1. Undulator Systems Integration
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Undulator Systems Integration
Geoff Pile
Test

2. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

3. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

4. Hazard and Risk Controls
[A few minutes in 30: An example of an integrated safety net]
Suspect Counterfeit Bolts
Integrating Safety into LCLS
ANL Training includes ESH273 (identifying counterfeit components) to comply with DOE order G
Integrating QA into safety at APS-LCLS
Tom Barsz (QA) has created a comprehensive QA program for APS – LCLS.
Every PARIS procurement requires QA approval. Every QA approval has built- in safety checks. Tom’s QA database double-checks PARIS acquisitions.
Net result: Enhanced Safety

5. Integrating Safety at APS-LCLS
PARIS gets linked to QA database
PARIS req # →
Tom’s supplier history →
ESH and QA checklists →

6. Integrating Safety at APS-LCLS
← Vendor product info
Tom’s issues →
ESH and QA
Check – flags
an item for disapproval →

7. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

8. Define Clear Roles and Responsibilities
Undulator Systems Integration
Why define clear roles in integration?
Helps prevent project failures. Defines who’s doing what, where, and when.
In the initial phases of the project, people look after their own design problems first. They may not always consider integration consequences.
When?
Weekly CAM, CPR, group meetings, and Internal Design Reviews help with integration and general awareness of issues.
Organized weekly ANL/SLAC meetings until the end of the project. RP and GP have regular teleconference between ANL & SLAC.
All APS/SLAC staff are invited to participate whenever they need/wish.
Who?
Rodd Pope (SLAC) and Geoff Pile (ANL) planning post-SUT activities at ANL and SLAC.
Cost account managers (CAMs); delegate project tasks to staff in order to meet defined goals in the Effort Scheduling & Reporting Tool.

9. Define Clear Roles and Responsibilities

10. Define Clear Roles and Responsibilities

11. Define Clear Roles and Responsibilities

12. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

13. Integration Priorities
Overall System Integration Philosophy
Design Phase
Understand the concept. Design the sub components. Integrate them together.
Build and Testing Phase
Verify form, fit and function. Integrate enhancements from SUT into the Final Designs for production.
Production Assembly Phase
Integrating the schedule for delivery, assembly and alignment of components.
Installation and Commissioning Phase
Integrate all mechanical, electrical and alignment tasks for installation prior to initial component turn-on and commissioning.

14. FY05 Integration Priorities
During Design and Build Phase
We continued to plan, schedule, and incorporate Base Line Changes
Continual review of overall concepts and specifications
Review all the most recent designs (even without IDRs)
Individual designs are integrated into complete assembly drawings
Review all interfaces
Good revision control
Internal Design Reviews firm up concepts
Building, testing, and verifying component designs for SUT
FY06: Now we’re in a better position to plan details for assembly, installation, and commissioning

15. FY05 Integration Priorities: get firmer designs
Significant change and progress in the past few months
SHORT BREAK
END VIEW at BPM
LONG BREAK

16. IDRs: Quad and Corrector Magnets 11/18/06
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IDRs: Quad and Corrector Magnets 11/18/06
Uses the same power supplies as SLAC:
MCOR Power Systems
Initial Concept for Quadrupole/Corrector Magnet
Quadrupole/Corrector Magnet
Location view
Test

17. IDRs: Vacuum Chamber 1/5/06
Vacuum Chamber (316LN SST)
The original chamber supports were adequate. A new design has evolved.
Quote from IDR report:
“The conceptual designs for the chamber, support, and bellows are thoroughly evaluated. They should achieve design requirements for the undulator system. However, the committee has recommendations to be evaluated during the prototype testing that could improve the design further.”

18. IDRs: Fixed Supports 1/12/06
Chronological Support Design
Design changes incorporated from design reviews involving ANL and SLAC personnel.
Internal Design Review 1/12/06
SUT should enhance production version
9-30
07-19
10-31
11-27

19. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

20. Equipment Integration at SLAC
Rodd Pope replaces Brad Youngman for FY06
FY05 Brad Youngman/GP +
An early integration example with SLAC: identifying requirements for “Heat loads in the tunnel” helped define more than just where things go inside and what’s outside.
FY06 Rodd Pope/GP +
Undulator design defined much better. Re-work detailed integration plan for delivery, assembly, and installation thru to commissioning. Rodd assumes additional assembly scope; e.g., Quad Magnet power supplies, racks, and cables.
Other examples: Barsz/Dutcher - ProE reports. Marsh - IDR info .

21. vxv
CELL 1
ASSUME AIR COOLED ELECTRONIC BOXES A,B,B+& C.
4.2W
4.2W
4.2W
4.2W 4W 4W 4W 4W
3.8W
3.8W
M3-10W
3.8W
0.23W
3.8W
M2-5W Q
M3-10W Q
0.23W
M2-5W
M3-10W
0.23W
M4-5W
M2-5W Q C
DLB A
M1-5W
M4-5W C B A
M1-5W
M4-5W C A
M1-5W B B+
Test

22. Equipment Integration at SLAC
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Equipment Integration at SLAC
Heat Balance in the LCLS Tunnel
Present Design QW QL QC QE QU
QW = heat dissipation in the tunnel wall and floor
QC = heat dissipation in chilled lines
QU = heat input from undulator components
QL = heat input from lighting
QE = heat input from electronics
Heat Imbalance:
ΔQ = QU + QL + QE - Qw – QC (for each undulator length)
SLAC CF takes info, compares their study and makes more educated decision
Test

23. Equipment Integration at SLAC
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Equipment Integration at SLAC
Recommended Approach (Sharma, Pile and Worek) QW QL QC QE QU QH
Radiator Panels
Resistive Heaters
20,000 cu ft/min should give good temperature control to within ±0.3° to 0.5°C
Adding radiator panels and resistive heaters are cheap additions, if required (would give faster stability control).
The radiator panels are selected to be large enough to provide a cold bias. All resistive heaters can be connected to a single controller. For a better heat balance, the resistive heaters are computer-controlled individually.
Test

24. Equipment Integration at SLAC
Heat Generators in the Undulator Tunnel
We optimized the positions of the heat generators.
Many questions on temperature control forced us to firm up designs for control electronics, diagnostics, quad magnets, power supplies, and cabling.

25. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

26. Balanced Priorities and Schedules
Single Undulator Integrated System Test
@ ANL
Prototype “Fixed Support” support due 3rd week of Feb 06
Prototype support/mover system: Girder, CAM movers, Rollaway system, controls software and hardware
Carefully coordinate return of prototype undulator from SLAC (may use dummy early March and switch to1st article when available)
“Quadrupole” with fiducialization surfaces
“BPM” with fiducialization surfaces
“Vacuum Chamber”
“WPM, HLS, BLM” sensors
Earthquake protection bracing

27. Goals of the Single Undulator Test
Balanced Priorities and Schedules
Goals of the Single Undulator Test
Provide critical input to the S/M system design reviews.
Help to determine whether the support/mover system design is ready for final production.
Measure girder and rollaway motions.
Determine precision and reproducibility of motions, including start and stop. Check for interference.
Measure vibration damping or (hopefully not) amplification.
Measure position stability and temperature dependence of components and subcomponents.
Practice undulator replacement technique on SUT translation stages.
Enhance the final integrated design for production.

28. Balanced Priorities and Schedules
Single Undulator Module Test
Start is driven by decision to wait for supports in late February 06.
SUT "performance” test is scheduled for two weeks in March 06 with six additional weeks planned for integration testing and enhancements.
Multiple Undulator Module Test
No MUT at APS.
EAA RF Area designated for re-assembly of one complete undulator and short and long break “mock-ups”. The EAA is readily available.

29. Undulator Magnet and Support
SUT – Paint by numbers
LCLS SUT Layout
Undulator Magnet and Support
Motion Controls
Vacuum System
Diagnostics

30. Undulator Magnet and Support Thermocouple Location
SUT: Integration Interfaces
LCLS SUT Layout
Undulator Magnet and Support
Motion Controls
Vacuum System
Diagnostics 3 15 14
Thermocouple Location 1
Undulator 2
Ambient Air 3
Ambient Air at Quad 4
Quad 5
RFBPM 6
Girder 7
Undulator Motor (Dwn Strm) 8
Undulator Motor (Up Strm) 9
Girder Motor (Single) 10
Girder Motor (Double) 11
Floor Support (Upper) 12
Floor Support (Lower) 13
Vacuum Chamber Support 14
Vacuum Chamber (At Beam) 15
Vacuum Chamber (Strngbk) 16
Ion Pump 5 4

31. Balanced Priorities and Schedules
Post-SUT Priorities …
Support/mover/module
Implement design enhancements prior to final design reviews
Updated drawings and documentation
Procurement and component fabrication, acceptance and delivery criteria
… and Schedules
Rodd Pope/Geoff Pile – Integrate final undulator designs and re-work the undulator system engineering plan that optimizes planning and scheduling for the assembly, installation, and commissioning at SLAC.
Geoff Pile integrates assembly procedures, coordinates component delivery schedules with SLAC, helps with assembly issues at SLAC.
Rodd Pope takes much assembly scope – e.g., undulator assembly in MMF, quad magnet power supply racks and cables for buildings 2.3 and 3.1.

32. Undulator System Integration
Integrated System Engineering
Hazard and Risk controls tailored to work being performed at ANL
Defining clear roles and responsibilities
Integration priorities during design, build, installation, and commissioning
Equipment Integration at SLAC
Balanced Priorities and schedules
Lessons learned – ESDs help integration

33. Lesson Learned from SLAC
We’ve learned why ESDs are valuable early on
ANL now understands it as an Engineering (Requirements and) Specification Document.
Status update received 1/20
– Quadrupole Magnet Specification
Author: Jaski Target Completion Date: 1/31
– Line Diagnostics System Engineering Specifications (UD1)
Author: Yang/Bailey Target Completion Date: TBD
Wire Position Monitor System Specifications
Author was Ruland. Needs new author assigned. In-Progress.
– Hydrostatic Leveling System Specifications
Author was Ruland. Needs new author assigned. In-progress.
– Vacuum System Specifications
Author: Walters 60% Complete
– Undulator Motion Controls
Author: Stein Target Completion Date: 1/31
– Wire Scanner Engineering Specifications (UN3)
Author: Bingxin/Bailey Target Completion Date: 1/31
1.4-XXX – Undulator and surrounding Thermal Monitoring Specifications
Author: Stein Target Completion Date: TBD
Undulator Protection System – Unassigned (ANL to take responsibility)
1.4-XXX – Undulator Cable, Tray and Rack Specifications
– Undulator Support/Mover System
Author: Collins/Sharma Target Completion Date: 1/13
1.4-XXX – Beam Finder Wire Specification
Author: Bailey Target Completion Date: 2/7
1.4-XXX – RF Beam Position Monitor Engineering Specification (UD5)
Author: Lill/Walters Target completion date: 1/31
4 additional ESDs planned requiring numbers assigned
ANL is pushing hard to get twice the amount of original ESDs out.

34. Vacuum Chamber Goes in Here
Ignore this slide.
Vacuum Chamber Goes in Here