Conventional Insertion Devices WBS U1.03.04

Conventional Insertion DevicesWBS U1.03.04

John GrimmerTechnical Lead, Conventional IDsSystem Manager, Insertion DevicesAccelerator Systems Division/Magnetic Devices Group

DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

Outline WBS Scope 1.03.04 Insertion Devices (excluding 1.03.04.03,

Superconducting Undulators) Staff / Org Chart Requirements Scope Details Design Value Engineering Prior Review Recommendations ES&H Cost Schedule Summary

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Conventional Undulators Project Scope and WBS Level 4U1.03.04.01, U1.03.04.02, U1.03.04.04, U1.03.04.05, & U1.03.04.07

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k$Labor Nonlabor TOTAL

U1 03.04 - Insertion Devices - Conventional 4,593 9,970 1,278 346 17,828 03.04.01 - Planar Undulators - Existing Period 560 1,082 150 36 1,916 03.04.02 - Polarizing Undulators 1,568 3,085 403 107 5,698 03.04.04 - Revolver Undulator 1,418 3,811 412 134 6,441 03.04.05 - Canted Section - Magnets and Corrector Magnets 380 415 118 15 1,034 03.04.07 - ID Vacuum Chambers 666 1,577 195 55 2,738

ESCALATION ($k)

DIV OH + ANL G&A ($k)WBS

DIRECT (k$)

A dual, canted undulator installation: two planar undulators, one canting magnet and one ID vacuum chamber in the APS storage ring.



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Insertion Devices, Org Chart

Insertion Devices, Requirements The insertion device requirements for APS-U are identified in

Physics Requirements Documents (PRDs) and Interface Control Documents (ICDs).

Existing-period undulator designs will be used for the magnetic structures on most of the planar undulators, including the revolver undulators. One new design for a period shorter than existing designs is included in the APS-U scope and will support the medium-energy brightness KPP.

Revolver undulators must perform as “two undulators in the space of one” and meet the same field quality and beam perturbation specifications as the regular, planar undulators. They require special mechanical, electromechanical, and controls development, as well as design of revolver-compatible support stands for ID vacuum chambers.

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Insertion Devices, Requirements The EMVPU is required to provide linear vertical, linear horizontal,

variable elliptical and circular polarization, as well as the ability to switch between left- and right-handed circular (or elliptical) polarization at 10 Hz.

Both APPLE-II undulators require magnetic field end corrections to minimize perturbation of the stored electron beam. The users of one APPLE-II undulator have requested a method for suppression of higher order harmonics in linear modes.

The insertion device activities support the APS-U KPP of 12 insertion devices installed.

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*Breakdown of the 48 undulators currently installed at the APS.

Insertion Devices, Scope DetailsAPS-U1.03.04.01 Planar Undulators (3)

Three planar, hybrid PM undulators will be built. The required gap separation mechanisms and control systems

are all proven designs, so no further development is scoped. Most APS-U device magnetic structures (including revolver

undulators) will be of existing APS period designs, but design of one new period, shorter than existing periods, is included as part of the APS-U scope.

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Analysis of differential deflection of pole mounting shoulders under magnetic force.

Insertion Devices, Scope DetailsAPS-U1.03.04.02 Polarizing Undulators (3)

• APS-U1.03.04.02.01 EMVPU (1)• APS-U1.03.04.02.02 APPLE-II (2)

One electromagnetic, variable polarizing undulator (EMVPU) and a custom power supply will be built. Prototype development of the device itself and the required power supply are funded outside of APS-U through an FY ‘13 LDRD.

A special vacuum chamber to allow fast switching of the EMVPU will be designed as a part of APS-U.

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CAD model of 4 period EMVPU prototype.

Insertion Devices, Scope DetailsAPS-U1.03.04.02 Polarizing Undulators (3)

• APS-U1.03.04.02.01 EMVPU (1)• APS-U1.03.04.02.02 APPLE-II (2)

Two APPLE-II devices will be purchased from an outside vendor, complete with basic control systems.

End correction schemes, magnets, and power supplies are included as a part of APS-U.

High-level controls and required interfaces will be designed as part of APS-U.

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Schematic illustration , APPLE undulator design and operation.

End view of APPLE undulator at SRC.

Insertion Devices, Scope DetailsAPS-U1.03.04.04 Revolver Undulators (5)

Five revolver undulators and their control systems will be built.

Each revolver undulator will have two magnetic structure pairs like those of the planar undulators.

APS-U will adopt the successful designs of an ongoing LDRD-funded development program for revolver undulators and controls.

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012CAD model of one of the APS revolver undulator prototypes.

Insertion Devices, Scope DetailsAPS-U1.03.04.05 Canting Magnets (8); Corrector Magnets (2)

Eight canting magnets, which include a dipole and a corrector, will be built, together with the required power supplies, for use in the APS-U dual, canted undulator sectors.

Two corrector magnets and their power supplies will be built for use upstream of the SPX cavities.

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Canting dipole/corrector magnet installed in an APS dual, canted undulator sector.

Canting Magnet

Upstream Undulator Vacuum Chamber

Insertion Devices, Scope DetailsAPS-U1.03.04.07 Insertion Device Vacuum Chambers (12)

• APS-U1.03.04.07.01 Standard, Canted & Long Straight Section (11)• APS-U1.03.04.07.02 EMVPU (1)

Eleven ID vacuum chambers of extruded aluminum construction, with stainless steel endboxes, will be built. Design of a chamber allowing a slightly smaller ID gap is scoped, as is design of an APPLE-II-compatible chamber.

Revolver-compatible stands will be designed and built for each of these chambers.

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CAD model of ID vacuum chamber extrusion, machined for dual, canted undulators. This part is then welded to two SS endboxes, which each have a bimetallic side.

CAD model of ID vacuum chamber support stand

Insertion Devices, Scope DetailsAPS-U1.03.04.07 Insertion Device Vacuum Chambers (12)

• APS-U1.03.04.07.01 Standard, Canted & Long Straight Section (11)• APS-U1.03.04.07.02 EMVPU (1)

One ID vacuum chamber, likely of welded stainless steel construction with an internal copper coating, will be designed and built for the EMVPU.

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Insertion Devices, Design - Planar Undulators The APS has designed, built, and installed 15 undulators with

periods of 2.3, 2.7, 3.0, 3.5 and 3.6 cms. APS-designed gap separation mechanisms are used for these and 15 others.

The magnetic structures of these devices are compatible with all of the planar undulators in APS-U, including the standard planar and the revolvers, in either full or canted length.

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Full-length 2.7-cm-period undulator installed in upstream location in Sector 3 of the APS storage ring.

Two full-length 3.0-cm-period undulators installed in Sector 30 of the APS storage ring.

Insertion Devices, Design - EMVPU The development of the EMVPU exploits the magnetic and

mechanical modeling, analysis, design, and measurement capabilities very successfully demonstrated by the APS in the recently-completed 4.8-m-long IEX electromagnetic undulator, shown below.

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3-D CAD model of 4-period IEX prototype and actual prototype.

3-D CAD model of final IEX undulator and actual final undulator, ready for measurement.

Insertion Devices, Design - Revolver Undulators Revolver undulators are mature technologies at other light sources. ESRF has had revolvers in operation for over a decade.

Revolver undulators were not envisioned when the design direction was set for IDs and ID vacuum chambers at the APS, so incorporating revolvers presents some challenges unique to the APS. (ID vacuum chamber/support design, need for gap tapering, 4-motor gap separation mechanism)

These issues are being addressed with an APS-specific revolver undulator development program, funded through an ANL LDRD.

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Upper jaw of revolver undulator at ESRF. The ID vacuum chamberwas designed to accept revolver undulators.

End view of an early APS revolver undulator design and the existing ID vacuum chamber and support. The support must be redesigned to accommodate the unused lower magnetic structure in the outboard position.

Insertion Devices, Design - Revolver Undulators Two main design concepts have been pursued. Both are based on the existing

APS 4-motor gap separation mechanism. Since the CD-1 review, single-jaw prototypes of each concept were designed,

analyzed, fabricated and assembled. They are now being tested. The single-jaw prototypes use an upper revolver jaw with two 3.3-cm period

magnet structures and a non-revolving lower jaw with a single, 3.3-cm structure.

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One revolver design approach uses a non-revolving strongback and only revolves the magnet structures and their mounts.

Non-revolving strongback

Revolver drive

Magnet structures

Insertion Devices, Design - Revolver Undulators Mechanical and electromechanical testing of the single-jaw prototypes with

and without magnet structures, including magnetic measurement and tuning, will determine which design will be the basis for the final prototype.

The final prototype will have 2.7- and 3.0-cm period magnetic structures and both jaws will revolve.

The final prototype will be further measured and tested, including installation in the APS storage ring, before the design is used by APS-U.

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Another revolver design approach uses a revolving strongback.

Revolving strongback

Wormgear axis (motor/gearhead is on back side)

Magnet structures

Insertion Devices Value Engineering Today’s APS designs for the undulator gap separation mechanisms

and magnetic structures were value engineered from the original designs. They meet specifications that are more relevant, and in some cases less stringent, than those applied to earlier versions.

Today’s gap separation mechanism structure is welded steel vs. bolted aluminum in the earlier undulators. The maximum magnetic attractive force requirement was also reduced, saving structure and drive size and cost. The device changes gap faster, holds position more accurately, and is less susceptible to “cant” change over the gap range.

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*A hybrid, permanent magnet undulator with APS-designed magnetic structures and gap separation mechanism being readied for magnetic measurement.

Insertion Devices Value Engineering

The magnetic structures have been simplified vs. earlier ones, but are more accurate as well, allowing easier magnetic tuning. They are also modular, so they can be converted between full and “canted” length (and back again, if desired).

The undulator control system was completely redesigned recently. It uses more off-the-shelf hardware to reduce both initial cost and maintenance cost. The control system also features greater gap feedback redundancy.

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CAD model of APS-designed magnetic structure showing method of pole location and pole and magnet retention.

Insertion Devices, Prior Review RecommendationsFrom CD-1: “The difficulty of the CPU and the increased changing polarization frequency

needed of the EMVPU lead the committee to conclude that it is likely underestimated as to complexity, difficulty and risk.” An LDRD is being pursued for prototype development of the device and power supply

off-project.

From CD-1: “The IDs group has engaged an external engineering firm for the design of the revolver mechanism. The qualifications of this external engineering firm in the specialized area of precision mechanisms was not cleanly identified and so the committee believes that comprehensive technical reviews by relevance subject matter experts will be necessary.” A preliminary design review was held in July 2011, and a final design review of the

single-jaw prototype was held in December 2011.

From CD-1: “As ID installation occurs during the same scheduled shutdowns as regular deployed ID maintenance the same resources are double booked this resource conflict is not easily resolved and will need to be addressed prior to CD-2.” This is being addressed through schedule sequencing in P6, through efforts at capturing

all of the operations workload with the same rigor at the APS-U workload, and through efforts to scale and backfill the capabilities of key resources.

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Insertion Devices ES&H


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Integrated Safety Management System (ISMS)– APS-U Project following Argonne’s ISMS program requirements – Argonne Integrated Safety Management System (ISMS) Description recently

revised and submitted to DOE ASO• Describes framework for integrating ESH requirements with mission objectives• References Argonne LMS procedures which implement specific portions of the ISMS

Identify General Safeguards and Security Requirements– APS-U Project required to follow Argonne’s Operations Security Program

(OPSEC) Master Plan

Identify General Safety Requirements to Specific WBS Level– Undulator permanent magnets require special handling and posting of high

magnetic field warning signs.– The EMVPU requires electrical safety postings and procedures.– The revolver undulators will need additional guards, safety postings, and

procedures due to the additional magnetic structures and mechanisms.


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k$

Labor Nonlabor TOTALU1 03.04 - Insertion Devices - Conventional 5,150 9,970 1,640 1,624 17,828

03.04.01 - Planar Undulators - Existing Period 560 1,082 88 186 1,916 03.04.01 - ACWP 6 - - 1 7 03.04.01.01 - Magnetic Structures 329 657 55 105 1,146 03.04.01.02 - Gap Separation Mechanism 55 346 20 29 450 03.04.01.03 - Controls & Cabling 67 75 6 22 170 03.04.01.04 - Integration & Installation - Planar Undulators 103 4 7 29 143

03.04.02 - Polarizing Undulators 2,125 3,085 535 510 5,698 03.04.02.01 - Electro Magnetic Variable Polarizing Undulator (EMVPU) ACWP1,158 803 179 188 1,771

03.04.02 - EMVPU ACWP 579 - - 5 27 03.04.02.01.01 - EMVPU Device 271 551 102 95 1,019 03.04.02.01.02 - End Correctors with Main Power Supply - EMVPU 147 230 48 47 472 03.04.02.01.04 - Controls - Hardware & Firmware - EMVPU 95 20 16 24 155 03.04.02.01.05 - Integration & Installation - EMVPU 65 2 13 18 98

03.04.02.02 - Apple II ACWP 967 2,282 356 322 3,927 03.04.02.02 - Apple II ACWP 1 - - 0 2 03.04.02.02.01 - Device - Apple II - (2) 335 2,039 258 149 2,781 03.04.02.02.02 - End Correctors with Main Power Supplies - Apple II - (2) 190 123 33 53 399 03.04.02.02.03 - Controls - Hardware & Firmware - Apple II - (2) 141 100 25 40 305 03.04.02.02.04 - Integration & Installation - Apple II - (2) 300 20 41 80 441

WBS

DIRECT (k$) ESCALATION ($k)

DIV OH + ANL G&A

($k)



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03.04.04 - Revolver Undulator 1,418 3,811 666 546 6,441 03.04.04 - ACWP 18 - - 4 22 03.04.04.01 - Magnetic Structures 350 2,175 305 162 2,993 03.04.04.02 - Revolver Supports 259 1,350 207 135 1,951 03.04.04.03 - Controls & Cabling 221 279 67 77 644 03.04.04.04 - Integration & Installation - Revolver Undulators 571 7 85 168 832

03.04.05 - Canted Section - Magnets and Corrector Magnets 380 415 106 133 1,034 03.04.05 - ACWP 7 - - 1 8 03.04.05.01 - Laminations 39 2 1 10 53 03.04.05.02 - Magnets w/ Stands 10 285 39 13 347 03.04.05.03 - Power Supplies & Controls 101 80 25 38 244 03.04.05.04 - Electrical Power 5 40 4 3 52 03.04.05.05 - Integration & Installation - Canted Section Magnets 218 7 36 68 330

03.04.07 - ID Vacuum Chambers 666 1,577 245 249 2,738 03.04.07 - ACWP 8 - - 1 9 03.04.07.01 - Standard, Canted, and Long Straight Section - (11x) 309 1,384 176 135 2,003 03.04.07.02 - Electro Magnetic Variable Polarizing Undulator (EMVPU) - IDVC 213 194 49 65 520 03.04.07.03 - Integration & Installation - ID Vacuum Chambers 138 - 20 48 206


Cost Estimation Drilldown Example

U1.03.04.04.01, Revolver Undulator Magnetic Structures (Cost Support for Award)


Undulator Magnetic Structures for Revolver Undulator (both sets for each jaw) Qty/System Source/Vendor Item Cost, $ Item Cost*Qty, $ Requisition #, Award # Notes/ExceptionsBill of Materials for 41010105-100001, Assembly Drawing of Upper and Lower Magnetic Structures ANL PARIS Requisition AMOS Order #,Bill is "exploded" to subassembly level, so detail numbers after 2 do not apply ANL AMOS Order Service Req. #Blue Denotes Catalog Items ANL Service Request or Other SupportDetail # Qty/System Drawing/Part # Title or Description

1 1 410101-101007 Upper Strongback 2 Lynn Machine 7,150.00 14,300.00 F0-103047 0A-517572 1 410101-101008 Lower Strongback 2 Lynn Machine 7,150.00 14,300.00 " Line 2

NA Lot Qty. 2 ANL Central Shops 39,260.00 78,520.00CS Quote 29Feb2012 for 2.7-cm structure parts0 41010105-100011 Base Plate, Center Included in Lot0 41010105-100021 Base Plate 'A' "0 41010105-100031 Base Plate, End (Type 'A') "0 41010105-100041 Base Plate, End (Type 'B') "2 4101010203-100012 Divider Plate Assy. 29p "2 4101010203-100022 Divider Plate 'A' Assy. 21p "2 4101010203-100027 Divider Plate 'B' Assy. 21p "2 4101010203-100032 Divider Plate 'A' Assy. 6p "2 4101010203-100042 Divider Plate 'B' Assy. 6p "2 4101010203-100013 2.7 x 29p Multiclamp "4 4101010203-100023 2.7 x 26p Multiclamp "4 4101010203-100033 2.7 x 6p Multiclamp "2 41010105-100014 Magnet Cap, 31.0 Lg. "4 41010105-100024 Magnet Cap, 24.75 Lg. "4 41010105-100034 Magnet Cap, 5.63 Lg. "

370 4101010203-100015 2.7-cm One Clamp "

NA 320 41010105-100050 3.0cm Magnet 320 Shin-Etsu Magnetics 249.00 79,680.00 Quotation BL11-130 date: 12/5/2011375 2.7 cm Magnet 375 Shin-Etsu Magnetics 330.00 123,750.00Quotation BL10-058A date: 11/25/2011

NA 380 41010105-100051 2.7-cm Pole 760 Hi-Tech Mfg. 148.00 112,480.00 Quote # 4880 date: 2/28/12

Hardware/Miscellaneous 2 2,750.00 5,500.00 Estimate

Note: Quantities of all items except magnets are doubled, relative to a planar undulator, to cover the cost of two magnetic structures. Total $428,530.00The cost of magnets includes one set of 2.7-cm-period magnets and one set of 3.0-cm-period magnets, as this is the most-likely combination.

Cost without 1.5% for shipping

Adding 1.5% gives the $435k total in P6. For the 5 structures, total cost is 5 x $435k =

$2,175k

Conventional Undulators Project Obligation Profile U1.03.04.01, U1.03.04.02, U1.03.04.04, U1.03.04.05, & U1.03.04.07

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EMVPU Installation

APPLE II Tuning & Installation;Assembly of

EMVPU

APPLE II Procurements &

Controls/Corrector Design;

EMVPU Final Design;

First Revolver Installed

First Installations;

First Revolver ProcurementsRIXS, ASL &

ID Vacuum Chamber Design & Procurement

Conventional Undulators Summary Schedule U1.03.04.01, U1.03.04.02, U1.03.04.04, U1.03.04.05, & U1.03.04.07

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5/14 RIXS Undulator & ID Vacuum Chamber Installation

9/15 First Revolver Undulator Installation

1/16-5/17 Polarizing Undulator Installations

Conventional Undulators BOE Contingency U1.03.04.01, U1.03.04.02, U1.03.04.04, U1.03.04.05, & U1.03.04.07

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Near-term Insertion Devices Activities for CD-3a Design a new period undulator for RIXS, likely 1.75-cm-period,

depending on allowable minimum gap, as defined by ongoing ID vacuum chamber development.

Begin procurement of magnets, poles, magnetic structures, gap separation mechanisms and control systems for two of these undulators.

Define the period for the ASL undulator and begin procurement of magnets, poles, and magnetic structures for that undulator. (The gap separation mechanism is not included in the early activities.)

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Key Insertion Devices Work Between CD-2 and CD-3APS Upgrade: Design a new ID vacuum chamber and revolver undulator-

compatible stands; review design; begin procurement of chamber extrusions.

Complete and review designs for planar undulators, revolver undulators, and canting magnets.

Expected deliverables to APS Upgrade: Finish testing of the revolver undulators and complete design

of the final revolver prototype. Design and build a short prototype of the EMVPU – externally

funded. Further investigate tuning methods applicable to APPLE-II

undulators; qualify vendors for APPLE-II procurements.

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Insertion Devices Summary

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The insertion device scope is clearly defined to meet the beamline requirements of the APS upgrade.

The preliminary design for conventional insertion devices is complete.

The cost is $17,828k dollars. We are ready for CD-2!


Conventional Insertion Devices WBS U1.03.04

Documents

review of aps

planar undulators

revolver undulators

aps upgrade project

polarizing undulators

planar hybrid undulators

aps storage

apsu scope