1 BROOKHAVEN SCIENCE ASSOCIATES Accelerator Systems Overview F. Willeke, Director, Accelerator...

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Systems Overview

F. Willeke, Director, Accelerator Systems Division5th NSLS-II ASAC

March 26-27, 2009


Outline

• Charge• Response to last meeting• Overview of Technical Progress

– Accelerator Physics– Injector– Magnets– Girders and Alignment– Frontend and Utilities– Vacuum– RF– Instrumentation– Controls– Insertion Devices

• Organizational Development– Staffing– Organization and Group Structure– Procurement Plans


Focus 2008: Finalize AS Designs which require strong coordination with building design

Major milestones achieved since last ASAC: • CD-3 Approval Jan. 9, 2009; • Ring Building contract awarded; • Site clearing activities completed, • Preparatory Construction Work started.

Designs being completed in several key areas (girder, magnets, vacuum chambers)significant progress in prototyping & testing (Magnets)

2009Project Funding granted as planned ($103M)Project expects to receive early funding Focus 2009: the ramp-up of procurements

Overall AS Status


Charge

•Focus on recent progress major subsystems with near-future procurement activities to offer a last chance to receive comments• Focus subsystems which were not extensively covered in previous meetings.

Specifically:• Review results on DA studies incl. the effect of ID assessment on proposed improvement of

non-linear and chromatic correction system• Review progress on design of the injector system and comment on procurement plans for

major components in the near future • Review results of SR magnet prototype program with respect to readiness to start the production soon• Review progress of the vacuum system; in particular the shielded bellow design & mitigation

of beam heating issues• Review the superconducting cavity designs and procurement strategies for the RF systems• Review the development of the control system, definition of interfaces between controls and

technical subsystems.• Review the major procurement plans, procurement strategies, assumptions made for the

procurement schedule.

The Committee kindly requested to formulate responses in a written report expected to by 4-30-09.


AGENDA


Response to Recommendations Last Meeting

•Comment on Staged Procurements: Project Default is phase funded procurements but funding situation has developed such that major ASD procurements can be fully committed

•Comments on LINAC procured too late: Funding limitations removed, beneficial occupancy of injector advanced by 6 months, funding available pull forward LINAC procurement in FY09 together with frontend

•LINAC Parameters within reach of Standard Technology, no frontend studies: 15nC/150ns routinely not commercially available

•Focus on D.A with ID: Being done, but make only sense if NL lattice optimization sufficiently matured

Decker Distortions Necessary?: They are not in the baseline, will be part of the beam lines in the when fully build-out all beam lines, will probably implement one up-front and get experience

•Effort to be made on XBPM: Recent workshop (organized by EFD)

•Staffing to be increased in ID, Diagnostics and RF: $5M (~30 FTE) in Labor budget added in September

•High Field Quality Necessary: NSLS-II strongly Touschek limited because of low emittance, high intensity and high intensity=New Regime, mechanism for DA reduction from high multipoles well understoodneed high field quality in center quads and sextupoles

•Tracking with Engineering Tolerances and Non-systematic errors : Being Done


Response to Recommendations Last Meeting

Variable Gap DW to control Emittance: Very expensive way to control beam size; because of DW, impact of ID relatively small: 400kW@25 devicesPrad~8% =4%

Individually Controlled Sextupoles Everywhere: Benefit/cost ratio not obviously optimum,

Could still be added any time by adding funds to PS and cabling

Include RF into Booster Turn key: Vendors not interested

Force Standardization of Equipment on Turn-key Vendors: Desirable, subject to negotiations the contracts, will eventually cost more money, needs to be seen

High Field Quality too demanding, measurable?: Required Field quality can be met by vendors and can be measured, field quality was relaxed where D.A. allows, high order multipole in large aperture magnet measured with 30mm radius coil

Flat Segments in Pole profile: Decided against to not compromise field quality

Corrector Results: Available, meet requirement but concepts has been changed, not presented

Building Vibrations Transferred to Tunnel: State of the art modeling says it is no problem


Vacuum Damage by Beam During Commissioning: High Intensity operation only after beam optics/orbit under control and safety systems tested, diagnostic works with single bunch, and at least down to 20% of design intensity : factor 5000 in Beam power, ID’s not installed, later gaps open initially, SR power from bending in commissioning: 0.5W ok for conflat flanges

Boil-off N2 necessary: Changed to air, more expensive initially but will safe on the long run

Sequence of Ring B.O. of Building Parts: Sequence changed in favor of early availability of RF and Injector buildings

Dirty DI Water initially, filters: plan to purge all piping before connecting to components, filters good idea

Availability: Availability Study done, 95% requires already MTBF above standard values for typical accelerator components


Accelerator Physics• Dynamic Aperture so far still in the focus (WM Guo’s, J. Bengtson’s presentations)

• Relaxation of field specifications of quadrupoles and sextupoles assed

• Dipole magnet field specification revisited

• Usefulness of a 3rd chromatic know acknowledged: Alternatives for implementation: - Use one of the Geometric sextupoles inside achromat or - move one chromatic sextupole inside achromat- decision pending, will use window of opportunity

• Good progress in integration of damping wigglers

• Progress in integration of IVU’s into the lattice (up to 10) : So Far not issue

• EPU studies started

• Lattice refinement, tolerance and flexibility studies continued

(longitudinal position, magnetic lengths, ps stability, working point flexibility,

• TOP-OFF studies continued, need to take up speed again

• Impedance assessment concentrated on vacuum chamber rogue-modes and BPM heating recently

• FAST Ion and e-cloud instabilities assessed, do not represent a threat

•Transverse Feedback Design Started

•Fast Orbit Feedback and Corrector Layout re-optimized for Separated Function Correctors


Fast Orbit Correction Task Force

• Kick-off Fast orbit feedback Taskforce headed by • Recent Results: measurements of the transfer function of the improved 156mm

corrector with a shielded bellow (APS design) in the magnet gap baseline solution of fast corrector satisfies requirements for NSLS-II

However: Each fast corrector will see different eddy current environment , will behave differently

Corrector PS design represents considerable challenge

Taskforce to explore alternatives:


Injector

• Large Efforts to clarify interfaces and define details of injector building: detailed layout of equipment rooms, tunnel wall penetrations, labyrinths etc, cable conduits etc…. confident that Injector building providing completely for injector needs

• Injector Linac specification and procurement documents nearly completed

LINAC turn-key procurement: one staged procurement (funds available) 4 interested vendors

• Booster design refined, improved latticeBooster procurement documents draftedBooster RF cavities on site, adaption to NSLS-II needs in progress ( RF, J. Rose)Plan and cost estimate for in-house integration of booster developed for purpose of reference and fall back

• Beam line designs iterated with building design refinements• Injection scheme about to be changed from 4-kicker bump to

sextupole injection Details: T. Shaftan’s Presentation


Storage Ring Magnets

•Prototypes production by 3 manufacturers completed

•Measurement and test program almost completed, NSLS-II Specs can be met, in some areas some relaxation of non-allowed harmonic specifications

•Construction readiness review completed and final Design Refinements completed

•Procurement Documents and Drawing packages completed

•Magnets will be built to Specifications (deviating from previous plans)

•Procurement awaiting DOE Approval for Go-Ahead

•Plan to submit request for proposals within 2 weeks

•Contract award planned for August 15 (back to original schedule)

Details J. Skaritka’s Presentation


Girder, and Alignment

•Girder and Alignment R&D completed, original procedures refined and revised

•Quadrupoles and Sextupole magnets can be aligned routinely on Girders with 30m precision using vibrating wire technique and motorized magnet movers and manual fixation

•Girder surface can be recorded to 5m precision using inclinometers and laser trackers

•Girders can be moved to the tunnel and the high precision alignment can be restored by restoring girder surface using inclinometers and laser trackers

•Girders in the tunnel can be bolted to the tunnel floor magnet position preserving the magnet alignment within 30 m.

•Girders in the tunnel will have no resonant mechanical vibration modes below 30Hz

• Girder thermal expansion hysteresis will be < 5m @ T= 1ºC

described in a detailed step-by-step procedure, each step has been demonstrated


Girder R&D: Behavior under Temperature Changes

Result:

Reproducibility after 1 °C Temperature Change : ~0.5 m

Temperature Cycling and Reproducibility Tests


Beam Line Front Ends

All components have been modeled. Detailed drawings are in progress.XBPMs and slits (if any) are to be designed

Beam Line Front-Ends designed ahead of time

Ray-tracing and thermal analysis performed


Process Water System

Process water s designs well advanced


Diagnostic Systems

• RF Button Redesigned to optimize the sensitivity(requires new vacuum chamber cross section)• Button heating suppressed by optimization of Geometry• High Stability BPM Stand iterated new concept based on Invar• Noise Performance of commercial electronics tested and found to meet NSLS-II requirements• Fast Orbit Correction Feedback re-assessed New concept based on separated function

correctors• Photon BPM Workshop held in March (organized by EFD)


Diagnostic Overview

Monitor LocationSR BTS Booster LTB Linac Gun

Wall Current Monitor 3Fast Current Transformer 1 1 2Integrating Current Transformer 1 2Fluorescent Screen 1 (3 position) 6 6 7 3Energy Slit 1 1Bunch Cleaner 1RF BPM – Single Pass 7 7 3*RF BPM – TBT & Stored Beam 180 20ID RF BPM 2 or 3 per IDPhoton BPMs 1 per IDDC Current Transformer 1 1Fill Pattern Monitor Stripline 1Tune Monitor Stripline 1 1Emittance Monitor (3PW source) 1Pinhole Camera (BM source) 1Optical Ports for visible radiation 1 1FireWire Camera 1 1Streak-camera 1Transverse Feedback Systems (Striplines & RF Amplifiers)

1 H & 1 V

Beam Oscillations Monitor 1P-i-n Diode Loss Monitors 60Scintillator Loss Monitors 10Beam Scrapers ( X & Y) 2 sets

* IPR 2007 recommendation


RF Button Redesign

the crucial dimension:

need enough material to get helicoil length for seal clamping force

16 mm

Sensitivities (/mm)

Sx =~ 0.09; Sy =~ 0.09 (OK)

Electronic Resolution (0.017 – 200 Hz BW)

H-Resolution =~ 135 nm V-Resolution =~ 135 nm Required =~ 200 nm

BPM flange with 2 buttons -Configuration requiring one large holeIn multipole chamber –Simplifies installation and survey


RF Button Heating

Heat flux of 8 watts per button worst case, 25% of the total heat load was applied to the button, 75% was applied to the stainless body directly outside the button perimeter, mating surface of the stainless held at 25 ºC

temperature maximum value of 109 ºC.

New design incorporates

a Boron Nitride heat sinking

washer on the ambient side

of the glass seal.

Washer

Seal


First Results from Libera Tests – Meet Drift Specification

TEMP

~ 1 oC

HOR

~ 200 nm

VERT

~ 150 nm

TEM

PHO

RVE

RT

Power level 6 dBm (0 dBm at each input)

80% fill (2 μs pulse duration with 2.62 μs pulse repetition rate)

Total drift 200 nm; Temperature Drift 100 nm /°C

50 Hrs

Igor Pinayev


New Concept, Prototyping and Tests of the High Stability BPM Stand


Vacuum Systems

• Extruded Al Vacuum chamber design well advanced

• Extrusion-, machining-, welding-tests successful, Prototype chamber built and tested

• Chamber profile revised to accommodate improved BPM antennas new prototyping

• Procurement for vacuum chamber has started

• NEG pumps prototype produced, installed & tested

•In-situ heating of chamber tested, meets requirements

•Dipole chamber bending tests successful

•Shielded Bellow design well progressed

•Vacuum laboratory assembled, ozon cleaning apparatus installed

•Vacuum assembly facility delayed

Details: Hsiao Chaun Hseuh’s presentation


Technical Progress: RF

• Storage Ring RF: CESR-B or KEK-B single cell 500 MHz sc. cavity• Three possible vendors for turn-key cavity module • CESR-B Cavity and Cryostat need design improvements to comply with FR

851; redesign effort started in collaboration with industry • Turn-key RF transmitter system defined and specified; Klystron or IOT • LLRF system FPGA based control module, designed, prototype fabricated, tests

performed; 2nd prototype (HJ Ma’s presentation) Extensive LLRF modeling in progress, optimize control algorithm to satisfy

high demands on RF phase stability of 0.5 °• NSLS-II Landau cavity design, copper module built, measurements in progr.• Cryogenic plant preliminary design completed See J. Rose’s presentation

LBL Collab.

LBL Collab.


PS System

•Design of power supplies for the main dipole and quadrupole, sextupole, and corrector magnet in progress

•Prototyping of Fast Corrector Supply

Tested

Alternative 2 channel DC corrector+

Independent fast corr. Supply developed

•Equipment Enclosures Prototypes being tested

• Detailed layout of cable system including cable conduits / penetrations from mezzanine into tunnel, cable trays, AC distribution


Layout of equipment on tunnel mezzanine

Detailed 3-D CAD models of PS equipment inside the racks

and

Rack Layout on Mezzanine (tunnel roof) incl. cable trays, cable conduits, AC distribution


Insertion Devices

•Design Contract for Damping Wiggler about to be placed

•Magnetic Design of DW, IVU, EPU completed

•Build out of Insertion Device Laboratory started

•Staffing Situation slowly improving:

Insertion Device group has now 1 ½ Scientist+ 0.5FTE MOU Scientists from Magnet Division from 1 Mechanical Engineer, 1 Electrical Engineer

•Scope of Project Insertion Devices is changing:

-Only one DW Beam line with a 2 x 3.5m device

-Need to develop IVU optimized for large beta straight

-Specialized IVU for ISX beam line to be developed

IVU

EPU3PW


Control System

Efforts concentrated on three areas:

• Controls Architecture Development development is the embedded device controller - standard EPICS and control system studio a

collaborative set of operator applications being developed at DESY and SNS.

• Relational Database DevelopmentDevelopment/formatting of configuration tools, scripting tools, web-based reports and machine files

• High Level Application Platform online model running tracy 2 is operational with a lattice derived from an elegant desk As it runs under EPICS all of the channel access clients work on it including the XAL

tools and the matlab middle layer toolkit and SDDS for that matter. open-source protocol (DDS)is examined whether suitable for the high level application

architecture.

L Dalesio’s Presentation

Device Controller Board Prototype

Device Controller Board Prototype


ASD Procurement in FY09


Staffing

• ASD 90 Staff & ~ 10FTE MOU & 3 FTE Temporary Staff

• Some key Staff still not on board, but hiring process is converging

Tight coordination with NSLS-II HR support

• Labor Budget increased by 5M$ (@~30FTE) in September (injector, mechanical engineering)

• Certain Areas still too lightly staffed: design room, survey, mechanical engineering electrical engineering @30FTE

• Staffing Concerns: Steep increase of temporary labor in FY11 and FY12

• Rapid decrease of project funding after 2012

• So far early operation to support commissioning not supported


Staffing

NSLS-II Staffing Plan vs. Project Requirements (FTEs)Accelerator Systems Division

0

20

40

60

80

100

120

140

160

180

FY2008

FY2009 FY2010

FY2011 FY2012

FY2013 FY2014

FT

Es

Required Hired Planned Hires Job Shoppers MOU/BNL


CONCLUSIONS

•ASD is moving from the design in the construction phase

• Design of key components is completed or sufficiently advanced to begin procurement

• Design optimization continues wherever there this is not in conflict with the schedule of components

• Storage Ring Magnet Program is proceeding well, prototype program successfully completed, Bid opening within the coming few weeks, contracts to be placed in August

•Technical challenges of support systems in meeting the tight alignment and stability tolerances

•Successfully completed, girder integration prepared

•Vacuum systems design well advanced, pre-production started, mass production will start in this FY.

• LINAC procurement in progress, plan to award contract in October

• ASD Organization and Management developing

• Staff almost complete

• Labor resources tight, ASD falling behind schedule in labor intense areas (~20FTE accumulated resources missing)

• Project received funds ahead of time, prioritization of work and procurement pulled forward in progress

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