Transcript Undulator Systems

LCLS Undulator System Update
FAC Review
October 29th(30th&31
2007
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
ANL/LCLS Undulator Project Management
Chart
Lori
Cesario
Bill
Berg
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
ANL/LCLS Undulator System Integration Engineer
BERG, WILLIAM
Argonne National Laboratory
9700 S. Cass, IL 60439
Extension:2-6929
BLDG 401-B2199
Radio Page:4-1882
E-mail Page:[email protected]
E-mail Address:[email protected]
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
ANL/LCLS Undulator System Program Control
Management System (PCMS)
Fran Clark retired in September 07 – STA advisor when required
Lori Cesario now ANL PCMS main point of contact
Lori Cesario
Argonne National Laboratory
9700 S. Cass, IL 60439
Extension:2-7389
BLDG 362 C169
E-mail Address: [email protected]
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
ANL LCLS Major Effort Covered for FY08
09/07 – Completed FY08 Agreement sheet estimates for ANL/LCLS workers
10/07 - ANL management agree LCLS effort profiles for FY08
1.4.1 Management:
Hired Integration Engineer (replacement for Pile)
Secured 2 QA Engineers/Reps(~ 1 FTE) thru Sept 08
Secured 2 QC coordinators for Progress, Task Coordination & Documentation ~ thru July08
Added part-time secretarial assistance
1.4.2 Controls:
Sufficient Effort available - continued support required
1.4.3 Undulator Magnet and Support:
Sufficient Effort available - continued support required
1.4.4 Undulator Vacuum System:
Sufficient Effort available - huge effort is required to meet schedule
1.4.5 Diagnostics:
BPM - Additional engineering and technician help added for BPM production
BLM - Sufficient Effort available - Using almost one extra FTE from Diagnostics group
- huge effort is required to meet schedule for both BPM and BLM
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
ANL LCLS Effort Profile/Plan FY08/09
ANL production engineering effort drops off significantly in March/April 08
April through July 08 technical leads and key players left to help with delivery and
installation issues
Documentation hand over will be covered through September 08
July 08 through September 08 only key 1.4.1 management left. All management effort is
reduced by 50%
End of September 08 – ANL plans to be off the project
FY09 ANL has small budget to contribute to Undulator Commissioning
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
LCLS Installation and Commissioning Time-Line
LTU/und. “Dirty Install”Beneficial Occupancy.
Und. Installation
hall “Co occupancy.”
Girder
Installation
Starts
Prep for Support
Stand Installation
A S O N D
2007
J
F M A M J
J
2008
Inj./Linac/BC2 Commissioning
linac/BC2 Install
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
LTU/Undulator System
instalation Check
out/Commissioning
Geoff Pile
[email protected]
Current ANL delivery schedules
Co-occupancy
Beneficial Occupancy
Undulator Support Stands
Cables/Cable Trays
Support Mover System
Girders, Control Electronics
Support Motion
Support Motion Est
45
Quadrupole
40
Quad Est
Vac Chamber
35
Vac Chamber Est
Vac Supports
30
Vac Supports Est
Vac Bellows
25
Vac Bellows Est
Vac Spools
20
Vac Spools Est
BFW
15
BFW Est
BPM
10
BPM Est
BLM
5
BLM Est
Tuning
0
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
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Tuning Est
Geoff Pile
[email protected]
Girder Assembly
Girder Inst
Major Deliverables
& Concern factors scaled to 10 (0-5 schedule 0-5 technical)
1.4.1 Management:
Safety
Quality Assurance
Budget and Schedule
Integration and Installation
Admin. – Procurement, vendor management and documentation.
1.4.2 Controls:
5 (4s -1t)
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.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Major Deliverables & Concern factors
scaled from 0 to 10
(0-5 schedule 0-5 technical)
1.4.3 Undulator Magnet and Support:
4 (3s+1t)
Undulator Magnet Assemblies
Quad magnets and translation stages
Fixed Supports and Motion Systems
1.4.4 Undulator Vacuum System:
7 (3.5s+ 3.5t)
Aluminum Vacuum chamber + Support and leveling System
Pumping – acquisitions move to SLAC
Bellows
1.4.5 Diagnostics:
8 (5s+3t)
Beam Position Monitors
Beam Loss Monitors
Beam Finder Wire
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
1.4.3 Magnets and Supports
Undulators
39 Undulators @SLAC
1 Undulator @Argonne
Support Mover System
1 Support & Motion System
@Argonne
8 Support & Motion Systems
@SLAC
4 Support & Motion System
@Hi-Tech ready to ship
Remaining 25 Support & Motion
Systems now in production
@Hi-Tech/Metalex
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Date
Totals SM systems
Delivered to SLAC
(current estimate)
10/24/2007
8
11/7/2007
12
11/21/2007
18
12/7/2007
23
12/21/2007
28
1/15/2008
33
1/23/2008
38
Geoff Pile
[email protected]
Quadrupoles
Two 1st articles - marginally low in field
Date
They were rejected and the revised design has
123 laminations instead of 115.
Two new replacement first articles are in
production and will be delivered to ANL this
week; we have negotiated with ET to speed up
the rest of the schedule and bring us back on
track.
1 production Quadrupole stage is at Argonne;
the rest were delivered to SLAC.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Totals Delivered to
SLAC
(current estimate)
11/5/2007
1
11/13/2007
2
11/19/2007
3
11/29/2007
5
11/29/2007
7
12/4/2007
11
12/19/2007
15
1/9/2008
19
1/18/2008
23
1/30/2008
27
2/8/2008
31
2/19/2008
35
2/25/2008
37
Geoff Pile
[email protected]
Long Term Test Update
Final Design 1st Article support stands and girder
delivered to ANL – installed QA accepted in
September 07.
The support motion and girder assembly installation
process is a “work in progress” – see LTT slides
The pre-production girder has been cut in half. We are
using it with the two pre-production supports to create
the short and long break sections too.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
1.4.4 Vacuum System
Un-resolvable questions with Stainless Chambers Decision made in September 07 to build production
Extruded Vacuum chambers
Two full sized Aluminum prototypes have been built.
All planned fabrication steps have been performed.
The chambers have been baked and their measured out-gassing rate is
lower than the specification
Many preparations for production are in-process or in place.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Aluminum Extrusion
Prototype Conclusions…
The extrusion can be manufactured and machined with wall thickness
and straightness required to meet final installation tolerances. The full
length chamber can be produced within all acceptable dimensional
tolerances.
Uniform 0.5 mm nominal wall thickness and vacuum integrity required
to maintain the specified average pressure was achieved.
Average surface finish achieved in testing - meets current PRD spec.
The polishing process improves the surface finish without introducing
contaminants
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
1.4.4 Vacuum System
ANL will be the “General Contractor” for manufacture of the
Aluminum Extruded Vacuum Chambers
Extrusions (in House)
Explosion bonded C-fix Flanges (on order)
Extrusion Polishing in process (outside Vendor)
Extrusion Machining in process (outside vendors)
Ready for flange welding and vacuum processing (in House)
Significant in house Engineering and QA oversight required
Outstanding progress so far on very demanding schedule (almost
parallels SS working schedule) but experienced group fully
committed to meet it.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
The Schedule…
The Cost……
Event
Original Completion
Date
Updated Completion
Date
Polishing of all
extrusions
12/07/07
11/30/07
Machining of all
extrusions
4/21/08
Chamber Processing at
ANL
4/23/08
Ship Chambers 1-5 to
SLAC
1/23/08
Ship Chambers 6-10 to
SLAC
1/28/08
2/22/08
6-11
Ship Chambers 11-20
to SLAC
3/10/08
3/14/08
11-22
Ship Chambers 21-30
to SLAC
3/26/08
4/4/08
22-33
Ship Chambers 31-40
to SLAC
4/25/08
4/29/08
33-40
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
2/1/08
1-6
Cost Items
Updated Estimates and
Quotes…Oct 07
Extrusions
$11,165.44
Flanges
$41,310.00
Polishing Prep
$350.00
Polishing
$152,819.85
Straightening
$15,600.00
Machining
$238,400.00
Crating
$4,979.60
Surface Sampling
$5,040.00
ANL labor
~$220,000
Total
$689,664.89
Geoff Pile
[email protected]
BPM Status
X-Band Cavity BPM
Development phase complete
Production procurement in place
First machined production units expected in November
Receiver Electronics
4 First article prototypes assembled and tested with good results
3-BPM testing prototypes incorporate receiver, local oscillator and filter first
article packaging
Production procurement ongoing -10 units at SLAC 1/4/08,
20 units by 1/5/08, 30 units by 1/6/08, 40 units by 1/7/08
Test Qualification
Successful collaborative effort testing and qualifying BPM system
Qualified system with the same ADC (PAD) as SLAC LINAC BPM upgrade
to minimize risk of integration
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Comprehensive BPM Test Program
1 m Resolution spec met: (09/27/07) < 0.6m
Long term drift spec for 1 hour spec met
Gain stability spec met
1 hour temperature stability spec met
24 hour temperature stability spec met electronics with
simulated beam
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Cavity BPM Production Status
Cavity BPM machining contracts
placed with parts expected 11/27/07
Two vendors will provide a single
machined First Article production
BPM for evaluation
Vacuum window first lot delivery
11/12/07
Group & #
Totals
Delivered to
SLAC
Date
RFI: Group A(2)
2
1/15/2008
RFI: Group B (6)
8
2/17/2008
RFI: Group C (10)
18
3/15/2008
RFI: Group D(8)
26
4/16/2008
RFI: Group E(10)
36
5/10/2008
Vendor for brazing BPM pending
contract award
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
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 and production
phase.
Wire Card is currently under final design at SLAC.
Alignment and Assembly Procedures are 90% complete
Schedule for production looks tight and will require good
vendor management to keep on target
•
•
•
•
FAC
Lot #1 ( 3) 12/12/2007 Beam Finder Wires at SLAC
Lot #2 (10) 1/14/2008
Lot #3 (10) 2/11/2008
Lot #4 10) 3/20/2008
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
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.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Pneumatic Solenoid Valve
(Cylinder Vent Position)
Lower Limit Switch
(Actuated Position)
Wire card
(Down Position)
Geoff Pile
[email protected]
1.4.5 Diagnostics
Beam Loss Monitor
Engineering re-design - design is for MPS system and
not Diagnostic
PRD complete – This design does not meet PRD
Current proposal for BLM is only as an MPS input for now
Even in simple form the cost and schedule is still of concern.
Future ANL/SLAC collaboration on upgrade may be viable later?
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Beam Loss Monitor
A Simple MPS/Beam Loss Monitor system for now!
Production design will inhibit beam when beam loss is detected above a predetermined set-point. Requires limited dynamic range from the detector(s)
Expect to install in undulator tunnel July 08
****************************************************************************************************
A more Sophisticated BLM may be required – no reasonable solution available
at present.
Future design will meet PRD requirements.
This design will keep track of the total accumulated exposure of the magnets in each
Undulator.
Helps predict, understand and curtail operational scenarios that may cause long term
magnet damage.
Requires a large dynamic range for the radiation detector(s) and much more sophisticated
electronics and software.
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Production BLM design
Detector
Moves with the
Undulator and
protects during
undulator roll
out
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
Geoff Pile
[email protected]
Summary
Good progress is being made in all
areas
Hot spots
Quadrupoles
Schedule – close attention req.
Vacuum Flanges
Very finicky – “first time” sealing <100%
Good QA, inspection and careful handling
required
Vacuum Chamber
Production quality, surface finish,
straightening and machining all require
careful oversight
FAC
29th, 30th& 31st October 2007
LCLS Und. System Update
BPM moves into Production
Lots of oversight required
Beam Loss Monitor
Completion of design
Final Large Procurements
Vacuum Chamber Machining
BPM body manufacturing,
BPM electronics manufacturing
Schedule Concerns
RF BPM
Vacuum Chambers
Beam Finder Wire Card
Beam Loss Monitor
Geoff Pile
[email protected]