1. Undulator Long-Lead Procurement Preparation
Marion M. White
ANL-ASD-LCLS

2. Outline Scope General Plan Present status of LLP Preparation
Procurement Philosophy
Risk mitigation
Near Term Milestones
Summary

3. Scope – 33 Undulator Systems +7 Spares
33 (+7) Precision magnetic arrays with canted poles
33 (+7) Support/alignment systems including
Cradle that supports the undulator, BPM, and permanent-magnet quadrupole.
Precision CAM movers and motors enabling precision positioning, alignment, and adjustment of the cradle.
Rail system to move the undulator, allowing remote retraction of an undulator out of the beamline and precision, reproducible re-insertion.
Transport Device

4. Scope – Seven (7) 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 and used for long-term stability monitoring.
3 undulators, plus support and mover systems; tuned, fiducialized, and stored in a temperature-controlled environment.

5. Plan
Procure long-lead items as early as possible in FY05; Meet the LCLS schedule, and match the funding profile.
Advance Procurement Plans (APP), prepared with input from ANL Procurement, detail the procurement schedule and philosophy. APPs for the Long-Lead items are ready.
Milestone: 8/07: 33 Undulator Production Units Received at SLAC.

6. Plan (2)
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. In the baseline, this occurs in FY06.
1st article undulators are not in the baseline for FY05, however, awarding them in FY05 to coincide with delivery of the first lot of long-lead items significantly reduces undulator schedule and technical risk.
Assembly vendors will provide complete electronic documentation and production travelers to ANL as deliverables. [SLAC gets copies of everything].

7. Acceptance and Assembly
First article undulators from each vendor are:
Factory/Site accepted and shipped to ANL
Magnetically tuned and mechanically measured at ANL
Tested together with 1st 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

8. Delivery/Installation
The complete, aligned module is Ready for Installation (RFI)
If the Undulator Hall is ready, the unit is installed.
If not, 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.

9. Of course, everything will be perfect….
NCR - Example
Nonconformance and
Discrepancy
Handling
Of course, everything will be perfect….
But just in case…

10. 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.

11. Where are we now? (mechanically speaking)
External Design Review - [March 04]
Internal design review [6/04]
The committee agreed that our proposed changes were in fact improvements; recommended destructive screw pull test, adding washers, and transport and re-measurement of the device.
These activities are almost complete.
Requirements meeting – 6/04
Final design review of the undulator structure is scheduled September 16-17, Kem Robinson, Chair.
Preparation of drawings and procurement packages for the long-lead items is nearing completion
Expect to process procurement packages as “stop at award,” enabling awards to be issued as soon as FY05 money is available. In order to hold bid packages open for an extended length of time, solicitation will allow for raw material escalation.

12. Long Lead Items – Description and Status
Titanium Strongback
APP
Drawing
SOW
Magnet Poles
Magnet Blocks

13. 40 Precision-Machined Titanium Strongbacks

14. Advance Procurement Plan for the Titanium Strongbacks

15. From the Titanium Strongback APP
Award Criteria:
Source selection committee to review and evaluate technical, cost, and schedule against evaluation criteria to select the effort that represents the best value for the project. Solicitation will allow vendors to bid on just the forging, forging plus rough machining, and/or precision machining of the components, or on the entire process. Project will evaluate the alternatives.
Proposed Contract Type:
Fixed-Price

16. Strongback Drawing (Sorry - Dimensions are in NGF)

17. Strongback SOW
The Statement of Work for the titanium strongbacks is complete and is out for review before signoff.

18. 19,200 NdFeB Permanent Magnets
Quantity allows for breakage and magnetic sorting
Magnets are premeasured and serialized at the factory, saving us a lot of time and effort.

19. Magnet APP

20. Magnet Drawing

21. It is similar to that used
Magnet SOW
A draft SOW exists
and is being finalized.
It is similar to that used
to order magnets
for the prototype.

22. 19,200 Vanadium Permendur Magnet Poles
Quantity allows for breakage and permits dimensional sorting
Poles are mechanically measured and serialized at the factory.
Wingless
Titanium Wings

23. Magnet Poles

24. Magnet Pole Drawing

25. Magnet Pole SOW A draft SOW is in progress.
It is similar to that used to order magnet poles for the prototype, although the process has been greatly simplified with the wingless pole design.

26. Risk Mitigation - Technical
A complete prototype undulator was
designed,
reviewed,
constructed,
tuned,
tested,
re-reviewed, and
value-engineered at ANL.

27. Prototype Undulator at ANL
Vacuum Chamber Goes in Here

28. Risk Mitigation - Technical
Simplifications that resulted from the value engineering effort were implemented in the entire undulator or at least in a 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 are in progress now.
A Final Design Review will be held Sept , 2004 at ANL.
High-coercivity magnet material will be used to make the devices more radiation resistant, and they will be protected upstream by collimation. (See Liz Moog’s talk)

29. “Old-Style” Poles with wings Section with new “Wingless” Poles

30. Risk Mitigation - Schedule
early procurement of long-lead items
initiate procurement of 1st article undulator assemblies in FY05 if at all possible, adding adequate time for thorough testing and to resolve any production issues
procure the 1st article support and mover system in FY05, as soon as requirements are determined, in order to decrease technical and schedule risk

31. Cost - Undulators
Costs for the long lead items are based on vendor quotes at some date.
Raw materials costs are now fluctuating significantly, so adequate contingency was allocated.
The basis of estimate was reviewed by the External Independent Review team during the EIR earlier this summer.

32. Near-Term Milestones (from P3)

33. Summary
The undulator procurement schedule is consistent with July 2007 completion of delivery of the 33 production undulator modules.
Procurement packages for the long-lead items are nearing completion.
A Final Design Review is scheduled next month
The complete basis of estimate was reviewed by the EIR.
The greatest schedule risks arise from:
Design changes and delays in finalizing the requirements.
Delayed funding.