A U.S. Department of Energy Office of Science Laboratory Operated by The University of Chicago Argonne National Laboratory Office of Science U.S. Department of Energy Undulator Magnet Systems Scope/Plan/Schedule/Cost Marion M. White APS-ASD

Pioneering Science and Technology Office of Science U.S. Department of Energy 2 Scope – Undulator Systems 33 Precision magnetic arrays with canted poles 33 Support/alignment systems including: -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

Pioneering Science and Technology Office of Science U.S. Department of Energy 3 Scope - Undulator Module Magnet Assembly BPM Quadrupole Rails CAM Movers Cradle

Pioneering Science and Technology Office of Science U.S. Department of Energy 4 Scope – Undulator Spares 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.

Pioneering Science and Technology Office of Science U.S. Department of Energy 5 Plan – Undulators (1) 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].

Pioneering Science and Technology Office of Science U.S. Department of Energy 6 Plan – Undulators (2) 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 1 st article undulator [per vendor] in late 2005 reduces the undulator schedule risk significantly, but advances the funding needs. -FY05 1 st article undulators are not in the current baseline and funding plan.

Pioneering Science and Technology Office of Science U.S. Department of Energy 7 Plan – Undulators (3) 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.”

Pioneering Science and Technology Office of Science U.S. Department of Energy 8 Plan – Undulators (4) The first two assembled undulators are: -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

Pioneering Science and Technology Office of Science U.S. Department of Energy 9 Plan – Undulators (5) 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.

Pioneering Science and Technology Office of Science U.S. Department of Energy 10 Plan – Undulators (6) All subsequent undulators are shipped directly to SLAC for tuning, measurement, fiducialization, final assembly, etc. 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.

Pioneering Science and Technology Office of Science U.S. Department of Energy 11 Plan – Undulators (7) Details of the interfaces between undulator modules and other systems will be documented with ICDs [Interface Control Documents] agreed upon by all relevant parties. Acceptance criteria will be clearly documented. APPs are in preparation at this time.

Pioneering Science and Technology Office of Science U.S. Department of Energy 12 Schedule – Undulators Risks are decreased by having already constructed a prototype -and by early procurement of long-lead items. Advancing 1 st article undulators to later in FY05 would further decrease schedule risks. All undulators are to be delivered to SLAC by end of March 2007, consistent with completion in July end of the talk – continues to be refined.

Pioneering Science and Technology Office of Science U.S. Department of Energy 13 Cost – Undulators Costs for the long lead items are based on vendor quotes. Details were presented by Den Hartog in the May 2003 DOE review. Fabrication and Assembly costs are based on the cost to create the prototype, with additional money added for profit. The resulting number was cross- checked against actual costs for APS undulators, decreased to account for non-moving jaws, and increased to account for greater length. Cost estimate refinement continues.

Pioneering Science and Technology Office of Science U.S. Department of Energy 14 Scope – Quadrupole Magnet Systems 34 Quadrupole Magnet Systems - installed -Permanent Magnet Quadrupole -Support with Precision Translator [manually settable to 5 um; readout to 1um] 4 Spare Magnet Systems Separate steering is not included

Pioneering Science and Technology Office of Science U.S. Department of Energy 15 Plan – Quadrupole Magnet Systems (1) 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. Procurement packages will be prepared by experienced ANL-APS personnel according to an APP.

Pioneering Science and Technology Office of Science U.S. Department of Energy 16 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.”

Pioneering Science and Technology Office of Science U.S. Department of Energy 17 Schedule – Quadrupole Magnet Systems Quadrupole magnet production will be awarded in FY06. The 1st article will be measured at ANL. Subsequent magnets are delivered to the SLAC MMF, measured, and fiducialized in time for undulator assembly and alignment. - Awarding a 1 st article quadrupole assembly late in FY05 would reduce schedule risk, in that a 1 st article could be more fully investigated prior to beginning the production run.

Pioneering Science and Technology Office of Science U.S. Department of Energy 18 Schedule Level 4 Roll-up schedule (1)

Pioneering Science and Technology Office of Science U.S. Department of Energy 19 Level 4 Roll-up schedule (2)

Pioneering Science and Technology Office of Science U.S. Department of Energy 20 Milestone (1) 6/22/06 Oops

Pioneering Science and Technology Office of Science U.S. Department of Energy 21 Milestone (2)

Pioneering Science and Technology Office of Science U.S. Department of Energy 22 Milestone (3)

Pioneering Science and Technology Office of Science U.S. Department of Energy 23 Milestone (4)

Pioneering Science and Technology Office of Science U.S. Department of Energy 24 Milestone (5)

Pioneering Science and Technology Office of Science U.S. Department of Energy 25 Milestone (6)

Pioneering Science and Technology Office of Science U.S. Department of Energy 26 Milestone (8) The Magnet Measurement, Fiducialization, and Alignment detailed schedule is shown in Robert Ruland’s talk.

Pioneering Science and Technology Office of Science U.S. Department of Energy 27 Milestone (9)

Pioneering Science and Technology Office of Science U.S. Department of Energy 28 Summary Significant effort has been devoted to planning, resulting in a 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 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