Accelerator Systems Overview

1 BROOKHAVEN SCIENCE ASSOCIATES

Accelerator Systems Overview

F. Willeke, ASD Director6th ASAC

October 22-23, 2009


Outline

• Comments on Charge• Responses to last ASAC Meeting• Conclusion of the R&D Program• Development in Overall Accelerator

Design• Technical Progress of Subsystems• Cost and Schedule Performance• Organizational Issues• Outlook


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


Response to the Committee’s Recommendations• 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

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 x

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


Nonlinear Dynamics Review

Methods and procedures endorsed

3rd chromatic knob recommended

No preference of how to implement


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 Physics• Dynamic Aperture : Magnetic field specifications updated• Chromatic corrections improved

23 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)


Lattice Functions for One Cell


Introduction of a Third Chromatic Knob

QM1 QM2 QM2 QM1

SM1L SM2 SM1R0.2 0.67

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.


Dynamic Aperture with Insertion Devices

Frequency Map Simulation (RADIA kick map used) basis lattice with well compensated chromaticity and tune shifts

Effect of DW is mainly linear Optics Distortion

Can be well integrated (requires 3-f symmetric installation)Add EPU’s

add IVU and imperfections

Add DW


Preliminary Layout of Transverse Damper


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


Storage Magnet SystemsOrders 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.


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•

Prototype chamber invar support on girder

Dipole chamber bending

Novel Design Shielded Bellow Prototype

New Vacuum Chamber Profile


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 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


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

Tanabe’s Presentation


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

Johnson’s Presentation


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


Accelerator System Budgeted Cost


Accelerator Systems Budgeted Costs


Registered AS Cost Changes

Note: Contingency is owned by Federal Project Director. Numbers are just used as a measure of cost increase!


Project Cartoon Schedule FY14

CriticalDecisions CD-0 CD-1 CD-2 CD-3 Approve Start of Construction CD-4

Approve Project CompletionApprove Mission Need Approve Alternative Approve

Aug 05 (A) Selection and Cost Performance Range - Jul 07 (A) Baseline - Jan 08 (A)

Conceptual Design Aug 05 Jul 07

Design of LOBs CompleteConventional Facilities Jan 11

Design

Booster Ready forExperimental Facilities Commissioning Dec 12

Procurement, Fabrication, Installation and Test Storage Ring Ready forAccelerator Systems Commissioning Apr 13

Construction& Installation

Long Lead Oct 13Conventional Facilities

Early Completion Feb 14

Commissioning BOD Commissioning & Pre-Opsand Pentant 3

Pre-Ops Sep 11EPU Install Oct 13

Legend (A) Actual Completed Planned Data Date Level 0 Milestone Schedule Contingency Critical Path

Construction

FY13

Accelerator Systems

FY08

Sep 08

FY05 FY06 FY07

Oct 08

FY09 FY10 FY11 FY12 FY15


Schedule

CD4


Cost and Schedule Performance


AssessmentTrend 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 ( @ 6.0M$ )Labor augmentation plan 36FTE to recover since June, too early to see an effectShould 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)


ASD Shortage of Labor Resources

ASD schedule variance at 4/30 associated with this effect is -4M$Causes: Late Hires, Resource Leveling, MOU contributing less than planned

[FTE]

[FTE]

Difference, Accumulated Difference

[FTE]


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


Schedule Recovery

FTE


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 10 FTE MOU


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


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

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Accelerator Systems Overview

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