1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems F. Willeke, Director Photon Sciences Accelerator...

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Systems

F. Willeke, Director Photon Sciences Accelerator Division

NSLS-II Project Advisory Committee Meeting

March 29-30, 2012


Outline

• Overview

• Injector Status

• Magnet Production and Girder Integration

• Other Production • Vacuum Components

• Power Supplies, Electrical Utilities

• Mechanical Utilities

• Installation and Testing

• Insertion Devices

• Commissioning with Beam

• Plans for Start-up of Operations


Overall Status of NSLS-II Accelerator Systems

• Significant progress has been made since the last PAC.

• The large production contracts have all been placed by now• Production

o RF power systems (LINAC, Booster, Storage Ring) is complete. o Production well advanced for magnets (78%), vacuum chambers (90%), utilities (~75%), and power

supplies (55%). o Frontend & instrumentation production starting upo Superconducting 500MHz cavities & cryo-plant are in production.

• Installation: progressing well o Overcoming initial challenges due to difficulties in taking over buildings, under estimated labor,

additional installation tasks identified, late utility installations by vendors• Commissioning

o The LINAC commissioning with beam has startedo The Authorization Base for commissioning of the booster synchrotron is well under way, and

Storage Ring effort has begun.o Good progress made on commissioning software and database.


Overall Status of NSLS-II Accelerator Systems cont’d

• Insertion Deviceso Damping Wiggler: Production started and first article expected to be delivered in Juneo EPU: Vendor design nearly completeo IVU: Contracts placed for two IVU20, one IVU21, and one IVU21 undulatoro ID’s for NEXT and ABBIX Projects: Design, production, installation and commissioning plan being

integrated with the NSLS-II Project.

• Schedule Performanceo Cumulative schedule variance for Accelerator Systems: being ~3 1/2 months lateo Detailed installation schedule is being continuously optimized on weekly basis based on latest

progress and production information o Additional labor resources being provided to reduce the schedule variance


LINAC

• 200MeV s-band LINAC was delivered on schedule last fall

• Installation now complete

• LINAC frontend successfully tested with beam and demonstrated that it met all specifications (charge, pulse length)

• LINAC RF power units (solid state modulators) successfully tested

• LINAC with beam commissioning started this week


Booster Progress

Completed large PSMagnet Production Girder Integration

Assembly Equipment received at BNL

Vacuum ChambersMagnetic Measurements

Packaging (Girders)

Prepare for Shipment

• Production of 3GeV booster synchrotron components (magnets, vacuum, girders, power supplies) at BINP and their subcontractors has progressed very well

• Shipping of components to BNL started in November. Containers with components are arriving since December 2011.

• Close coordination with BINP for installation and commissioning plan

• Installation of utilities in service building and booster tunnel has begun

• Booster on track for start of commissioning in February 2013


Booster Magnet Girders at BINP - Ready for Shipment


Storage Ring Magnets

• Storage ring magnet production well underway at all manufacturer’s. • ~80% of the production complete; • 63% of the magnets delivered to BNL. • All technical issues resolved at this point. Quadrupoles: BINP Production of 120 magnets nearing completion (April). TESLA Production of 120 magnets ramping up (10 magnets /month, 16 received)Sextupoles: Danfysik production: 169 sextupoles proceed. steadily,14 magnets /month, 87% complete)

IHEP Production rate is no issue, 89% complete, however quality needs to be watched Large Aperture Quadrupoles and Sextupoles:

Buckley Production of 60 quadrupoles and 30 sextupoles going well, ~93% of the production complete, quality ok

Dipoles: Technical issues resolved, production picking up speed, Buckley Production of 60 magnets at rate of 1 magnet / week, 8 units received Correctors: Production of 189 units close to completion (>95% )Fast correctors: Production of 90 units started in February.

Production of Storage Ring Magnets no longer a limiting factor for accelerator schedule.


Magnet Production Summary


Fabrication Results and Magnetic Data

Sextupole transfer function uniformity

Magnetic measurement data:1. Transfer function and harmonic data for each quadrupole and sextupole2. Hall probe scan for one magnet per type3. By mapping at three vertical planes for all the main dipole magnets

Typical lower order terms Typical systematic terms

Saturation in strong quad Current dependence of first systematic harmonic


Girder Status

Present Status:27 Girders installed 9 Girders being integrated

•Magnet Production not limiting girder integration anymore•Magnet Girder Vacuum Integration fully developed•Alignment of better than 30 micron routinely achieved•2 Shift 6 days/week operation established•Rate 2 girders /week (goal)•Girder installation will be completed Dec 2012


Vacuum Systems

• The production of vacuum chambers for multi-poles and dipoles (150 units) nearing completion (welding at APS was completed in February, chamber assembly will be completed in July).

• Production of 27 “day-1/2” chambers for ID straights started• Design of injection straight vacuum completed; finalizing of drawing

packages while injection kicker and injection septum design is being completed; RF straight vacuum system design underway

• Gate valves in production (40% complete)• Shielded Bellows in production, sufficient units for P1 and P2 ready• Absorbers: production well underway, most units for P1 and P2, crotch absorbers delayed due to manufacturing issues.• Ion and TSP pumps are in hand, in-house assembly of integrated NEG

pumps keep up with chamber production.• Vacuum instrumentation and infrastructure: pump controllers and HV

supplies, RGA, cables, TSP power supplies and cables and termination; production far advanced or complete

Vacuum production on track for installation, no technical issues


Power Supplies

• Power supply production has progressed well. • Overall, about 55 % of the production is at hand.• In-house testing of components set up• Integration in progress• Main Dipole PS will be completed end of 2012

Controls Interface

Power ConverterPower Converter

Excellent performance: 2.5 ppm << 10 ppm (spec)

Regulator

PSC


Utilities

Electrical Utilities: •All 575 equipment enclosures at hand, 65% installed, 40% fully functional •All cable at hand, a significant fraction already installed (P1:100%, P2: 60%, P3: 10%) •All UPS units received, 40% installed•All cable tray installed (99% complete)Electrical Utilities Hardware at hand, significant fraction already installed. Mechanical Utilities: •Process chilled water, compressed air systems and central DI-water systems either already in operation or ready for operation•Di-Water secondary systems, all 13 pump skids delivered, •RF and Injector systems are complete and operational•DI-Water piping installation underway ~75% completeMechanical utilities available for start-up of testing and commissioning


Beam-line Frontends

• Final Drawing packages released after numerous revisions and design changes

• Materials such as GLIDCOP at hand

• Production of components has started

• Tables for installing components have been delivered

• Vacuum components such as pumps at hand

• Contracts placed for brazing of absorbers and masks

• Materials for safety shutters available

• Integration and assembly of components started

Beamline frontends are delayed with respect to the project baseline schedule, but are not near the critical path.


Storage Ring RF Transmitter Systems are complete, installed, and tested

The IOT transmitter for the Booster is complete and partially installed

The design of superconducting cavity completed, construction started.

The 3rd harmonic niobium cavity and its cryostat is complete, the design of auxiliary systems in progress

The liquid Helium cryogenic plant vendor design phase is completed (FDR) and manufacturing of the systems started.

Liquid Nitrogen system contract awarded in February.

The low level RF controls have been successfully tested at CLS which demonstrated the superiority of the FPGA based system compared to conventional systems.

RF Systems

NSLS-II

CLS


RF Systems

HV PS

Klystrons

HV Transformer

Circulator, loads, Water manifolds and

waveguides


Instrumentation

• Production of BPM buttons completed this month.

• BPM electronics development successful, 200 nm resolution and stability confirmed with beam tests at ALS, full production started

• Transverse Damper System in production, electronics tested

• Beam Current monitors have been received

• Optical-,X-ray- monitors (emittance, bunch length ) designed and components are on order.

• The design of photon BPMs has started.

• Injector Instrumentation well advanced, systems for the first step of commissioning installed and tested


Pulsed Magnets

• The NSLS-II Storage Ring injection septum being built in industry, design complete, production started

• The NSLS-II kicker systems are being built in-house.

• A prototype kicker and pulser has been produced.

• Long lead items such as coated ceramic chambers and IGBT based switching elements are on order.

• Pulsed magnets for booster injection and extraction are part of the BINP booster scope. The systems have been built and bench tests have demonstrate that they meet requirements.

Prototype Kicker-Pulser AssemblyTest: 3 x 10-5 amplitude reproducibility


Controls

• Controls Software for accelerator systems developed, built and tested ready for use in integrated testing and commissioning.

• Controls hardware (VME crates, digital I/O output modules, network hardware, computers) at hand and partially installed

• Optical fiber cables for connecting the network hardware available, being installed • Timing system hardware at hand, software well

developed• Cell controller hardware (real time control) is in

production. • The IRMIS data base system developed, semi

automated link of data from component testing• High level application programs well advanced

commissioning will start with full suite of high level applications

C Controls efforts are on schedule


Status NSLS-II Project Beamline Insertion Devices

Damping Wiggler (DW) Contract was issued on Nov.7, 2010. FDR was completed on June 6th, 2011; PM & hi- materials available, production started, first article in May’12.

In-Vacuum Undulators IVU 21(SRX), IVU20 for HXN & CHX and & IVU22 (IXS) IVU20, IVU21 contract awarded in November/December 2011, vendor design in progress, IVU22 award in March’12

Elliptically Polarized Undulator (EPU) Contract was issued on April 28, 2011. CDR was completed on June 9th, 2011, FDR October 2011, production has started

Three Pole Wiggler (3PW) Contract was issued on March 25, 2011. FDR was completed on May 20th, 2011, in production


ID-Magnetic Measurement Facility

State of the Art Facility Completed: • Clean Room has been completed• Hall probe bench in operation• Calibration Dipole in operation• Flip/long coil system (IFMS)

received • Helmholtz Coil System in place

Calibration Dipole System

Hall Probe Bench

Flip/Long Coil System


Installation

• Installation had a late start (~3 months)

• Start-up slow, but speeded up significantly now

• After injector building BORE Aug’11, concentration on injector installation LINAC complete, Booster well underway

• Challenging Coordination issues resolved : Building contractors, AD contractors, AD technicians, temporary labor, laboratory services now work together closely

• At present: ~4 months behind schedule, we have added some 12 FTE’s (electricians, cable pullers, surveyors, electrical technicians to catch up with the work)


Installation Progress

completed LINAC installation Completed LINAC to Booster Transfer line Part 1



Di-ionized Controls Computer rooms equipped with Water distribution systems and pumps sealed electronic racks, servers, network Skids for Injector and Injector Complex hardware completed and installedCompleted and installed



Personal Protection System PLC Cabinet with the 2 redundant Safety PLCs


Integrated Testing and Hardware commissioning

• Integrated testing is the demonstration of the proper functioning of the hardware systems in the final, installed configuration, in presence of the neighboring systems and by using the computer control system for extensive test of the full functionality of the systems.

• Plans for integrated testing have been developed, they will happen module by module, a module being as small as one of the 30 cells

• Resources have been revisited and revised by adding labor.

• Integrated testing started with the completion of the 1st storage ring cell (#25) in February: First cell pumped down,


Commissioning with Beam

•LINAC and LtB-Transfer-line beam commissioning started benefiting from well developed plans and all software systems in place and tested.

•The ASE and SAD for the booster synchrotron have been reviewed by the lab safety committee with no major concerns raised

• The documentation for the Storage ring has been started

• Data-base for commissioning and operations has been developed. Many of the needed data are already available. Commissioning data taskforce continues with a more pragmatic approach making sure that all needed data exist and are accessible.

• Commissioning plan is concentrating on creating high level controls software in support of commissioning.


Accelerator Schedule

DESIGN

Production

Installation

Testing

Commissioning

now


Cost and Schedule Performance 1.02.01 1.03 & 1.06.02

Accelerator schedule performance continues to be explained by an overall delay(from Apr-9-Dec12: 3 months, Mar 12 3.5 months)

Forecasted and realized SV based on 3.5 months delay

Cost index

Schedule Index


NSLS-II Start-Up of Operations Schedule

Float could become user operation

Float could become user operation


First Part of Commissioning Goals• Beam Stored• Injection set-up for beam accumulation• Beam Orbit Corrected to 30 microns• Beam Vacuum Conditions checked and compared with expectations• Beam Optics Verified and Corrected, confirm 2nm horizontal emittance• RF Parameters measured, confirmed and RF loops tested and optimized• Alignment of Quadrupoles and Sextupoles confirmed/corrected• Dynamic Aperture measured, compared with Simulations and improved• Orbit Feedback commissioned and turned on, differential orbits control with submicron precision• Injection Optimized for low loss and high efficiency• Top-Off Injection Mode set-up and top-off interlocks tested • Beam Loss Control and Monitoring, commissioned, interlock tested• Local Orbit interlock at ID locations, implemented and tested• Active Damper Systems Tested and Commissioned• Single Bunch limitations explored and Touschek Lifetime measured vs Bunch Intensity• Radiation Monitoring Tested with Increased Beam Currents• Vacuum Component Temperatures Monitored vs Beam Current and Compared with expectations• Beam Current Increased to 50 mA - 200mA• Vacuum conditioning with high Beam intensity

Accelerator ready for Insertion Device/Frontend Commissioning


Insertion Device Installation

Schedule for Installation of 12 Project IDs: 6 DW, 2 EPU, 1 IVU21, 2 IVU20, 1 IVU22

Serial Activities: Rigging, Installation in the Tunnel, survey, cabling, electrical connectionsParallel Activities: Vacuum installation and connections, pump-down, vacuum conditioning, installation of instrumentation, testing of operations software


Time Needed for Frontend Commissioning•Frontend functionality test with beam: XBPM, shutters, slits: 24 h •EPS interlock settings 16 h•Temperature monitoring and heating tests 16 h•Vacuum Conditioning 24 h •Top-off safety tests 56 hTotal 17 shifts

Time for ID, Frontend & Beamline Commissioning

Time Needed for Insertion Device Commissioning•ID integration into the lattice 40 h •Implementation of feed forward corrections 24 h•Vacuum conditioning 40 h•High Beam Intensity tests, temperature monitoring and check 24 hTotal 16 shifts

• Time Needed for Beamline Commissioning (dedicated non-parasitic times only) 2 shifts• Note: Commissioning of Insertion Devices and Frontend is interleaved First beam to Exp. Floor could be delivered after 1st ID and FE is fully

accommodated


High Intensity Commissioning• High Intensity studies and commissioning will continue during 1st year of operations• High Intensity Commissioning has to be taken in small steps• Need to be careful not to damage vacuum and frontend components• RF systems are very delicate, there is the possibility of damaging the superconducting cavity• The impact of high intensity operations on radiation levels needs to be carefully monitored

and inacceptable conditions must be first corrected• Vacuum conditions are expected to improve slowly, we need to keep the pressure always

under control• We will not rush to get to high intensity early on• During the first year(s) of operation we will regularly work on improving intensity• Step by step procedure, increase from 25-50 mA (established at end of project) to 300mA in 6 modules of 50mA each, allocated time: 6 X 12 shifts - radiation monitoring with beam loss 24 h - LCM adjustments 24 h - injection optimization 8 h - feedback and RF adjustments 16 h - monitoring of critical FE components, special set-up 8 h - trouble shooting 8 h - recovery from trips 8 h

Intensity Ramp-up 1st Year 25 - 200 mA 2nd Year 200 - 400 mA 3rd Year 400 - 500 mA


NSLS-II Availability

NSLS-II is designed for high reliability and availability >95%DOE definition: Reliability User time delivered at scheduled time/ total scheduled user time

However: during the first years of operation the reliability is expected to suffer from teething problems.

Expectation:

FY14 70%

FY15 85%

FY16 90%

FY17 95%

FY18 >95%

Expectation:

FY14 70%

FY15 85%

FY16 90%

FY17 95%

FY18 >95%


Analysis


Environmental Impact: Dust, Humidity, Temperature

Dust causing frequent failures on TEVATRON QP electronics )copied from H. Edwards/P. Czarapata, FNAL, Groemitz Miniworkshop 2005

NSLS-II Electronics/PS Rack Solution

Lifetime of film capacitors vs int.temperature C. Chen et al IEEE PESC, Aachen 2004


NSLS-II Performance Simulation

2 years


Operation Cycle


Summary• NSLS-II Accelerator made good progress; overall about 65% complete • LINAC is being commissioned• All large construction contracts placed• There are no major technical issues with construction any more• Keeping pace with Installation schedule to start storage ring commissioning by mid 2013 is the

largest challenge• Labor for installation has been increased by ~12 FTE already, project EAC accounts for

additional labor that will be most likely be necessary to maintain schedule• Integrated testing started• Cost performance is good, schedule performance well understood - and so are the required measures for keeping pace with the schedule• Plans for start-up and operations well developed


NSLS-II Project, NEXT, and ABBIX Insertion Devices

PPM: Pure Permanent Magnet

EM: Electro Magnet

H: Hybrid Magnetic Design

* Depending on location within ID straight section

** Off-center canting magnet location in ID straight section

BL ID straight

typeID type, incl. period

(mm)Length Kmax FE type

# of ID's (base scope)

# FE's Project

CSX lo-β EPU49 (PPM) x2 4m (2 x 2m) 4.34 canted 2 1 NSLS-IIIXS hi-β IVU22 (H) x2 6m (2 x 3m) 1.52 std 1 1 NSLS-IIHXN lo-β IVU20 (H) 3m 1.83 std 1 1 NSLS-IICHX lo-β IVU20 (H) 3m 1.83 std 1 1 NSLS-IISRX lo-β IVU21 (H) 1.5m 1.79 canted 1 1 NSLS-IIXPD hi-β DW100 (H) 6.8m (2x3.4m) ~16.5 DW 0 1 NSLS-II

ESM hi-β EPU56 (PPM) & EPU180 (EM)

3m4m

3.646.8 canted 2 1 NEXT

SIX hi-β EPU49 (PPM) x2 7m (2 x 3.5m) 3.5 std 1 1 NEXT

ISR hi-β IVU23 (H) 3.0m 1.6-2.07* canted** 1 1 NEXT

SMI lo-β IVU22 (H) 1.3m 2.05 canted 1 1 NEXT

ISS hi-β DW100 (H) 6.8m (2x3.4m) ~16.5 DW 0 1 NEXT

FXI hi-β DW100 (H) 6.8m (2x3.4m) ~16.5 DW 0 1 NEXT

FMX lo-β IVU21 (H) 1.5m 1.79 canted 1 1 ABBIX

AMX lo-β IVU21 (H) 1.5m 1.79 canted 1 0 (joint w/FMX) ABBIX

LIX hi-β IVU23 (H) 3.0m 1.6-2.07* canted** 1 1 ABBIX

Same device

1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems F. Willeke, Director Photon Sciences Accelerator...

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