Transcript Scope/Schedule/Costs/Plans

Undulator Magnet Systems
Scope/Plan/Schedule/Cost
Marion M. White APS-ASD
Argonne National Laboratory
Office of Science
U.S. Department of Energy
A U.S. Department of Energy
Office of Science Laboratory
Operated by The University of Chicago
Scope – Undulator Systems
• 33 Precision magnetic arrays with canted poles
• 33 Support/alignment systems including:
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- Cradle that supports the undulator, BPM, and
quadrupole magnet.
- Precision CAM movers and motors enabling
positioning, alignment, and adjustment of the cradle.
- Rail system to move the undulator, facilitating manual
retraction of an undulator out of the beamline and
precision reproducible re-insertion.
7 Spare Undulator Systems
1 Undulator Transport Device for Installation
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Scope - Undulator Module
Quadrupole
Rails
Magnet Assembly
CAM Movers
BPM
Cradle
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Scope – Undulator Spares
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7 spare undulator units
- 4 complete modules -- assembled, together with
BPM and quadrupole, aligned, fiducialized, and
stored in a temperature-controlled environment.
- 3 modules are ready for installation at any time.
- 1 is a reference module, maintained in a thermally
stable environment and used for long-term stability
monitoring.
- 3 include just the undulator and support systems, no
quadrupole or BPM; not final assembled.
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Plan – Undulators (1)
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To meet schedule and funding profiles, and to ensure
that the Undulator Systems are complete by July
2007, we plan to procure the following long-lead items
as early as possible in FY05:
- Precision-machined titanium strongbacks
- Magnet blocks
- Magnet poles
The same APS undulator experts, who were relied
upon for design, construction, and assessment of the
prototype, will finalize procurement packages for the
LL items, in accordance with our Advance
Procurement Plans [APP].
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Plan – Undulators (2)
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Undulator magnet and support fabrication and
assembly contracts will be awarded as early as
possible in 2006, to at most two pre-qualified
vendors who are competent in precision mechanical
fabrication and assembly.
- Awarding a 1st article undulator [per vendor] in late
2005 reduces the undulator schedule risk
significantly, but advances the funding needs.
- FY05 1st article undulators are not in the current
baseline and funding plan.
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Plan – Undulators (3)
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Responsibility for vendor management and vendor
performance oversight rests with ANL-APS.
• Periodic travel is required during the procurement
and production phases for vendor pre-qualification,
QA, process monitoring, and acceptance testing.
• Undulator assembly vendors will be furnished with
all “travelers” from the long lead-item production,
and they will provide complete undulator
documentation, information, and production
travelers. Relevant data will be reviewed prior to
“permission to ship.”
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Plan – Undulators (4)
• The first two assembled undulators are:
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Factory accepted at the vendor(s) and shipped to ANL
Tuned and measured (magnetic & mechanical) at ANL
Accepted officially by ANL
Shipped to SLAC
Re-measured at the MMF
Fiducialized
Assembled together with
- Measured and fiducialized quadrupole,
- Calibrated, cleaned, baked, and fiducialized BPM,
- Cleaned, baked, and aligned vacuum chamber
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Plan – Undulators (5)
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The first two assembled undulators (cont’d.):
- The complete undulator module undergoes final
alignment and is - Declared Ready for Installation
- It’s then either installed, or, if the building is not
deemed an undulatorially-safe environment at the
time, it is carefully transported to a long-term,
temperature- and humidity-controlled storage area.
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Plan – Undulators (6)
• All subsequent undulators are shipped directly to
SLAC for tuning, measurement, fiducialization, final
assembly, etc.
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Some ANL-APS effort is associated with 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.
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Plan – Undulators (7)
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Details of the interfaces between undulator modules
and other systems will be documented with ICDs
[Interface Control Documents] agreed upon by all
relevant parties.
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Acceptance criteria will be clearly documented.
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APPs are in preparation at this time.
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Schedule – Undulators
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Risks are decreased by having already constructed
a prototype
- and by early procurement of long-lead items.
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Advancing 1st article undulators to later in FY05
would further decrease schedule risks.
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All undulators are to be delivered to SLAC by end of
March 2007, consistent with completion in July 2007.
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Schedule @ end of the talk – continues to be refined.
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Cost – Undulators
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Costs for the long lead items are based on vendor
quotes. Details were presented by Den Hartog in the
May 2003 DOE review.
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Fabrication and Assembly costs are based on the
cost to create the prototype, with additional money
added for profit. The resulting number was crosschecked against actual costs for APS undulators,
decreased to account for non-moving jaws, and
increased to account for greater length.
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Cost estimate refinement continues.
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Scope – Quadrupole Magnet Systems
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34 Quadrupole Magnet Systems - installed
- Permanent Magnet Quadrupole
- Support with Precision Translator [manually settable
to 5 um; readout to 1um]
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4 Spare Magnet Systems
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Separate steering is not included
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Plan – Quadrupole Magnet Systems (1)
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The permanent-magnet quadrupoles, including
supports and translators, will be procured from and
designed by a vendor per our physics, engineering,
and magnet quality specifications.
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Procurement packages will be prepared by
experienced ANL-APS personnel according to an
APP.
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Plan - Quadrupole Magnet Systems (2)
•
Responsibility for vendor management and vendor
performance oversight rests with ANL-APS.
•
Periodic travel is required during the procurement
and production phases for vendor pre-qualification,
QA, process monitoring, and acceptance testing.
•
The vendor will provide LCLS with complete
documentation, information, and travelers from the
production. Relevant data will be reviewed prior to
“permission to ship.”
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Schedule – Quadrupole Magnet Systems
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Quadrupole magnet production will be awarded in
FY06. The 1st article will be measured at ANL.
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Subsequent magnets are delivered to the SLAC
MMF, measured, and fiducialized in time for
undulator assembly and alignment.
- Awarding a 1st article quadrupole assembly late
in FY05 would reduce schedule risk, in that a 1st
article could be more fully investigated prior to
beginning the production run.
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Level 4 Roll-up schedule (1)
Schedule
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Level 4 Roll-up schedule (2)
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Milestone (1)
6/22/06
Oops
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Milestone (2)
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Milestone (3)
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Milestone (4)
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Milestone (5)
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Milestone (6)
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Milestone (8)
The Magnet Measurement, Fiducialization, and Alignment
detailed schedule is shown in Robert Ruland’s talk.
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Milestone (9)
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Summary
• Significant effort has been devoted to planning, resulting in a
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detailed undulator construction schedule that is integrated with
the BPM, quadrupole and vacuum chamber construction and
testing. The undulator schedule and the magnet measurement
schedule are mostly integrated, and are consistent with
completion of undulator systems in July 2007.
A skeleton installation schedule exists; details are being added
and integration with the rest of the schedule is ongoing.
Schedule refinement is ongoing.
Costs were estimated by in-house experts with relevant
experience and were based on vendor quotes and previous
experience. Cost scrubbing will continue.
The greatest schedule risks come from:
- Design changes
- Delayed funding
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