupole. CAM movers and motors enabling precision remote positioning, alignment, and adjustment of the cradle. Translation system allowing remote retraction of an undulator out of the beamline and precision, reproducible re-insertion.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Scope: Comment from Last FAC “The roll away option should be available from remote and controlled via length encoders etc.” Done.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Scope: Spares 4 complete undulator modules -- assembled, together with spare BPM and spare quadrupole, tuned, fiducialized, aligned, and stored in a temperature-controlled environment. 3 modules - ready for installation at any time. 1 reference module - maintained in a thermally-stable environment - used for long-term stability monitoring. 3 undulators, tuned and fiducialized 3 complete support and mover systems

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Scope: Quadrupole Magnets Comments from last FAC: “A quadrupole is still rigidly connected to the corresponding undulator segment. Thus quadrupole and undulator segment can only be moved together via the micro mover system.” “The quadrupole in then present proposals are fixed Permanent Magnet ones. BBA then only works via electron beam variation. This proved to be not favorable an inaccurate in TTF due to Linac instabilities. BBA is much superior implemented if the quadrupole strengths can be altered. Electromagnets or adjustable PM one are recommended for this purpose.” Quadrupoles are now electromagnetic

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Scope: Layout

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Plan Unchanged: Long Lead Items Procure the long-lead items as early as possible in FY05. Issue the RFPs such that the awards can be made in March The Continuing Resolution causes uncertainty as to when money is available at ANL. We should know whether money will be available by March 2005 before the RFPs go out in January.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Plan: Assembly Contracts for undulator structure assembly will be awarded to contractors pre-qualified in precision mechanical fabrication and assembly. Multiple awards (2) are based upon low price, technically acceptable source selection strategy. Production of units 3 thru 40 begins in FY06. 1 st article undulator assemblies will be ordered from each vendor in FY05; this was proposed and well rec’d at the DOE review.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Plan: Acceptance Sequence First article undulators from each vendor are: Factory/Site accepted and shipped to ANL Magnetically tuned and mechanically measured at ANL Tested together with 1 st article support/mover system Accepted by ANL Shipped to the SLAC Magnet Measurement Facility (MMF), together with complete traveler docs and Acceptance Criteria Listing (ACL) Re-measured at the MMF and Fiducialized Assembled together with Measured and fiducialized quadrupole, Calibrated, cleaned, baked, and fiducialized BPM, Cleaned, baked, and aligned vacuum chamber Calibrated cradle/mover/rail system

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Plan: Delivery/Installation The complete, aligned module is Ready for Installation (RFI) If the Undulator Hall is ready, the unit is installed. Else, it is transferred to long-term, temperature- and humidity- controlled storage. Subsequent undulators are shipped directly to SLAC for tuning, measurement, fiducialization, final assembly, installation, etc. Details of the interfaces between undulator modules and other systems are being documented with Interface Control Documents (ICDs) that are to be signed off by all relevant parties. Acceptance Criteria Listings (ACLs) will clearly document the performance on all acceptance criteria. Non-conformances will be clearly documented and dealt with as appropriate.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Philosophy: Roles and Responsibilities The APS undulator experts responsible for design, construction, assessment, and value engineering of the prototype, are responsible to oversee the long-lead procurements and undulator production. Responsibility for vendor management, vendor oversight and performance, and for 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 the effort; SLAC personnel observe/participate. Mentor – SLAC leads the effort – ANL observes. Consult –ANL personnel are available for questions, troubleshooting, brainstorming.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Status: Reviews and Preparation External Design Review - [March 04] Internal design review [6/04] Requirements meeting – 6/04 Final design review of the undulator structure scheduled Sept , but was moved to mid- November as a result of the CR/replan. Kem Robinson, Chair. Preparation of drawings and procurement packages for the long-lead items is almost complete

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Status: Long Lead Procurement Packages Titanium Strongback Magnet Poles Magnet Blocks Procurement packages for all three items are almost complete.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS 40 Precision-Machined Titanium Strongbacks

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Status: Strongback Drawing Done

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Status: Strongback Statement Of Work The Statement of Work for the strongbacks is ready and signed off.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS LLPs Already Advertised in CBD Active Postings: 27/ Page of 1 October 07, 2004 Agency: Agency: Department of Energy Department of Energy Location:Location: ArgonneArgonne Poste d: October 07, 2004 Type:Synopsis Title:95 -- Titanium Strongbacks for Linac Coherent Light Source SOL:Reference-Number TS Poste d: October 07, 2004 Type:Synopsis Title:95 -- Magnet Poles for Linac Coherent Light Source SOL:Reference-Number MP Poste d: October 07, 2004 Type:Synopsis Title:99 -- Undulator Assembly for Linac Coherent Light Source SOL:Reference-Number UA Active Postings: 27/ Page of 1 October 07, 2004 Agency: Department of Energy Office: Argonne National Laboratory (DOE Contractor) Location: Argonne Posted: October 07, 2004 Type: Synopsis Title: Titanium Strongbacks for Linac Coherent Light Source SOL: Reference-Number TS95 -- Titanium Strongbacks for Linac Coherent Light Source Posted: October 07, 2004 Type: Synopsis Title: Magnet Poles for Linac Coherent Light Source SOL: Reference-Number MP95 -- Magnet Poles for Linac Coherent Light Source Posted: October 07, 2004 Type: Synopsis Title: Undulator Assembly for Linac Coherent Light Source SOL: Reference-Number UA99 -- Undulator Assembly for Linac Coherent Light Source

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS We have already received expressions of interest from vendors to these postings.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Changes Under Consideration We are asked to consider doubling the magnet gap and increasing the period to mitigate wakefield issues. First indications are that it is possible without losing the entire baseline design concept, however: All drawings will require some modifications A 1-meter-long (approx) prototype should made and tested prior to production, else there is significant technical risk Some cost increase and schedule slip are unavoidable. Need very clear direction very quickly if this is to be implemented into the baseline.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS The Path Forward We shouldn’t build something that we believe might not work Yet - delay could cost the Project dearly How do we quickly determine what is the best course of action for the Project?

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Risk Mitigation - Technical A complete prototype undulator was designed, reviewed, reviewed, reviewed… constructed, tuned, tested, re-reviewed, and value-engineered at ANL.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Prototype Undulator at ANL Vacuum Chamber Goes in Here

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Risk Mitigation: Technical Simplifications (Wingless Poles, Pole Clamp (screws), Wedge Shims, Side Shims, New Assembly Fixture) that resulted from our value engineering effort were implemented in the entire undulator or at least in a 1-m section of the undulator, and the device was re- measured. The modifications and test results were successfully reviewed internally by in-house undulator experts. A few additional tests were recommended, and those were successfully completed. A Final Design Review will be held Nov , 2004 at ANL.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Status: Improvements Wingless poles Wingless Poles (New) Wingless Pole (Old) Winged Pole

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS “Old-Style” Poles with wings Section with new “Wingless” Poles

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Internal Design Review – June 04 Charge to the IDR committee: Is the technical performance of each of the modified designs at least as good as the old designs, in terms of long-term stability, precision, repeatability and other relevant parameters? Is the magnetic performance of the undulator with these modifications likely to be as good as the previous design? Are there any concerns relevant to mass production of 40 undulators? Any other concerns?

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS IDR Committee Findings “The committee unanimously agreed on the value of the design improvements for enhanced performance and cost reduction of the LCLS undulators.” Destructive testing of the screws, plus transport and re-measurement of the undulator, were performed as requested and completed successfully. Good suggestions from the committee, such as adding washers, were implemented.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Risk Mitigation: Schedule Procurement of long-lead items in FY05 Procurement of 1st article undulator assemblies in FY05, allowing ample time for thorough testing and resolution of any production issues Prototyping and procurement of two 1 st article support and mover systems in FY05, as soon as requirements are clearly frozen and signed off

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Measurement and Fiducialization A review of the magnet measurement facility (MMF) will be held October 14 th The next two slides contain the tolerance budget for quadrupoles and undulators from the physics requirement budget.

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Tolerance Budget: Quads Quadrupole Conventional Alignment Tolerance Budget Quadrupole Fiducials Vert.Horiz. Pulsed Wire Center Definition 10 µm 10 µm Wire to WF Fiducial (WF) 15 µm 15 µm WF Fid. to Quadrupole Fid. 10 µm 10 µm 25 µm Quadrupole BBA Offset (rms) 20 µm 20 µm

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Tolerance Budget: Undulators Undulator Fiducials Vert. Horiz. Hall Probe Resolution/Positioning 20 µm 20 µm Needle Hall Probe Resolution 10 µm 30 µm Needle Hall Probe to Mechanical 20 µm 30 µm Needle Fid to Undulator Fid 20 µm 20 µm 40 µm 50 µm Undulator Roll-Away Repeatability 5 µm 10 µm Alignment Quad to Undulator 40 µm 40 µm Grand Total 65 µm 70 µm

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS FEL2004 Paper LCLS UNDULATOR DESIGN DEVELOPMENT Isaac Vasserman, Roger Dejus, Patric Den Hartog, Elizabeth Moog, Shigemi Sasaki, Emil Trakhtenberg, Marion White, ANL/APS, Argonne, Illinois 60439, USA

Marion M. White Undulator Prototype Status and 12 October 2004 LCLSLCLSLCLSLCLS Summary The procurement timeline is consistent with the Project Schedule for completion of delivery of the 33 production undulator modules, barring major requirement changes. Procurement packages for the long-lead items are nearly complete. A Final Design Review is scheduled next month The greatest schedule risks arise from: Requirement and specification changes or major delays. Funding delay.