Procurement and Manufacture of LCLS Undulators FY 04 Activity:

Procurement and Manufacture of LCLS Undulators
FY 04 Activity:
Complete design of Second Prototype Undulator
This will include field control comb
Procure Fabrication Engineering to manufacture the second prototype
Build to specification. Model of undulator provided to vendor
Vendor would perform value engineering on the ANL design, and make
recommendations to improve assembly process and cost reductions
The intellectual property for these improvements would belong to ANL and
will be used for the production quantity
One of the critical issues will be quality control
Final magnetic measurements and tuning would be done at APS
FY 05 activities:
Following measurements and review, complete the design of the production LCLS undulator
Procure production quantities of the Ti strongback, magnet blocks, and magnet poles. Blocks
and Poles should be delivered in FY 05. Strongback delivery completion is predicted for Dec.
Prepare a statement of work to procure the first article of the LCLS undulator
Use “long lead procurement” funds
Possibly award contracts to two vendors to manufacture first articles
After evaluating the first articles, procure the remaining undulators. In the two vendor
model, the quantity awarded to the vendor would depend on the productivity and cost
demonstrated in the first article
The vendors quality assurance plan will be a determining factor in making the award.
Initial magnetic measurements and tuning will be done at APS. These measurements will
provide calibration for the SLAC facility
Construction of the magnetic measurement facility at SLAC should start this fiscal year
FY 06 activities:
Award the contract (s) for manufacture of LCLS undulator
Total quantity will be 40 including the first
Delays in FY 06 funding will hurt the delivery schedule
Delivery should start in Feb 06 and continue through July 07. The estimated production rate
would be 2 per month.
Magnet measurements at SLAC could begin in Mar 06 and continue through Aug 07. The
estimated measurement rate is 2 per month. It is forecast that the 33 undulators necessary for
LCLS would be measured by May 07.
Resources would be drawn from the Experimental Facilities Engineering and Magnetic Devices
Engineering and Design:
Pat Den Hartog
Emil Trahktenberg
Bran Brajuskovic
Mark Erdmann
Magnetic Design and:
Liz Moog
Shigemi Sasaki
Isaac Vasserman
Tom Powers
Glenn Lawrence
Gary Edgell (ANL-Procurement)
The assignments would require 100 % commitment for short duration.
Plan to Fabricate
the Second Prototype Undulator
Complete design changes to First Prototype: Trahktenberg
12 weeks
Prepare statement of work for Ti forging
magnet blocks, and magnet poles, and procure
3 weeks
Delivery of forge:
8 weeks
After design is complete:
Prepare statement of work for Ti machining
and procure
Delivery of machined Ti strongback
Prepare statement of work for Fabrication
Engineering contract to manufacture the
second prototype and procure
9 weeks
Delivery of second prototype
3 weeks
14 weeks
16 weeks
6 weeks
1 week
Plan for Undulator Production
Complete design for Production:
12 weeks
Review for production:
Prepare statement of work for
Ti strongback, magnet blocks,
magnet poles, and procure
3 weeks
Delivery of magnet blocks:
15 weeks
Delivery of magnet poles:
18 weeks
Delivery of strongbacks:
37 weeks
Prepare statement of work for:
production undulators
12 weeks
Plan, review and approval:
5 weeks
86 weeks
Measurements at SLAC:
80 weeks
Because of the success of scientists and engineers in the MD and XFE groups in achieving
specifications, the LCLS undulators are essentially procurement and quality control
problems. There appears to be no technical barrier to achieving requirements for the LCLS
The estimated schedule for procurement, from second prototype through production, does
identify time constraints.
If continuing resolutions occur in FY 05, the delivery of long lead items is
threatened. This could choke undulator manufacture, especially for the Ti
If a continuing resolution occurs in FY 06, the ability of manufacturing to
meet the installation schedule is threatened.
Procuring fabrication engineering services to manufacture the second prototype creates a
problem for procurement of the production quantity. Under DoE acquisition regulations, the
vendor that manufactures a prototype is typically excluded from bidding on the production
contract. Since there are so few undulator manufacturers, this is a major problem.
Discussions are continuing with the contract officer to resolve this barrier.