The Effort Reporting System: A Tutorial

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 FTEs (made
  up from 59 contributors) 7- 8 are assigned full
  time.
• The other 12 FTEs 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.

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The Effort Reporting System A Tutorial

• Its seems simple to report and invoice SLAC
  correctly but its 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

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The Effort Reporting System Feb 21st (to group)
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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
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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
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The Effort Reporting System

• Heres the web address for the LCLS site
• http//www.lcls.aps.anl.gov/
• Heres 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
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

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

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. Toms QA database double-checks PARIS
  acquisitions.
• Net result Enhanced Safety

16
Integrating Safety at APS-LCLS
PARIS gets linked to QA database
PARIS req ?
Toms supplier history ?
ESH and QA checklists ?
17
Integrating Safety at APS-LCLS
? Vendor product info
Toms 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

19
Define Clear Roles and Responsibilities

• Undulator Systems Integration
• Why define clear roles in integration?
• Helps prevent project failures. Defines whos
  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.

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

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 were in a better position to plan
  details for assembly, installation, and
  commissioning

26
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
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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
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

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 whats 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

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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
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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 ?Q QU QL QE - Qw QC
(for each undulator length)

SLAC CF takes info, compares their study and
makes more educated decision
34
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 0.5C 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

37
Balanced Priorities and Schedules

• Single Undulator Integrated System Test
• _at_ 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
LCLS SUT Layout LCLS SUT Layout
Undulator Magnet and Support Motion Controls
Vacuum System Motion Controls
Diagnostics Motion Controls

41
SUT Integration Interfaces
LCLS SUT Layout LCLS SUT Layout
Undulator Magnet and Support Motion Controls
Vacuum System Motion Controls
Diagnostics Motion Controls

3
15
14
Thermocouple Location Thermocouple Location
1 Undulator
2 Ambient Air
3 Ambient Air at Quad
4 Quad
5 RFBPM
6 Girder
7 Undulator Motor (Dwn Strm)
8 Undulator Motor (Up Strm)
9 Girder Motor (Single)
10 Girder Motor (Double)
11 Floor Support (Upper)
12 Floor Support (Lower)
13 Vacuum Chamber Support
14 Vacuum Chamber (At Beam)
15 Vacuum Chamber (Strngbk)
16 Ion Pump
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

44
Lesson Learned from SLAC

• Weve 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