Accelerator Systems Overview

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Systems Overview

F. Willeke, ASD DirectorNSLS Project Advisory Committee Meeting

December 10-11, 2009


Outline

• Completed Critical R&D

• Development in Overall Accelerator Design

• Technical Progress of Subsystems

• Cost and Schedule Performance

• Outlook


NSLS-II Accelerator Design Goals

beam energy quasi constant, high beam current

horizontal beam emittance vertical beam emittance

moderate beam energy spread High Orbital Stability

Large Space for Insertion Devices

3 GeV500 mA, I / I = 1%0.6 nm (ultimate design goal)8 pm (diffraction limited @12keV) 0.1% (RMS)10% of , ’226 m incl bend sources >58 beam lines

average spectral brightness (2-10) keV spectral flux density

≥ 1021 mm-2 mrad-2s-1 (0.1%BW)-1

≥ 1015 s-1 (0.1%BW)-1 @ 2 keV.


Scope OverviewSynchrotron Light Source with a Beam Current of 300mA (designed for 500mA) , a horizontal beam emittance of 1nm (designed for 0.6nm), Energy spread of <1% and orbital stability of 10% of the beam size.

Storage Ring, 792m Circumference with• 60 dipole, 300 quadrupole, 300 sextupole and 210 corrector magnets and power

supplies• 190 Al vacuum chambers with integrated NEG pumping• 2 superconducting 500MHz Single Cell cavities driven by a 310kW klystron RF

amplifier and two passive superconducting 3rd harmonic cavities• Six 3.5m long damping wigglers, two serving a baseline beam line, four in vacuum

undulators (3 straights), and two 2m long elliptical polarized undulators including front ends for all devices

• EPICS control system and a full suite of instrumentation• Full suite of state of the Art of Instrumentation Injector with a • 200MeV S-band Linac and a • 3GeV booster synchrotron with 1Hz repetition frequency


Status Overview

Accelerator Systems Design is coming to an end: - Accelerator Lattice is stable now, do not expect significant changes

- Design of Injector, SR Magnets, Girder, Vacuum Chambers, Utilities completed or far advanced & Prototypes built and tested successfully

-Outstanding Designs: Power Supplies, Insertion Devices, Instrumentation Safety Systems, RF cavities (modifications to meet code)

Procurement of major systems started: SR Magnets orders have been placed LINAC RFP published Vacuum Chambers and components production started Booster RFP in preparation Many procurements such components for accelerator production and test

facilities in progress


Accelerator Physicsactivities of accelerator physicists are shifting from

• lattice design (lattice frozen)

• dynamic aperture (nonlin. correction scheme updated)

to

• analysis of prototypes (magnets)

• support of component design impedance measurements, orbit feedback, transverse damper, application programs

•operational issues beam containment systems, top-off safety


NSLS-II INJECTOR

LINAC ParametersEnergy 200MeV Frequency S-Band Charge 15nCE/E <1%

3 sectors Thermionic Gun Subharmonic Buncher

Booster ParametersCircumference 158mInjection Energy 200MevExtraction Energy 3GeVCycle Frequency 1HzCharge 10-15nC

@20-30mA

on-energy top-off injection with 1/min top-off rate


Storage Magnet Systems

Orders have now been placed for the industrial production of NSLS-II Storage Ring Magnets

Prototype production confirmed that NSLS-II magnets with demanding field quality can be built and are affordable


Girder, Supports and Integration• Girder R&D and Girder Design Completed Manufacturing

Drawings being completed • The precision alignment procedure is well defined by having

tested each step in the procedure • The R&D and the design of the girder system is complete, all

the critical issues have been addressed and solved. Ultimate test: After transport, all magnets within 5m aligned • Environmental Room equipped and functional • The girder integration procedure re-planned: only one

environmental room necessary, final magnet adjustment performed manually;

- optimizes procedure - this will save costs - helps to compensate the enhanced labor needed in setting up

the production facility and performing R&D dedicated presentation

Fully Functional and Equipped Environmental Room (T < 0.1 C ) for 30 m Precision Alignment


Final Demonstration of Feasibility of 30mm Magnet-to-Magnet Alignment

June 2009


Mechanical Systems, Front-Ends• Front end design 80% complete• Outside-Vacuum prototype of safety shutter built,

cycle-tested successfully• Compressed gas system redesigned and based on

compressed air• DI water systems (5 x CU; 5 x AL, RF, Linac, Booster,

Cryo-Compressors) detailed system design, component layout, service building equipment room detailed design with 3-D layouts


Vacuum Systems• Vacuum Production Facilities: Clean-room for

assembly prepared, vacuum conditioning lab is now fully equipped and tested, vacuum cleaning and measurement lab started to operate (late) , brazing oven installed, chemical cleaning procurement delayed

• Vacuum Chamber prototype extrusions successful, orders for production of MP extrusions place, dipoles will follow soon, dipole chamber bending under control, but is considerable effort; contracts for prototype welding and machining in place; vacuum chamber bake-out iterated and improved, Bi-metal flange in production

• Collaboration with APS in place for Production Chamber Welding

• NEG Pump Design tested, support system iterated and improved, Rogue mode shielding integrated

• Novel Design for Shielded Bellows, 2nd prototype being built

• Commercial Ion pump comparative test•

invar chamber support

Machining of first articles in progress

Novel Design Shielded Bellow Prototype

Extrusions being manufactured

In-house dipole chamber bending under control

Robotic welding at APS set up


RF Systems• Storage Ring SC RF Cavities: Nonlinear

Stress Analysis demonstrates compliance with equivalency to pressure vessel code

Failure of over-pressured system reproduced benchmarked calculation

Procurement documents in preparation reviewed by lab safety committee which

confirms adequacy of the procedure• Optimization of Coupling for 500mA• LLRF: 2nd FPGA based prototype build, still

basic functionality , under test with Booster 7-cell cavity (tuner loop)

• Booster RF: New tuner motors and electronics, adaption of input coupler to co-axial waveguide

• RF Power: RF engineer hired, • Cryogenic System: Cryo engineer on board,

consultant help to refine valve and pipe dimensions, design being wrapped up resulting in preliminary specification for first iteration with vendor


Instrumentation• BPM System still major activity RF button first article successfully tested,

production released

Commercially available BPM electronics meets demanding NSLS-II requirements (resolution, stability 0.1m)

Concerns about obsolete electronics and vendor support in-house development

• Efforts on other diagnostic systems started: Photon BPMs, Fast orbit control, transverse damper system, fast orbit control, optical monitoring, scraper systems, loss monitors

New 7mm 2-in-1 RF Button First Articles with Boron Nitride Washers


Electrical Systems• Main Dipole PS component design

and prototype testing well advanced, next step is system integration

• MP power supply design meets higher (25 ppm) stability standards easily, order for DCCTs have been placed

• New dual corrector power supply in progress

• Equipment enclosure design completed and power test on prototype with PS and heaters completed

• Detailed cable plans developed, layout of cable trays

• Calibration system for PS DCCT developed

Full Power Test of NSLS-II Sealed Air-Cooled Power Supply Rack with prototype PS’s

Low noise regulator prototype for Main DP switch-mode supply

DCCT

AC Power Control Module Power

Converter


NSLS-II Insertion Devices

49


Possible NSLS-II DW Production by APS

Damping Wiggler: APS provided a preliminary design, a cost estimate and a schedule. However APS has difficulties with NSLS-II DW specifications.

Attractive APS fixed gap NSLS-II DW proposal with horizontally moving in/out beam position


Bldg. 832 3D-Layout

Pulsed Magnet LabRF Lab

ISO-7 Clean Room for MeasurementID Lab

Tech Shop


Safety Systems

Beam Imminent Beacon

Search In Progress Beacon

Search indicator

Beam Disabled

Area Secure

Emergency Stop

Search Button

Beam Imminent Siren

Single Pentant Siren

• Design of SPPS and EPPS systems well advanced, completion end of FY

• Successful external reviews of the systems conducted

• Engineering prototypes in progress


Control System• High Level Applications

-Standard interface for orbit control running using existing beam optics dynamics codes

-Data Description Service is deployed as an interface/complement to basic channel access mechanisms.

• Database: IRMIS API for machine lattice entry and report is running and integrated into the online model environment.

• Equipment Controls: Preliminary design doc’s for vacuum, power supply, diagnostics, RF, Timing, EPS/PPS

• Prototype of Controls for Subsystems startedVacuum, beam line, PPS, beam correlated

applications, Diagnostics, power supplies, and LLRF

• Network preliminary design of network hardware system


WBS 1.3 Cost Baseline

WBSCD-2

(Nov ‘07)

($K)

CD-3(Oct ‘08)

($K)

June '09 Lehman Review

($K)

Current Baseline (Oct ‘09)

($K)

Changes since CD-2 Baseline

($K)

1.3.1 Accelerator Systems Management 5,251 6,019 6,019 6,019 769

1.3.2 Accelerator Physics 13,477 10,072 10,072 10,072 -3,405

1.3.3 Injection System 36,082 39,420 39,906 42,692 6,609

1.3.4 Storage Ring 135,104 139,473 140,727 148,936 13,832

1.3.5 Controls System 20,661 20,122 20,122 20,207 -454

1.3.6 Accelerator Safety Systems 4,297 4,297 4,297 4,471 174

1.3.7 Insertion Devices 22,706 22,985 22,986 24,225 1,519

1.3.8 Accelerator Fabrication Facilities 4,603 5,713 5,722 6,961 2,358

Grand Totals 242,181 248,101 249,851 263,583 21,402


Major AS Cost Changes


Schedule

CD4


Cost and Schedule Performance


Assessment

Trend since October 2008:• cost variance positive, (decreasing from M$ 2.6 to M$ 1.8)• a negative schedule variance has been building up reaching 5.8M$ at the end of FY09 Major Delays: vacuum, vacuum facility, insertion devices, RF slow procurement process with many medium size procurements behind schedule

Reasons: late hires, scheduling issues, procurements slowMitigation:

Labor augmentation plan 36 FTE Schedule Improvements immediate effect Additional procurement support added (Liaison Engineer AS, more buyers)

Clear Trend of Schedule Variance Improvements


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

0

50

100

150

200

FY2008

FY2009 FY2010

FY2011 FY2012

FY2013 FY2014

FTEs

Required Hired Planned Hires Job Shoppers MOU/BNL

Accelerator Systems Division Staffing

PlannedHired MOU BNL Temporary Labor Budgeted


FY09 AS Hires

FY 09 Staffing

11 Controls System Experts

10 Engineers

7 Physicists

11 Technicians and Designers

present staff 103

supported by 10 FTE MOU (laboratory internal)


Category Description Risk Ranking

Management

Booster Turn Key Procurement (ASD-03)

Procurement cost significantly higher due to only few vendors available or market condition for cooper worsens

Medium Monitor price index trends; Encourage alternative vendors; Be prepared to procure components and assemble in-house

SR Vacuum Chamber Production (ASD-05)

Vendors have difficulties producing acceptable quality extrusions or welding.

Medium Working closely with the vendorto resolve the technical issues, Ok for now, though will be hard to recover lost time

SR RF Cavity Production (ASD-07)

Only single vendor available; Vendor fails to deliver acceptable quality cavity; Cavity fails during commissioning

Medium Develop alternative sources for cavity; Build-up and assemble in-house high power RF window test stand

Insertion Device Production (ASD-09)

Cost increase of raw materials required for insertion device production

Medium Monitor market trends and be ready to initiate associated procurements as soon as possible

Risk Analysis & Management


Organization

• 39 new staff hired

• Deputy Division Director assigned: E. Johnson• Project Engineer hired: G. Fries • Organization augmented by task forces (FOF, BC)

N


Accelerator Systems FY 10 Project Goals

• Recover from Schedule Variances.• Develop a dynamic accelerator model including a full suite of IDs• Plan LINAC, Transfer-Lines, Booster and Storage Ring Installation• Generate Detailed Commissioning Plans for LINAC and Booster• Complete the Vacuum Facility.• Qualify first article Storage Ring magnets to start series production.• Complete design and prototyping of magnet power supplies.• Complete the design of the Cryogenic System.• Advance Production Machining of Vacuum Chambers.• Start Magnet-Girder-Vacuum Integration.• Start Production of the Damping Wigglers.• Develop design and procurement of EPU for start production in FY10.


Conclusion • Design of Accelerator Systems approaches conclusion: Magnet, Vacuum Chamber design and prototyping ready for production

• Accelerator Systems entered the construction phase, major procurements and production have started: SR Magnets, Vacuum Chambers, Production Facilities

• Negative Schedule Variance has built up; is mitigated by adding labor to make up for labor resources not available the time work was scheduled,

• Focus in the next months will be to mange construction contracts for magnets, and vacuum chambers, and award contracts for LINAC, booster and support systems

• Accelerator systems in good shape, no major technical issues, schedule under control

Accelerator Systems Overview

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