LCLS Undulator System Update
FAC Review
April 16th & 17th
2007
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
LCLS Management at ANL
Change in ANL Project Director since last FAC
Milton becomes director for Fermi project at Elettra Feb
1st 07
Pile takes over 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
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
ANL Organization Chart
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Approximately 50 matrixed workers = ~ 20 FTEs
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
ANL LCLS Major Effort Issues
1.4.1 Management:
Need to Hire Integration Engineer (replacement for Pile)
Will need to replace QA Engineer ~June 07
Will need to replace Engineer for Progress, Task Coordination & Documentation ~June 07
Need secretarial assistance now
1.4.2 Controls:
Needed to ramp up effort - CPI and SPI need improvement.
Utilizing additional 2.5 Engineers + 1 technician from ESD
1.4.3 Undulator Magnet and Support:
Need to replace Vendor manager/contract specialist (GL’s contract could not be renewed)
Hired 66% of STA for checking drawings and SOWs. (Will use 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 - continued support required
1.4.5 Diagnostics:
BPM - Hired additional 25% of NE mechanical engineer for BPM production
BLM - Utilizing almost 1 combined extra FTE from Diagnostics group
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Effort
required from ASD
Diagnostics
BERG, WILLIAM
LILL, ROBERT M.
YANG, BINGXIN
ZABEL, RANDALL B.
DOMBROWSKI, PATRICK
ERWIN, LESTER L.
ASD- Diag
ASD- Diag
ASD- Diag
ASD- Diag
ASD-Diag
ASD-Diag
Magnetic Devices
DEJUS, ROGER J.
JASKI, MARK
KASA, MATTHEW
MERRITT, MICHAEL
MOOG, ELIZABETH
SASAKI, SHIGEMI
TERHAAR, JOHN
VASSERMAN, ISAAC
ASD-MD
ASD-MD
ASD-MD
ASD-MD
ASD-MD
ASD-MD
ASD-MD
ASD-MD
Operations
PASKY, STAN
ASD-Ops
588
0.5
Physics
WHITE, MARION
ASD-Phy
1092
0.93
RF Systems
WALDSCHMIDT, GEOFF
LANHAM, RENEE
ASD-RF
ASD-RF
1050
980
280
490
350
1176
3.68
385
280
280
70
280
280
1.34
40
0.03
LCLS STA
LAWRENCE, GLEN
16th &17th April 2007
LCLS Und. System Update
ASD-STA
1008
0.86
Geoff Pile
pileg@aps.anl.gov
Effort
required from ESD
16th &17th April 2007
LCLS Und. System Update
Controls
STEIN, S. JOSHUA
NORUM, WILLIAM ERIC
SHOAF, STEVEN
XU, JOSEPH Z.
LAIRD,BOB
BENES, SCOTT
FARRELL, SHARON
AES -Con
AES -Con
AES -Con
AES -Con
AES -Con
AES -Con
AES -Con
1092
1092
1176
280
480
720
588
4.62
Design Drafting
BUFFINGTON, TOM
GIVENS, MICHELLE
KEITHLEY, ROBERT L. JR.
CAPATINA, DANIELA
AES-DD
AES-DD
AES-DD
AES-DD
140
240
672
280
1.13
Mechanical Engineering & Design
LEE, SOON HONG
MORRISON, LEONARD
COKELEY, LORETTA
COLLINS, JEFFREY T.
DIDENKO, ALEXANDER
TRAKHTENBERG, EMIL
AES-MED
AES-MED
AES-MED
AES-MED
AES-MED
AES-MED
840
700
70
385
280
840
2.65
Survey and Alignment
JANSMA, WILLIAM G.
AES-SA
100
0.09
Geoff Pile
pileg@aps.anl.gov
Effort required from
Others: Note 2
additional AES staff
QA
BARSZ, THOMAS
AES-ADM
560
0.5
*Temps being replaced
* LEWELLEN, JOHN W.
* SCHNEIDER, JOHN F.
* SKUBAL, LAURA R.
AST-ONR
AST-ONR
AST-ONR
255
1176
1176
2.22
ECT
VOOGD, RICH
FMS-Electronics
LCLS
COOSE, FRANCES
LCLS
PILE, GEOFFERY
WALTERS, DEAN
LCLS-ADM
LCLS-PM
LCLS-PM
840
0.71
1176
1
1176
1176
2
Vacuum
HARRIS, GUY
AES-Vac
840
0.71
Nuclear Engineering
CLARK, FRANCES
NE
301
0.26
Nuclear Engineering
Bailey, James
MORGAN, JAMES
NE- Me
NE- Me
1176
875
1.74
Nuclear Engineering
DORAN, DARRELL SCOTT
GHILARDI, DONALD
SALAZAR, ESIQUIO
KMAK, RONALD T.
NE-DD
NE-DD
NE-DD
NE-DD
1176
210
140
700
1.89
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Effort Summary to ANL
The LCLS Undulator System will require ~15 APS
FTEs (+ 5 “others”) of effort to complete FY07
APS Group Leaders must own their Staff’s part of the schedule for the
LCLS project
Roughly 50 different people are named
This is spread over 16 groups
This is an estimate - we will still need to meet our commitment if our
estimate isn’t perfect
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
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.
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Major Deliverables
1.4.3 Undulator Magnet and Support:
Undulator Magnet Assemblies
Quad magnets and translation stages
Fixed Supports and Motion Systems
1.4.4 Undulator Vacuum System:
Stainless steel Chambers+ Support and leveling System
Pumping – acquisitions move to SLAC
Bellows
1.4.5 Diagnostics:
Beam Position Monitors
Beam Loss Monitors
Beam Finder Wire
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
CurrentCo-occupancy
ANL delivery schedules
Beneficial Occupancy
Undulator Support Stands
Cables/Cable Trays
Support Mover System
Girders, Control Electronics
Systems
16th
&17th
April 2007
LCLS Und. System Update
First Light:
Geoff
Pile18, 2008
July
pileg@aps.anl.gov
LCLS Installation and Commissioning Time-Line
Drive-Laser
Commissioning
Drive-Laser
Installed
LTU/und.
Install
Controls
Checkout
LTU/und.
hall “ready”
First Spont.
Light
A SOND J FMAM J J A SOND J FMAM J J
2006
2007
2008
Gun/Inj./BC1
Install
(8/21 – 2/20)
16th &17th April 2007
LCLS Und. System Update
Gun/Inj./BC1
Commissioning
Inj./Linac/BC2
Commissioning
linac/BC2
Install
LTU/und.
Commissioning
Geoff Pile
pileg@aps.anl.gov
Cost and Performance Report: 02-28-07
Rpt Period
02-28-2007
WBS
Level
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
04
04
04
04
04
04
04
04
04
04
04
04
04
Description
3 4 5 6
01
02
03
04
05
06
01
02
03
04
05
06
UNDULATOR SYSTEM
Undulator System Management & Integration
Controls
Undulator Magnet & Support
Vacuum System
Diagnostics
Undulator System Installation and Alignment
Undulator System Management & Integration
Controls
Undulator Magnet & Support
Vacuum System
Undulator System Diagnostics [OPC]
Undulator System Commissioning
16th &17th April 2007
LCLS Und. System Update
Cumulative to Date
Budgeted Cost
Variance
Actual Cost
Work
Work
Work
Cost
Scheduled Performed Performed Schedule
26,601,394 24,293,209 27,034,248 -2,308,185 -2,741,039
6,293,913 6,293,913 6,418,288
0 -124,375
1,779,283
581,698
387,213 -1,197,585
194,485
15,003,747 15,152,054 16,810,262 148,307 -1,658,208
1,103,937
775,479 1,357,650 -328,458 -582,171
2,399,599 1,467,505 2,031,856 -932,094 -564,351
20,916
22,561
28,979
1,645
-6,419
393,786
393,786
367,440
0
26,346
129,614
36,739
41,028
-92,875
-4,289
896,872 1,071,965
69,025 175,093 1,002,940
217,205
212,736
222,171
-4,469
-9,435
237,938
263,565
125,791
25,627
137,774
0
0
0
0
0
Geoff Pile
pileg@aps.anl.gov
Perf. Indices
SPI
0.91
1.00
0.33
1.01
0.70
0.61
1.08
1.00
0.28
1.20
0.98
1.11
CPI
0.90
0.98
1.50
0.90
0.57
0.72
0.78
1.07
0.90
15.53
0.96
2.10
FY 07 Financial Situation and the
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
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
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
“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
Remaining $3M will be required as soon as Support Mover contract and
Vacuum requisitions have been placed. (SM vendor evaluations are in
progress at ANL – Vac system component orders are being processed now)
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.1 Management
Organization and Responsibilities
ANL is now mainly in the procurement and delivery
stages of the project
Developed the ASK procurement and delivery system software
and are currently loading information – will deploy May1st 07
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
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
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)
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.3 Magnets and Supports
Undulator #33 was accepted on 15 February 2007.
Thirty- five undulators are now complete
Enough Undulators have been manufactured to complete the full
installation in the LCLS tunnel - this is a milestone of sorts.
20 undulators at SLAC, 1 at ANL and fourteen ready to ship from
vendors
All forty undulator assemblies will be completed in June
Final Design Pre-production support stands and a
girder have been delivered to ANL
The support installation and girder assembly process is a “work in
progress” –see LTT slides
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.3 Magnets and Supports
Support Mover System.
Designs, drawings, documentation and Statement of Work completed. Zero
funded req allowed for vendor bids - Currently evaluating responses, Funds
are available & should place contract in next week or two. Schedule may be
an issue with some potential vendors
Quadrupoles
Working with Everson -TESLA to advance the schedule of first articles.
Details for the production units are being decided upon as and when we get
info from the vendor- delivery schedule is very tight. No additional info on
corrector effects – no power planned for correctors
Quad production support/translation stage requisition processed in April 07delivery schedule looks promising
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Long Term Test
The re-designed support mover stands and
their mounts 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 1000lb weight
(simulating the undulator).
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Long Term Test
Quad centre is
affected by undulator
weight during roll out
Keyence Testing of
micron level
movements to
pedestal caused by
1000lbs of 80mm roll
out
Final design of
support mounting
improves stand
deflection by at least
three times
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Long Term Test
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.4 Vacuum System
FY07 – Risk reduction required due to
uncertainties in design, production and schedule of
Stainless Chambers
Started parallel effort and construction of Aluminum Vs
Stainless prototype Chambers
Progress review and decision tree applied to both
systems in February – neither system mitigates all risks
Reviewers choose Stainless Chamber and Aluminum
effort is dropped
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.4 Vacuum System
Two full sized prototypes have been built.
All planned fabrication steps have been performed.
Seam Welds were performed by Laser Welding.
Even though leaks were found, they have been repaired.
The vendor is organizing further work to address them.
Construction of the 12 foot fixture and initial development of
the AC Diode Sputtering process has lead to Aluminum
coatings applied to both prototypes.
The chambers have been baked and their measured
outgassing rate is lower than the specification
See string tests in Dean Walters Talk
Many preparations for production are in-process or in place.
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.4 Vacuum System
ANL will be the “General Contractor” for
manufacture of the vacuum Chambers
Materials acquisition (in House)
Aluminum Coating (in House)
QA and engineering oversight (in House)
Machining (outside vendors)
Laser Welding (outside vendor)
2-3 month (up front) Schedule slip caused by lack
funds for long lead materials - CR has had it’s
effects.
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Vacuum System Schedule
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.5 Diagnostics
RF BPM
Single RF BPM at brazing vendor
Vendor problems during development of brazing fixtures – first brazed
bpm delivery is delayed possibly another month
Three bpms waiting for brazing immediately first bpm braze is perfected
Production schedule for BPMs is of serious concern – Prototype brazing
is taking much longer than planned Current production estimates push
us out many months late – We know we have to do everything we can
to pull dates back
3 BPM Test
Modifications decided on
Test with beam similar to LCLS injector beam
See R. Lill’s talk for details
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Prototype BPMs for 3-BPM test
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
LEUTL 3 BPM Test Readiness
Mid-May Testing
Scheduled
PC gun beam 325 MeV
to dump
33 Hor. and 23 Vert.
micron normalized
emittance
Compressed beam
less than 1 ps
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.5 Diagnostics
Beam Finder Wire
Weldment, Machined Parts, Chamber, Catalog Items
and all Hardware Design and Procurement Documents
are complete and are in the procurement process
Wire Card is currently under final design.
Fixture designs are 90% complete.
Alignment and Assembly Procedures are 50% complete
Schedule for production looks tight and will require good
vendor management to keep on target
See Dean Walters talk for schedule
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
1.4.5 Diagnostics
BFW Assembly (Body Sectioned) Wire Card Down in Inactive Mode
Electrical Connectors
(Down Position)
Potentiometer
(Out Position)
Internal Return Spring
(Expanded Position)
Internal Kinematic Stop
Plates
(Open Position)
Bellows Seal
(Compressed Position)
BEAM
From J. Bailey et al.
16th &17th April 2007
LCLS Und. System Update
Pneumatic Solenoid Valve
(Cylinder Vent Position)
Lower Limit Switch
(Actuated Position)
Wire card
(Down Position)
Geoff Pile
pileg@aps.anl.gov
1.4.5 Diagnostics
Beam Loss Monitor
Conceptual designs are in good shape
Multi-tiered to cover a very large dynamic range
Simulations In Process
Determination of distribution and dose
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
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov
Summary
Good progress is being
made in many areas
Hot spots
Vacuum Chamber
Production quality, welding,
coating and permeability
require careful
management/oversight
Quadrupoles
Schedule –close attention req.
Hysteresis
16th &17th April 2007
LCLS Und. System Update
Beam Loss Monitor
Completion of design
Final Large
Procurements
Support Mover
Schedule concerns
RF BPM
Vacuum Chambers
materials
Beam Finder Wire Card
Beam Loss Monitor
Geoff Pile
pileg@aps.anl.gov
Re-cap: FY07 and the CR Effects
October 06 thru early January 07
No new long lead production procurements started
Vacuum chamber competition used to enhance production –delays large value procurements
Support Motion drawings & documentation developed to more acceptable levels – SM system
Statement Of Work allows for construction of complete system by General Contractor (s)
Effort : planned worst case scenarios
Mid January 07 thru March 07
Effort commitments from ANL: not easy to negotiate.
Procurements put on hold - very difficult to plan
Utilized every aspect of ANL’s procurement systems to generate approved zero funded reqs
April 07
Funds available - routing funded requisitions for re-approvals
Re-planning of Cost and Schedule +BCRs
Effects: are schedule slips ~3 to 4 months – core team needs to be around until end of FY08
Costs: 1 month burn rate of ANL effort and service centers ~$600K x 4mnths = $2.4M
Management effort needs to be increased and extended
Controls effort needs to be increased and extended
Vacuum system hardware costs increase
LTT costs added
Need: funds to cover CR schedule and cost effects – should be CR rebate not contingency
16th &17th April 2007
LCLS Und. System Update
Geoff Pile
pileg@aps.anl.gov