Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 1 Undulator System Assembly, Installation, and Integration Rodd Pope, SLAC

Undulator System April 16-17, 2007 FAC Meeting 2 Past Six Months (1 of 4) Production Control Communication 10/06 - Geoff Pile is developing a tool. 4/07 - Tool is developed. 4/07 - Accessed successfully 4/12. 4/07 - Must be fully populated with data and maintained to add value. 10/06 - Release document transfer process is in place. 4/07 - Transfer of large assemblies plus drawings becoming more difficult but still more than worth the effort. 4/07 - Access to ANL ICMS successful on 4/11. 4/07 - SLAC has the ability to “PULL” released engineering drawings, Pro-E models, and STEP translations on-demand – FANTASTIC! 10/06 - Exact Statement of Work content will solidify scope of SLAC work. 4/07 - Undulator, Quadrupole, and Support Mover SOWs release to SLAC 4/07 - Vacuum Chamber Support SOW draft to SLAC 4/07 - Others not to SLAC. This has retarded the assembly and installation planning.

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 3 Past Six Months (2 of 4) 10/06 - WPM mockup operational in B750. 4/07 – Mockup built, operated, data recorded and analyzed, de- commissioned. 10/06 - Material handling equipment in place. 4/07 – Undulator cart refused by MMF. To be used by the assembly and installation group. MMF to produce their own handling cart. 10/ % of Undulators RFI. 4/07 – 0% RFI. 2 of 33 measured and ready for shimming. Technical issues with the shimming hardware design to be resolved with ANL support. 10/06 - Component deliveries beginning. 4/07 – All mu-metal shields and housing feet are at SLAC. 20 of 33 undulators and a portion of the undulator shims are at SLAC.

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 4 Past Six Months (3 of 4) 10/06 - HLS/WPM Final Design Review – 1/07 4/07 – Completed March 23, /06 - HLS/WPM Procurements Placed 4/07 – HLS sensors ordered. Delivery starts June /07 – Vendor qualification for WPM sensors April /07 – Balance of mechanical hardware RFQ by July /06 - Girder Assembly and Component Fiducialization 10/06 - Plan complete 4/07 – Preliminary plan review scheduled for 4/23 10/06 - Tooling designed and ordered 4/07 – Preliminary designs to be reviewed with the plan on 4/23

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 5 Past Six Months (4 of 4) 10/06 - Production Drawings and SOW’s archived at SLAC 4/ of ? Drawings archived at SLAC 4/ of ? SOW’s archived at SLAC 10/06 - Cable Plant Preliminary Design Review Complete – Long Lead Procurement Placed 4/07 – PDR now 6/07, FDR now 10/07, Installation 3/08 10/06 - Pedestal installation Statement of Work out for bid 4/07 – Per the integrated “2008 Installation” schedule, SOW RFQ is 8/07

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 6 Next Six Months (1 of 4) Deliveries through September 2007 Assembly will not start until Vacuum Chambers and RF BPMs have arrived (November 2007).

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 7 Next Six Months (2 of 4) HLS/WPM Sensors and Mechanical Hardware Delivered HLS/WPM Electronics on Order 20 of 33 of Undulators RFI 11 of 33 Quadrupoles RFI

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 8 Next Six Months (3 of 4) Cable Plant PDR 6/07, FDR 10/07, Installation 3/08 Award Davis-Bacon Contracts: Core drilling contract award 9/07 Pedestal installation contract award 9/07 Install Cable Plant contract award 12/07 Girder installation contract award 12/07

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 9 Next Six Months (4 of 4) Production Control Communication As the SOW’s are released, archive online at SLAC. Use the ASK system to track procurements, deliveries, and transfer of design ownership. Pull released drawings from ANL into SLAC archive. Incorporate information into assembly and installation documentation.

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 10 Schedule

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 11 Component Delivery Schedule Actual Plan

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 12 Assembly Delayed start until November 2007 due to component deliveries Impacted by the Continuing Resolution Fixed Support, Support Mover, Girder, and Translational Stage assembled and delivered in a 3 sub-assembly kit: 3-Cam Pedestal, 2-Cam Pedestal, Girder SLAC to perform QC and modify as necessary

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 13 Installation Member of Integration Management Team Member of Installation Management Team Coordinating Davis-Bacon contracts project wide Core drilling, pedestal install, cable plant, girder install Risks include girder assembly, project wide coordination of access and resources

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 14 Integration Communication More complicated through Continuing Resolution, challenging before. Technical data beyond drawings is limited. Focus has been getting the procurements on the street. Quality Issues Drawing errors, lack of QC data, communication of QC data that is available. Example: The oversized outer diameter of the undulator strongback was known since the strongbacks were machined. But the information was not forwarded and the impact of the deviation was not thoroughly analyzed. This deviation caused the ANL mu-metal shields not to fit, the SLAC kinematic mounts not to fit, and the ANL support feet not to fit.)

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 15 End of Presentation

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 16 Component Delivery Schedule

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 17 Undulator Assembly, Installation & Maintenance (U-AIM) Ben Poling, S&E Associate Ed Akerstrom, Principle Technician Nicolas Horton, Senior Technician TBH – When? Responsibilities include: Material handling, assembly, installation planning and execution Assembly and QA documentation Space and personnel resource planning

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 18 Assembly, Install, & Storage Space B750 – Storage/Assembly B081 – MMF Tuning/Fiducialization Undulator Tunnel

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 19 SLAC Magnetic Measurement Facility Wolf, Zachary, LCLS Management Presentation, April 11, 2006, Slide 3 Floor plan divided into three functional areas Magnetic Measurements (± 0.1º C) Fiducialization and Assembly (± 1º C) Storage (± 2.5º C) Quadrupole Fiducialization CMM Shared Area: Magnetic Measurements/Cam Calibration LCLS-TN-04-1

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 20 Girder Assembly Flow

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 21 Undulator System Girder Assembly Field Installation Precise/Vacuum Assembly performed in a control environment

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 22 Process Travelers Traveler Drafts Out For Review Undulator Tuning & Fiducialization Girder Assembly BFW Fiducialization Quadrupole Measurement & Fiducialization Pedestal Assembly CAM Assembly Inventory Database Physical location tracking Quality Assurance data collection Installation location mapping

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 23 SHORT BREAK By Scott Doran, ANL

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 24 SHORT BREAK CROSS SECTIONS By Scott Doran, ANL

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 25 LONG BREAK By Scott Doran, ANL

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 26 LONG BREAK CROSS SECTIONS By Scott Doran, ANL

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 27 Girder Assembly Prerequisite All necessary components fiducialized Stands aligned in all staging areas Outside MMF (possibly in Building 750) following the SPEAR3 Approach as suggested by Richard M. Boyce Step 1 Prepare Girder: Mount CAM wedges under girder Step 2 Component Installation, part 1 roll-away slides, component supports HLS & WPM components undulator vacuum chamber Step 3 Component Installation, part 2 quadrupole, BFW and BPM Step 4 Wiring / Plumbing In the Controlled Environment of the MMF Step 1 Optical Alignment Step 2 CMM Storage LeCocq, Catherine, October 27-28, 2005, FAC Meeting, Slide 13

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 28 UNDULATOR CELL ASSEMBLY NEXT CELL UNDULATOR SHOWN FOR CLARITY By Scott Doran, ANL

Rodd Pope, SLAC Undulator System April 16-17, 2007 FAC Meeting 29 UNDULATOR CELL ASSEMBLY NEXT CELL UNDULATOR SHOWN FOR CLARITY By Scott Doran, ANL