The Effort Reporting System: A Tutorial & A Look at LCLS Undulator System Integration

1. The Effort Reporting System: A Tutorial & A Look at LCLS Undulator System Integration Geoff Pile

2. The Effort Reporting System: A Tutorial • The APS/LCLS portion of the overall LCLS project is approximately $45M included in almost $400M for SLAC. • FY06 effort required from APS is ~20 FTE’s (made up from ~59 contributors) 7- 8 are assigned full time. • The other 12 FTE’s are made up from over 50 very important part-time contributors. • Apart from the academic experiences gained, these contributors earn money for the APS if their effort is reported and invoiced correctly.

3. The Effort Reporting System: A Tutorial • It’s seems simple to report and invoice SLAC correctly but it’s not easy! • We have a lot of people and a lot cost accounts to book against (See the complex WBS system). • We have developed our own LCLS electronic effort reporting system to interface with the ANL existing system. • How do we get it right and minimize corrections? • How does it all work?

4. The Effort Reporting System: A Tutorial • The existing system: Using February as an example • Feb 21st: Your Effort sheet for Feb – required by groups (This means you have to estimate the last week or so ) • Feb 24th: Division sends all groups effort to 201 • Feb 28th: Staff absence sheet required by div (You also get paid for February as well!) • March 3rd or 4th: LCLS gets the detailed charges to compare with effort booked against cost-codes • 17th March: Your February Effort (real) correction sheets due • 21st : March ANL prepares invoices to SLAC from ANL reporting system

5. The Effort Reporting System: Feb 21st (to group)

6. The Effort Reporting System: Daily Effort 2/21 This info can be obtained accurately from the LCLS T/E system Totals 176 hrs

7. The Effort Reporting System: Absence 2/28

8. The Effort Reporting System: Compared by 3/3 LCLS checks and does a comparison

9. The Effort Reporting System: Feb Effort Confirmation by 3/17

10. The Effort Reporting System: • Here’s the web address for the LCLS site http://www.lcls.aps.anl.gov/ • Here’s the web address for the Effort Reporting System http://beam.aps.anl.gov/pls/apsweb/lcls0001.start_page

11. The Effort Reporting System: • How can you help? • Understand the process. • Fill out the Green Sheets every week. • Look at the tasks on the green sheets and think about providing your best estimates. • Print up a copy of your T/E report and use it for your ANL daily effort estimate. • We want you to ask questions if your not sure. • Thanks a million……………..

12. Vacuum Chamber Goes in Here Vacuum Chamber Goes in Here The LCLS Prototype Undulator - & Integration

13. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

14. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

15. Hazard and Risk Controls [A few minutes in 30: An example of an integrated safety net] Suspect Counterfeit Bolts • Integrating Safety into LCLS ANL Training includes ESH273 (identifying counterfeit components) to comply with DOE order G440 1-6. • Integrating QA into safety at APS-LCLS Tom Barsz (QA) has created a comprehensive QA program for APS – LCLS. Every PARIS procurement requires QA approval. Every QA approval has built- in safety checks. Tom’s QA database double-checks PARIS acquisitions. Net result: Enhanced Safety

16. Integrating Safety at APS-LCLS PARIS gets linked to QA database PARISreq # → Tom’s supplier history → ESH and QA checklists →

17. Integrating Safety at APS-LCLS ← Vendor product info Tom’s issues → ESH and QA Check – flags an item for disapproval →

18. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

19. Undulator Systems Integration Why define clear roles in integration? Helps prevent project failures. Defines who’s doing what, where, and when. In the initial phases of the project, people look after their own design problems first. They may not always consider integration consequences. When? Weekly CAM, CPR, group meetings, and Internal Design Reviews help with integration and general awareness of issues. Organized weekly ANL/SLAC meetings until the end of the project. RP and GP have regular teleconference between ANL & SLAC. All APS/SLAC staff are invited to participate whenever they need/wish. Who? Rodd Pope (SLAC) and Geoff Pile (ANL) planning post-SUT activities at ANL and SLAC. Cost account managers (CAMs); delegate project tasks to staff in order to meet defined goals in the Effort Scheduling & Reporting Tool. Define Clear Roles and Responsibilities

20. Define Clear Roles and Responsibilities

21. Define Clear Roles and Responsibilities

22. Define Clear Roles and Responsibilities

23. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

24. Integration Priorities Overall System Integration Philosophy • Design Phase • Understand the concept., design the sub components. Integrate them together. • Build and Testing Phase • Verify form, fit and function. Integrate enhancements from SUT into the Final Designs for production. • Production Assembly Phase • Integrating the schedule for delivery, assembly and alignment of components. • Installation and Commissioning Phase • Integrate all mechanical, electrical and alignment tasks for installation prior to initial component turn-on and commissioning.

25. FY05 Integration Priorities During Design and Build Phase • We continued to plan, schedule, and incorporate Base Line Changes • Continual review of overall concepts and specifications • Review all the most recent designs (even without IDRs) • Individual designs are integrated into complete assembly drawings • Review all interfaces • Good revision control • Internal Design Reviews firm up concepts • Building, testing, and verifying component designs for SUT FY06: Now we’re in a better position to plan details for assembly, installation, and commissioning

26. SHORT BREAK FY05 Integration Priorities: get firmer designs Significant change and progress in the past few months END VIEW at BPM LONG BREAK

27. IDRs: Quad and Corrector Magnets 11/18/06 Uses the same power supplies as SLAC: MCOR Power Systems Initial Concept for Quadrupole/Corrector Magnet Quadrupole/Corrector Magnet Location view

28. IDRs: Vacuum Chamber 1/5/06 Vacuum Chamber (316LN SST) The original chamber supports were adequate. A new design has evolved. Quote from IDR report: “The conceptual designs for the chamber, support, and bellows are thoroughly evaluated. They should achieve design requirements for the undulator system. However, the committee has recommendations to be evaluated during the prototype testing that could improve the design further.”

29. 10-31 07-19 9-30 IDRs: Fixed Supports 1/12/06 Chronological Support Design Design changes incorporated from design reviews involving ANL and SLAC personnel. Internal Design Review 1/12/06 SUT should enhance production version 11-27

30. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

31. Equipment Integration at SLAC . • Rodd Pope replaces Brad Youngman for FY06 • FY05 Brad Youngman/GP + • An early integration example with SLAC: identifying requirements for “Heat loads in the tunnel” helped define more than just where things go inside and what’s outside. • FY06 Rodd Pope/GP + • Undulator design defined much better. Re-work detailed integration plan for delivery, assembly, and installation thru to commissioning. Rodd assumes additional assembly scope; e.g., Quad Magnet power supplies, racks, and cables. • Other examples: Barsz/Dutcher - ProE reports. Marsh - IDR info

32. Q Q Q CELL 1 ASSUME AIR COOLED ELECTRONIC BOXES A,B,B+& C. 4.2W 4.2W 4.2W 4.2W 4W 4W 4W 4W 3.8W 3.8W 3.8W M3-10W 3.8W 0.23W M2-5W M3-10W 0.23W M2-5W M3-10W 0.23W M2-5W M4-5W C DLB M1-5W M4-5W A C B M4-5W M1-5W A C A M1-5W B B+

33. QC QL QE QW QU Equipment Integration at SLAC Heat Balance in the LCLS Tunnel Present Design QW = heat dissipation in the tunnel wall and floor QC = heat dissipation in chilled lines QU = heat input from undulator components QL = heat input from lighting QE = heat input from electronics Heat Imbalance: ΔQ = QU + QL + QE - Qw – QC (for each undulator length) SLAC CF takes info, compares their study and makes more educated decision

34. Radiator Panels QC QL QE QW QU QH Resistive Heaters Equipment Integration at SLAC Recommended Approach (Sharma, Pile and Worek) 20,000 cu ft/min should give good temperature control to within ±0.3° to 0.5°C Adding radiator panels and resistive heaters are cheap additions, if required (would give faster stability control). The radiator panels are selected to be large enough to provide a cold bias. All resistive heaters can be connected to a single controller. For a better heat balance, the resistive heaters are computer-controlled individually.

35. Equipment Integration at SLAC Heat Generators in the Undulator Tunnel We optimized the positions of the heat generators. Many questions on temperature control forced us to firm up designs for control electronics, diagnostics, quad magnets, power supplies, and cabling.

36. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

37. Balanced Priorities and Schedules Single Undulator Integrated System Test • @ ANL • Prototype “Fixed Support” support due 3rd week of Feb 06 • Prototype support/mover system: Girder, CAM movers, Rollaway system, controls software and hardware • Carefully coordinate return of prototype undulator from SLAC (may use dummy early March and switch to1st article when available) • “Quadrupole” with fiducialization surfaces • “BPM” with fiducialization surfaces • “Vacuum Chamber” • “WPM, HLS, BLM” sensors • Earthquake protection bracing

38. Goals of the Single Undulator Test Balanced Priorities and Schedules • Provide critical input to the S/M system design reviews. • Help to determine whether the support/mover system design is ready for final production. • Measure girder and rollaway motions. • Determine precision and reproducibility of motions, including start and stop. Check for interference. • Measure vibration damping or (hopefully not) amplification. • Measure position stability and temperature dependence of components and subcomponents. • Practice undulator replacement technique on SUT translation stages. • Enhance the final integrated design for production.

39. Balanced Priorities and Schedules • Single Undulator Module Test • Start is driven by decision to wait for supports in late February 06. • SUT "performance” test is scheduled for two weeks in March 06 with six additional weeks planned for integration testing and enhancements. • Multiple Undulator Module Test • No MUT at APS. • EAA RF Area designated for re-assembly of one complete undulator and short and long break “mock-ups”. The EAA is readily available.

40. SUT – Paint by numbers

41. SUT: Integration Interfaces 3 15 14 5 4

42. Balanced Priorities and Schedules Post-SUT Priorities … • Support/mover/module • Implement design enhancements prior to final design reviews • Updated drawings and documentation • Procurement and component fabrication, acceptance and delivery criteria … and Schedules • Rodd Pope/Geoff Pile – Integrate final undulator designs and re-work the undulator system engineering plan that optimizes planning and scheduling for the assembly, installation, and commissioning at SLAC. • Geoff Pile integrates assembly procedures, coordinates component delivery schedules with SLAC, helps with assembly issues at SLAC. • Rodd Pope takes much assembly scope – e.g., undulator assembly in MMF, quad magnet power supply racks and cables for buildings 2.3 and 3.1.

43. Undulator System Integration Integrated System Engineering • Hazard and Risk controls tailored to work being performed at ANL • Defining clear roles and responsibilities • Integration priorities during design, build, installation, and commissioning • Equipment Integration at SLAC • Balanced Priorities and schedules • Lessons learned – ESDs help integration

44. Lesson Learned from SLAC We’ve learned why ESDs are valuable early on • ANL now understands it as an Engineering (Requirements and) Specification Document. Status update received 1/20 • 1.4-102 – Quadrupole Magnet Specification • Author: Jaski Target Completion Date: 1/31 • 1.4-103 – Line Diagnostics System Engineering Specifications (UD1) • Author: Yang/Bailey Target Completion Date: TBD • 1.4-104 - Wire Position Monitor System Specifications • Author was Ruland. Needs new author assigned. In-Progress. • 1.4-105 – Hydrostatic Leveling System Specifications • Author was Ruland. Needs new author assigned. In-progress. • 1.4-106 – Vacuum System Specifications • Author: Walters 60% Complete • 1.4-107 – Undulator Motion Controls • Author: Stein Target Completion Date: 1/31 • 1.4-110 – Wire Scanner Engineering Specifications (UN3) • Author: Bingxin/Bailey Target Completion Date: 1/31 • 1.4-XXX – Undulator and surrounding Thermal Monitoring Specifications • Author: Stein Target Completion Date: TBD • 1.4-108 - Undulator Protection System – Unassigned (ANL to take responsibility) • 1.4-XXX – Undulator Cable, Tray and Rack Specifications • Author: Stein Target Completion Date: TBD • 1.4-112 – Undulator Support/Mover System • Author: Collins/Sharma Target Completion Date: 1/13 • 1.4-XXX – Beam Finder Wire Specification • Author: Bailey Target Completion Date: 2/7 • 1.4-XXX – RF Beam Position Monitor Engineering Specification (UD5) • Author: Lill/Walters Target completion date: 1/31 • 4 additional ESDs planned requiring numbers assigned • ANL is pushing hard to get twice the amount of original ESDs out.