Accelerator Systems Overview

1
Accelerator Systems Overview
F. Willeke, ASD Director 6th ASAC October 22-23,
2009
2
Outline

• Comments on Charge
• Responses to last ASAC Meeting
• Conclusion of the RD Program
• Development in Overall Accelerator Design
• Technical Progress of Subsystems
• Cost and Schedule Performance
• Organizational Issues
• Outlook

3
Charge

• Review AS recent progress near-term plans
  technical, cost, schedule performance
• ? overview presentation
• Review the plans for BPM system, comment on
  in-house development regarding technical
  performance, cost, and schedule
• ? dedicated presentation
• Review the overall machine protection system and
  the integration of personal protection system,
  beam containment and top-off safety measures
• ?3 dedicated presentations
• Comment on the Injection systems including the
  plan for the pulsed magnet facility and the
  procurement strategy for the booster
• ?Injector presentation
• Review and comment on the NSLS-II power supply
  systems
• ?dedicated presentation
• Review the plans for production, assembly, and
  installation of accelerator systems
• ? dedicated presentation
• Review the plans for start-up, test, and
  commissioning of accelerator systems
• ? Dedicated presentation

4
Response to the Committees Recommendations
Project acknowledges importance of comment, BB
monitor calibration planned to be used,
achievable precision ?2008 tech note Workshop
held, positive feedback This is being done, but
not systematically, so far given our present
solution, overall tune footprint shrinks with
positive xx Prototype would be too costly, not
in budget, vertical cold tests are planned, no
vendor decision yet comment is
acknowledged taken into account in the ongoing
design considerations Aggressive staffing plan
pursued, resources from other labs used (Al
Chamber welding, DW, controls) Magnet procurement
split into 5 packages, sextupole and quadrupole
packages split into 2 similar sub-packages

• Achievable precision of BPM offset by BBA
  Introduce realistic errors into the orbit and
  optics correction model!
• In-depth workshop of the storage ring lattice and
  tracking results in the near future
• Investigate the performance of the Storage Ring
  lattice at higher positive values of vertical
  chromaticity, which are generally required to
  control instabilities!
• The Project should plan on building and testing a
  (500MHz) superconducting cavity prototype,
  especially if the contract goes to a company that
  has no experience
• Make an effort to decrease R/Q of the passive
  cavity.
• Keep focus on rapid staff-up. Look for resources
  at other labs.
• Give serious consideration to parallel awards and
  easy escape clauses in contracts for magnets,
  to facilitate a shift of scope from one vendor
  (who might not be performing satisfactorily) to
  another

5
Nonlinear Dynamics Review
? Methods and procedures endorsed 3rd chromatic
knob recommended No preference of how to
implement
6
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

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Accelerator Physics

• Dynamic Aperture Magnetic field specifications
  updated
• Chromatic corrections improved
  2?3 chromatic sextupole
  families decision made
• Integration of Damping wigglers improved
  ? acceptable DA with 3 DW
  and up to 10 IVUs, work on EPU
  accommodation started
• Work on Beam confinement including planned
  experiments, top-off safety study continued
• Revision of fast orbit correction separated
  function scheme reduces performance risk
• Impedance calculations pursued, collaborating
  with instrumentation and vacuum on suppression of
  rogue mode, calculations and measurements (review
  held in September)
• Transv Damper conceptual design filtering (
  Button BPM, locations, detector layout, Digital
  filter layout 9-tapFIR, strip-line kicker)

8
Lattice Functions for One Cell
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Introduction of a Third Chromatic Knob
Center of Long Straight
Center of Short Straight
Center of Long Straight

• Symmetry in lattice
• Reflection symmetry about the center
• of the straights
• Reflection symmetry and translation symmetry
  between super-periods

• Functions of the sextupoles
• 2 chromatic sextupole families to
• correct the linear chromaticity
• 7 geometric sextupoles to compensate
• the nonlinearity
• One more chromatic sextupole to
• correct the nonlinear chromatic
• effects.

10
Dynamic Aperture with Insertion Devices
Frequency Map Simulation (RADIA kick map used)
basis lattice
with well compensated chromaticity and tune shifts
add IVU and
imperfections
Add DW
Effect of DW is mainly linear Optics
Distortion Can be well integrated (requires 3-f
symmetric installation)
Add EPUs
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Preliminary Layout of Transverse Damper
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Injector System

• The RFP of the 200MeV s-Band Linac will be
  published end of October there are 4 strong
  vendors
• Booster will be semi turnkey, vendor responsible
  for overall performance, some subsystems
  (controls interfaces, BPM electronics,
  installation labor contributed by BNL)
• Transfer line design matured
• Transfer Line magnet design in progress
• Pulsed Magnets Workshop in August
• ? Pulsed Sextupole Injection Scheme abandoned,
  baseline 4kicker-bump
• Pulsed magnet laboratory installed

13
Storage Magnet Systems
Orders have been placed for the industrial
production of NSLS-II Storage Ring Magnets
The 240 68mm aperture quadrupole magnets in 6
variants will be produced by Everson/Tesla and
BINP, orders placed Sept 23 The 68 mm sextupole
magnets will be produced by IHEP and Danfysik,
Orders placed October 16 The 60 large aperture
quadrupoles and the 30 large aperture sextupoles
will be produced by Buckley, orders placed
Oct. The vendor for the 54 35mm aperture and the
6 90mm dipoles has been selected. The 180 100mm
and 156mm hor./vert. correctors will be produced
by Everson Tesla.
14
Girder, Supports and Integration

• Girder RD and Girder Design Completed
  Manufacturing Drawings being completed
• The precision alignment procedure is well defined
  by having tested each step in the procedure
• The RD 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 5mm 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 RD ? dedicated
  presentation

Fully Functional and Equipped Environmental Room
(DT lt 0.1 C ) for 30 mm Precision Alignment
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Final Demonstration of Feasibility of 30mm
Magnet-to-Magnet Alignment
June 2009
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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

17
Vacuum Systems
Prototype chamber invar support on girder

• 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

Dipole chamber bending
New Vacuum Chamber Profile
Novel Design Shielded Bellow Prototype
18
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

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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 0.1mm)
• Concerns about obsolete electronics and
  vendor support? in-house development seriously
  considered
• 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
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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 PSs
AC Power Control Module
Power Converter
DCCT
Low noise regulator prototype for Main DP
switch-mode supply
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NSLS-II Insertion Devices
49
? Tanabes Presentation
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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
23
Bldg. 832 3D-Layout
ISO-7 Clean Room for Measurement
ID Lab
Tech Shop
Pulsed Magnet Lab
RF Lab
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Safety Systems

• Design of SPPS and EPPS systems well advanced,
  completion end of FY
• Successful external reviews of the systems
  conducted
• Engineering prototypes in progress

? Johnsons Presentation
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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 docs for
  vacuum, power supply, diagnostics, RF, Timing,
  EPS/PPS
• Prototype of Controls for Subsystems started
• Vacuum, beam line, PPS, beam correlated
  applications, Diagnostics, power supplies, and
  LLRF
• Network preliminary design of network hardware
  system

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Accelerator System Budgeted Cost
27
Accelerator Systems Budgeted Costs
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Registered AS Cost Changes
Note Contingency is owned by Federal Project
Director. Numbers are just used as a measure of
cost increase!
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Project Cartoon Schedule
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Schedule
CD4
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Cost and Schedule Performance
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Assessment

• Trend since October 2008
• Cost variance becoming smaller
• Schedule Variance becoming negative reaching
  5.8M at the end of FY09
• Reasons
• Late hires and Missing MOU Labor 36 FTE ( _at_
  6.0M )
• Labor augmentation plan 36FTE to recover since
  June, too early to see an effect
• Should start to see improvement within the next 6
  month
• There is one remaining EVMS issue Controls has
  worked on activities scheduled to
• start in FY10? no earned value, self repairing in
  FY10
• There are real delays Vacuum Chamber 1.5 M
  due to technical issues and procurement or vendor
  problems and slow progress with the vacuum
  facility (recovering now)
• Slow procurement process with many medium size
  procurements behind schedule
• ? Additional procurement support added (Liaison
  Engineer AS, more buyers)

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ASD Shortage of Labor Resources
Causes Late Hires, Resource Leveling, MOU
contributing less than planned
ASD schedule variance at 4/30 associated with
this effect is -4M
FTE
FTE
Difference, Accumulated Difference
FTE
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Mitigation of Schedule Variances
Goal Stop Growth of SV within 3 months ?
recover the schedule within 24months
Preliminary Plan in Place to satisfy immediate
needs 18FTE, plan to complement by another 18FTE
Additional 18 FTE ? Slow recovery
35
Schedule Recovery
FTE
36
Accelerator Systems Division Staffing
Temporary Labor
Budgeted
Planned
Hired
MOU BNL
37
FY09 AS Hires

• FY 09 Staffing
• 11 Controls System Experts
• 10 Engineers
• 7 Physicists
• 11 Technicians and Designers
• Present staff 103
• Supported 10 FTE MOU

38
Organization

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

N
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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 to award
  construction contracts for magnets, vacuum
  chambers, LINAC, booster and support systems
• Accelerator systems in good shape, no major
  technical issues, schedule under control