1. LCLS Undulator System Status
5/19/2019
LCLS Undulator System Status
Lehman Review
July 10th-12th
2007
Test

2. Undulator System - Argonne WBS Responsibility
5/19/2019
Undulator System - Argonne WBS Responsibility
Management
1.4.2 Controls
1.4.3 Magnets & Supports
1.4.4 Vacuum Systems
1.4.5 Diagnostics
Test

3. Major Deliverables 1.4.1 Management: Safety Quality Assurance
Budget and Schedule
Integration and Installation
Admin. – Procurement, vendor management and documentation.
1.4.2 Controls:
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.

4. Major Deliverables 1.4.3 Undulator Magnet and Support:
Undulator Magnet Assemblies [40 complete, final delivery this week]
Quadrupole Magnets, including Stages & Stands
Support and Motion Systems, including Fixed Supports
1.4.4 Undulator Vacuum System:
Chamber – (Stainless steel on Hold) Alternatives under consideration
Support and leveling System
Pumping – acquisitions move to SLAC
Bellows
1.4.5 Diagnostics:
Beam Position Monitors
Beam Loss Monitors –(on Hold)
Beam Finder Wire

5. LCLS Management at ANL
Change in ANL Project Director since last Lehman Review
Milton leaves to become director for Fermi project at Elettra Feb 1st 07
Pile – new ANL/LCLS project director Jan 8th 07
ANL/LCLS project retains direct link in org chart to ANL ALD
Efim Gluskin becomes ANL/LCLS Scientific Advisor
ANL/LCLS gets more support from ASD and ESD

6. ANL-APS Organization Chart

7. 1.4.1 Management
ANL is committed to delivering a well documented, well engineered, high quality Undulator System
We have improved & standardized our documentation
We have increased the level of QA effort
We have added an engineering design checker
We have renegotiated appropriate level of effort to complete the project (from ANL divisions)

8. 1.4.1 Management Organization and Responsibilities
ANL is now mainly in the procurement and delivery stages of the project
ASK procurement and delivery system software deployed May1st 07 - Information updated on continual basis
SLAC also granted remote access to ANL ICMS document system
Equipment has started to arrive at SLAC. Minor Integration and design issues are being seen in MMF and CMM during assembly
We are working with SLAC to develop standard processes to handle changes. Early resolution of these issues now will avoid delays during the assembly bottleneck in FY08

9. Required Effort - Summary to ANL
The LCLS Undulator System requires ~15 APS FTEs (+ 5 “others”) of effort for FY07
ANL is fully committed to LCLS through delivery. Begin ANL effort reduction during installation. Further effort reduction during commissioning. We plan to be finished and off the LCLS project by the end of FY08.
APS Group Leaders now own their Staff’s part of the schedule for the LCLS project
Roughly 50 different people are required, distributed in 16 Groups
This is an estimate - we will still need to meet our commitment even if our estimate isn’t perfect

10. 50 matrixed workers = ~ 20 FTEs

11. ANL LCLS Major Effort Issues
5/19/2019
ANL LCLS Major Effort Issues
1.4.1 Management:
Need to Hire Integration Engineer (replacement for Pile) – Was difficult but it’s imminent.
Hired additional .5 FTE for experienced QA oversight – Yeldez Amer
Will need to replace Engineer for QA/ASK support ~ end of 07
Will need to replace Engineer for Progress, Task Coordination & Documentation ~end of 07
1.4.2 Controls:
Ramped up effort in last six months – much improved CPI and SPI against optimized working schedule.
Utilizing additional 2.5 Engineers + 1 technician from ESD to catch up.
1.4.3 Undulator Magnet and Support:
Currently replacing ANL Vendor manager/contract specialist.
Hired 50% design FTE for checking drawings and SOWs. (Have used for Controls, Vac & Diag.) Sufficient Effort from ME groups - continued support required.
1.4.4 Undulator Vacuum System:
Sufficient Effort from NE and ME groups until May – Serious design issues in June 07
Cost and Schedule under review – ANL & SLAC will provide additional support for parallel design efforts. See Technical talks
1.4.5 Diagnostics:
BPM – Re-directed additional 50% of NE mechanical engineer effort for BPM production
Utilizing almost 1 combined extra FTE from Diagnostics group for 3 BPM tests
Test

12. FY 07 Financial Situation and Effects of the Continuing Resolution
The FY07 Technical Addendum to ANL MOU states that ANL will receive ~ $15M.
Early September 06 - Advanced payment of $2M for FY07 undulator assemblies
Oct 07 – ANL uses carry over funds -CR is an issue but Vacuum and Support Mover Systems could do with more R&D and Production Engineering
Stainless Vs Aluminum Vac chamber effort created – (was good strategy to confirm processes before production)
January 07 - CR Now becomes a major issue
Mid-January
Enough funding left for 6 weeks of effort only
Put all procurements on hold
Planned core team disaster scenario

13. FY07 and the CR Received additional $2M 2/6/07
February 07 prioritized procurements – zero funded >$50K procurements for vendor responses.
planned to release only low-value long lead items but had “undulator assembly commitments” issue
Received additional $2M 3/16/07
March 07 released low-value long lead items
Received $6M end of March 07
April 07 – routing funded requisitions for re-approvals
SM vendor evaluations in progress at ANL – Vac system component orders routed for approvals.
May 07 – Awarded Support Mover contract
Received remaining $3m May 07

15. Undulator SPA Report
April 2007 Actual Cost of Work Performed (ACWP) negative variance due to:
Spares were purchased together with production units in a cost saving exercise. (As agreed with SLAC)
Cost of spares was backed out of April ACWP. Actual cost will be posted to project as spares are used. Spares were budgeted in FY09.
Month_Year

16. 1.4.2. Controls: Latest Working Schedule
Undulator Control Module
FDR July,2007 (will slip)
Award Blade IOC contract August, 2007
Award First article UCMI November, 2007
Receive final UCMI February, 2008
Populated racks ready for ship to SLAC March, 2008
Intra-undulator cable contract
Award contact July, 2007
Receive final shipment September, 2007
Electronics Interface Assembly
Receive final delivery September, 2007
Software
Support Motion and System monitoring March 2008
SLAC Installation
Begins March 2008

17. 1.4.3 Magnets and Supports
All forty undulator assemblies are complete.
One first Article is at ANL
Final shipment to SLAC this week (total 39 units)
Final Design pre-production support stands and girder were delivered to ANL
The support installation and girder assembly process is a “work in progress” –see LTT slides

18. 1.4.3 Magnets & Supports Support Motion System.
Production contract awarded to Hi tech
(w/Metalex) end of May
10 week delivery for 4 first Articles – progress made so far – well on track with no show stoppers expected

19. LCLS Undulator Quadrupole 1st Article
Working with Everson -TESLA. First Articles in test and evaluation. Production delivery schedule is very tight. No tests yet on corrector effects – no power planned for correctors. Argonne and SLAC will each extensively test the first articles.
Quad production support/translation stages complete.

20. Long Term Test
The re-designed support and motion system stands were tested in the Long Term Test area.
The installation technique proved successful. The supports deflected less than 1.5 microns during an 80mm roll out of a 1000lb weight (simulating the undulator).

21. Long Term Test

22. 1.4.4 Vacuum System since last Lehman
October 06 – Risk reduction required due to uncertainties in design, production and schedule of Stainless Chambers
Started parallel effort and construction of Aluminum Clamshell Vs Stainless prototype Chambers
Progress review and decision tree applied to both systems March 07 – neither system mitigates all risks
Reviewers choose Stainless Chamber and Aluminum Clamshell effort is dropped
June 07 Permeability testing - appears to be a show stopper for Stainless Chamber.

23. Vacuum System Chamber/Undulator magnetics
Magnetic measurements of a short section of Stainless Steel Chamber in an Undulator -
Permeability effects are much higher than expected
Too much risk with too many difficult questions to answer
Is a uniform 8 gauss OK?
What are the issues with the end field?
What is the variability in the permeability/material inconsistencies along a full chamber?
What's the variability chamber to chamber?

24. Re-evaluate specs, designs, cost and schedule
Meeting all current Specifications is very hard. What is an alternative Chamber?
Re-evaluate specs, designs, cost and schedule
Time is of the essence. Correct path to pursue is paramount. Management + expert advise = Decision Matrix.
Parallel efforts are ongoing to obtain input to the decision Matrix. Design & production plans, including cost & schedule are being developed. Three options will be prototyped:
Al extrusion chamber
Results of the extrusion development effort are very promising, and it is now the preferred option.
Cu Chamber – original baseline, requires minimal development
Al Clamshell – requires development

25. LCLS Undulator Vacuum Chamber Matrix/Down-select Process:
We aren’t starting again – The project could accept a lower performance chamber than the ultimate one we’ve been striving for.
Al Clamshell
Al Extrusion
Cu Tube
T. Fornek*
G. Pile*
T. Fornek *
Significant effort and success in initial design during SS Chamber V’s Aluminum Clamshell
Was back up R&D project for ANL Good progress: All extrusions exist.
Vacuum Flanges exist. Recent progress on tooling for prototypes machining. Working on surface finish
Was original ANL design for LCLS chamber. Lead by Dean Walters
AC conductivity and surface finish issues pushed change to SS
Issues:
Needs more development for manufacturing processes. Could meet all specs
Needs more development for manufacturing processes. Surface finish development required
Needs more development for manufacturing processes. Surface finish development required

26. LCLS Undulator Vacuum Chamber Matrix/Down-select Process
Design
Physics
SS 4-Weld
Al Clamshell
Al Extrusion
Cu Tube
Specs for 800eV
Person Responsible
* Until further notice
D. Walters
T. Fornek*
G. Pile*
T. Fornek *
H. D. Nuhn
Team (2 Independent ANL teams)
ANL + slac
SLAC + anl
ANL
ANL + SLAC
Documentation Due (ESDs, Drawinhgs, Estimates into Quotes etc).
7/30/2007
7/16/2007
Full Length Prototype Due
N/A
9/1/2007
Production Plan & Schedule Due
Final Design Review Due
9/7/2007

27. Stainless Steel Vacuum System Schedule Feb 07

28. AL Extrusion Production Schedule Estimate
AL Extrusion Production Schedule Estimate V’s Existing SS Vac Chamber Schedule: Detailed plan in Undulator Vacuum break-out section
SS Vacuum Chamber Lot (A ) 10/26/07 12/26/07 (4) Ship to SLAC 1/2/08
AL Vacuum Chamber Lot (A ) (5) Ship to SLAC 1/10/08
SS Vacuum Chamber Lot (B ) 11/28/07 1/07/08 (7) Ship to SLAC 1/14/08
AL Vacuum Chamber Lot (B ) (5) Ship to SLAC 1/21/08
SS Vacuum Chamber Lot (C ) 1/02/ /31/08 (7) Ship to SLAC 2/7/08
AL Vacuum Chamber Lot (C) (12) Ship to SLAC 2/19/08
SS Vacuum Chamber Lot (D) 1/31/ /03/08 (7) Ship to SLAC 3/11/08
AL Vacuum Chamber Lot (D ) (12) Ship to SLAC 3/26/ Available
SS Vacuum Chamber Lot (E) 3/03/ /31/08 (8) Ship to SLAC 4/2/ Available
AL Vacuum Chamber Lot (E ) (12) Ship to SLAC 4/16/08 AL Spares
SS Vacuum Chamber Lot (S) 3/19/ /09/08 (4) Ship to SLAC 4/16/08 SS Spares

29. LCLS Installation and Commissioning Time-Line
5/19/2019
LCLS Installation and Commissioning Time-Line
Drive-Laser Commissioning
LTU/und. Install
Drive-Laser Installed
Controls
Checkout
LTU/und.
hall “ready”
First Spont. Light A S O N D J F M A M J J A S O N D J F M A M J J
2006
2007
2008
Dec 22: PPS Certified
Dec 20-Jan 1: Holidays
Jan 2: VVS’s switched on for PEP-II (RF power available)
Jan 15: L0a, L0b, L1 RF processing begins
Feb. 1: X-band RF processing begins
Feb 20: GTL beamline installation complete
Mar 6: Virtual cathode fully characterized (ready to install gun)
Mar 7: RG gun installation begins – laser rate to 30 Hz
Mar 16: First laser UV-light on cathode!
Mar 17: Electrons in GTL and gun-spectrometer
Apr 9: Beam through L0a, L0b and down to 135-MeV spectrometer
Apr 24: Beam into main linac (to TD11 dump)
~July: Take beam down full linac (to BSY SL2 stopper)
Gun/Inj./BC1 Install
(8/21 – 2/20)
Gun/Inj./BC1 Commissioning
Inj./Linac/BC2 Commissioning
linac/BC2 Install
LTU/und. Commissioning
Test

30. ANL Delivery Schedules
Beneficial Occupancy
Support Mover System
Girders, Control Electronics
Co-occupancy
Undulator Support Stands
Cables/Cable Trays
First Light:
July 2008
Systems

31. Component Delivery Schedule – 7/10/07
5/19/2019
Component Delivery Schedule – 7/10/07
Actual
Plan
Test

32. Working Schedules

33. 5/19/2019
1.4.5 Diagnostics
RF BPM
Four RF BPMs produced for 3 BPM and evaluation testing
Vendor problems during development of brazing fixtures – first brazed bpm delivery delayed two months
Production schedule for BPMs is of concern – Prototype brazing took much longer than planned. Current production estimates push us to critical path – We know we have to do everything we can to pull dates back
3 BPM Test
Very promising results so far – Production design almost complete
Major components for BPM procurement routed for approvals.
See R. Lill’s talk for details
Test

34. Prototype BPMs for 3-BPM test

35. LEUTL 3-BPM Test PC gun installed and LEUTL tunnel commissioned
PC gun beam 325 MeV (400 pC) to dump
33 Hor. and 23 Vert. micron normalized emittance
Compressed beam 1 ps bunch length
Testing ongoing

36. 1.4.5 Diagnostics Beam Finder Wire
5/19/2019
1.4.5 Diagnostics
Beam Finder Wire
Weldment, Machined Parts, Chamber, Catalog Items and all Hardware Design and Procurement Documents are complete and are either in procurement or out for manufacture
Wire Card is currently under final design.
Fixture designs are complete.
Alignment and Assembly Procedures are almost complete
Schedule for production looks tight and will require good vendor management to keep on target
Test

37. BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode
5/19/2019
1.4.5 Diagnostics
BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode
Potentiometer (Out Position)
Electrical Connectors
(Down Position)
Internal Return Spring
(Expanded Position)
Internal Kinematic Stop Plates
(Open Position)
Pneumatic Solenoid Valve
(Cylinder Vent Position)
Lower Limit Switch
(Actuated Position)
Bellows Seal
(Compressed Position)
BEAM
Wire card
(Down Position)
From J. Bailey et al.
Test

38. 1.4.5 Diagnostics Beam Loss Monitor
5/19/2019
1.4.5 Diagnostics
Beam Loss Monitor
Engineering Begun but design is in flux
PRD is not complete – is BLM a diagnostic or a binary MPS input?
Cost is a major issue
Conceptual designs were in good shape but are they fit for purpose?
Multi-tiered to cover a very large dynamic range
Appeared too expensive to take chances
Simulations In Process
Determination of distribution and dose
Test

39. Summary - Good progress in many areas
5/19/2019
Summary - Good progress in many areas
Hot spots
Vacuum Chamber
3 design options
Extrusion
Copper tube
clamshell
Which design can meet requirements?
Is it possible to hold cost and schedule
Quadrupoles
Schedule – watch closely
Hysteresis measurements
Manufacturers QA
Beam Loss Monitor
Requirements doc needed
Completion of design
Final Large Procurements
Undulator Control Module
Support Motion System
Vacuum system components
Schedule concerns
Vacuum Chambers
RF BPM
Beam Finder Wire Card
Test