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LIU-SPS 200 MHz RF upgrade presentation to sck-cen

This presentation provides a brief overview of the RF power project at CERN, including the building of BAF3, power systems, transmission lines, cavities, FPC, and tunnel integration. The project timeline, budget, and manpower are also discussed.

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LIU-SPS 200 MHz RF upgrade presentation to sck-cen

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  1. LIU-SPS200 MHz RF upgradepresentation to sck-cen Eric.Montesinos@cern.ch

  2. Outlook • Brief description of the RF power project & Summary • Building BAF3 • Power systems • Transmission Lines • Cavities • FPC • Tunnel Integration • Conclusion eric.montesinos@cern.ch

  3. Description of the project • First definition of the project (2011) • Four to become six Travelling Wave Cavities • Four existing amplifiers upgraded to 1.05 MW* feeding four cavities • Two New power amplifiers delivering 1.4 MW* to two cavities (became 1.6 MW* in 2015) • A new building • A new SPS-LSS3 layout *All RF power levels being peak power operating with a duty cycle at 50% at 42 kHz or 172 kHz Courtesy Elena Chapochnikova Available RF voltage as a function of Irf eric.montesinos@cern.ch

  4. Description of the project • Three main sub-tasks • New RF Building project • Cavities re-arrangement project • RF Power Amplifiers project New RF Building 1 mW 1.7 MW RF amplifier Coaxial transmission line 150 meters 1 mW 1.7 MW RF amplifier Accelerating cavity Accelerating cavity eric.montesinos@cern.ch

  5. Description of the project • New RF Building project • Cavities re-arrangement project • LSS3 • Coaxial lines • Cavities • Fundamental Power Couplers • RF Power Amplifiers project • Present amplifiers upgrade • New amplifiers New RF Building project RF BE/RF Eric BE Space Management BE/ASR Paula Safety DGS/SEE Enrico Ventilation and cooling EN/CV Mauro Electrical Network EN/EL Joël Transport EN/HE Keith Integration EN/MEF Yvon Alarms GS/ASE Christophe Civil Engineering GS/SE Natasha New RF Power Amplifiers project Power BE/RF Eric LLRF BE/RF Wolfgang, Philippe Controls BE/RF Andy HVPS TE/EPC David Cooling (air/water) EN/CV Mauro Diacrode Los Alamos John MICE Andy SSA SOLEIL Patrick TTI (Spain) José Tetrodes Thales,E2V EU CPI, L3com USA Thoshiba Japan 26,500 kCHF Cavities re-arrangement project RF Coaxial lines BE/RF Eric New couplers BE/RF Eric Spare sections BE/RF Eric Dampers (LSS2-LSS3) BE/RF Wolfgang Pickups BE/RF Thomas Optics BE/ABP Gianluigi Safety DGS/SEE Enrico Cooling EN/CV Mauro Transport EN/HE Catherina Integration EN/MEF Yvon Vacuum TE/VSC Miguel eric.montesinos@cern.ch

  6. Outlook • Brief description of the RF power project & Summary • Manpower • Schedule • Budget • Building BAF3 • Power systems • Transmission Lines • Cavities • FPC • Tunnel Integration • Conclusion eric.montesinos@cern.ch

  7. Manpower • A lot of people from many teams ! (more than 160 directly involved) • All teams involved know the requested manpower regarding their activities eric.montesinos@cern.ch

  8. Schedule eric.montesinos@cern.ch

  9. Outlook • Brief description of the RF power project & Summary • Building BAF3 • Power systems • Transmission Lines • Cavities • FPC • Tunnel Integration • Conclusion eric.montesinos@cern.ch

  10. BAF3 • Design completed by end of October 2011 to allow Civil engineering studies and authorisation requests to be launched • Goal to have the bare building completed by end 2014 (taking advantage of LS1 to minimize accident impacting SPS operation during construction) • Even if we did not know what amplifier technology will be selected ! Bare building 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  11. BAF3 • Point 3 is the best area even if we need a new building • New building between BA3 and BB3 in front of 929 RF workshop : • Ground floor 20m x 25m = 500 m2 • Mezzanine: 10m x 25m = 250 m2 800 MHz RF workshop New RF building Faraday Cage Siemens Philips eric.montesinos@cern.ch

  12. BAF3 Total combiners = 200 m2 • Amplifier tendering process opened to several technologies • 2 x 16 tetrodes (well known) • 2 x 2048 SSPA (Solid State Power Amplifiers) • 4 x Diacrodes (new tube) • 4 x IOT (Inductive Output Tube, almost new) • Answer of the selected technology (volume needed) after the building approval • Hybrid combiners and coaxial lines will be similar to the ones in use with present systems 1 tube (160 kW) = 4 m2 HVPS = 192 m2 Total 32 tubes = 320 m2 Total combiners = 200 m2 4 tours (320 kW) = 33 m2 LVPS = 72 m2 total 64 towers = 600 m2 Courtesy Patrick Marchand (SOLEIL) 2.3 m 4.7 m 4.7 m eric.montesinos@cern.ch

  13. BAF3 • All main RF equipment around • Close to RF workshop • Take advantage of ‘nearly empty’ GT10 gallery to install 350 mm RF coaxial transmission lines • Easiest path to the pit • Access through 929 RF workshop • Reserved area for BB3 transformers • if needed in the future to replace oil transformers to cast resin transformers BC3 New RF Amplifiers 929 RF workshop BA3 Siemens BAE3 Philips BB3 800 MHz RF Faraday Cage GT10 Gallery Reserved area for new BB3 transformers 28m x 4m eric.montesinos@cern.ch

  14. BAF3 • Total surfaces: • Basement : 19.5 m x 36.5 m = 710 m2 • Mezzanine : 475 m2 • Total = 1185 m2 • Total surfaces for RF: • Basement = 550 m2 • Mezzanine = 475 m2 • Total = 1025 m2 36.5 m 19.5 m eric.montesinos@cern.ch

  15. BAF3 • BAF3 with Tetrodes • BAF3 with SSPA eric.montesinos@cern.ch

  16. BAF3 • 2011 Integration studies completed • 2012 Enquiry ‘Etude Genie Civil’ sent out • 2013 Construction • 2014 Bare building delivered • 2015 Ready for services integration eric.montesinos@cern.ch

  17. Outlook • Brief description of the RF power project & Summary • Building BAF3 • Power systems • New amplifiers • Present amplifiers upgrade • Transmission Lines • Cavities • FPC • Tunnel Integration • Conclusion eric.montesinos@cern.ch

  18. Future power systems in the SPS BA3 Siemens 2 x 1.1 MW CCC BB3 Electrosys 2 x 240 kW BAE3 Philips 2 x 1.1 MW BAF3 New 2 x 2.0 MW eric.montesinos@cern.ch

  19. New systems 2 x 2.0 MW @ 200 MHz • Three contracts • Drivers : • 2 x 16 x SSPA • Finals : • Tetrode : 2 x 16 x 110 kW • IOT : 2 x 16 x 110 kW • SSPA : 2 x 16 x (110 x 1 kW) • Diacrode: 2 x 2 x 850 kW • No klystron at 200 MHz • Combiners + lines : • 3 dB hybrids • 850 kW power loads One line (input cavity ~120 to 180 m away) From Beam Control 1/16 splitter 2 x 1.6 MW at cavity input 4 stages of 3 dB combiners = - 0.6 dB 120 to 180 m Coaxial lines = - 0.2 dB Final Amplifier output = 1.6 MW + 0.8 dB = 2.0MW / 16 = 125 kW eric.montesinos@cern.ch

  20. Purchasing strategy • Two contracts • IT-3842 Drivers • IT-3841 Finals • A first contract for the Drivers (IT-3842) • SSPA only (best technology for a few kW amplifier) • Will be a first input for a predefined cost for the Finals • Combining systems • Done in house or subcontracted • Will be a second input for a predefined cost for the Finals • Once Drivers contract adjudicated, a second contract for the Finals Drivers IT-3842 cost + Combiner cost (defined by CERN) + Finals IT-3841 offer _______________________________________ IT-3841 adjudication to the lowest compliant eric.montesinos@cern.ch

  21. IT-3842, DriverS Consulted Selected • 72 companies consulted • 20 selected • 10 offers • Defined a 1.25 kW unit • Compatible with all Finals technologies • 32 for SSPA & IOTS, 256 for Tetrodes, 192 for Diacrodes • 12 pre-series for qualification (end of contract clause in case of any failure without any payment) • One to six batches of 50 (total 62 to 312) regarding result of future Finals IT-3841 • TTI Norte, Spain, awarded the contract (3.7 €/W) November 2011 March 2014 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  22. IT-3842, DriverS August 2015 • RF design is impressively robust • Double circulators ! • Sustained the CERN Fast Short-Circuit test ! • Successfully performed the 1000 hours test with five units (not a single failure) • Many broken transistors after 6 months of operation (first half 2017) • Very quick reaction of the company (TTiNorte, Spain) that repaired at no cost all the already produced units • 64 units in operation since mid-2017 without very few failures ! • 300 units total delivered and successfully tested November 2011 March 2014 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  23. IT-3842, DriverS August 2015 • RF design is impressively robust • Double circulators ! • Sustained the CERN Fast Short-Circuit test ! • Successfully performed the 1000 hours test with five units (not a single failure) • Many broken transistors after 6 months of operation (first half 2017) • Very quick reaction of the company (TTiNorte, Spain) that repaired at no cost all the already produced units • 64 units in operation since mid-2017 without very few failures ! • 300 units total delivered and successfully tested November 2011 March 2014 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  24. IT-3842, DriverS September 2017 • RF design is impressively robust • Double circulators ! • Sustained the CERN Fast Short-Circuit test ! • Successfully performed the 1000 hours test with five units (not a single failure) • Many broken transistors after 6 months of operation (first half 2017) • Very quick reaction of the company (TTiNorte, Spain) that repaired at no cost all the already produced units • 64 units in operation since mid-2017 without very few failures ! • 300 units total delivered and successfully tested January 2017 November 2011 March 2014 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  25. IT-3841, Finals December 2014 • Technical Specification to be finalized taking into account Drivers outcome • Power level request increased • Cavity 1.4 to 1.6 MW • Amplifier from 1.6 to 2.0 MW ! TS TS MS 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 Drivers eric.montesinos@cern.ch

  26. IT-3841, Finals additional costs • Drivers IT-3842 cost • 5500 CHF per 1.25 kW unit • SSPA & IOT 176 kCHF • Tetrodes 1’408 kCHF • Diacrodes 1’056 kCHF • Combiner cost (defined by CERN) • SSPA & IOT 2’760 kCHF • Tetrode 3’160 kCHF • Diacrode 800 kCHF • Total additional cost per technology • SSPA & IOT 2’936 kCHF • Tetrode 4’568 kCHF • Diacrode 1’856 kCHF eric.montesinos@cern.ch

  27. IT-3841, Finals Bidders conference • Defined the scope of the contract • being as fair as possible regarding the technology • Defining a quite costly Demonstrator in order to disqualify ‘non serious’ companies (we do not want to be R&D at low cost) • Not a single CHF paid in case of failure of the demonstrator • Taking into account tubes on an as long as possible period (over 5 years) • Including spares in order to operate during 20 years • Answered 102 questions from the suppliers 20 January 2015 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  28. IT-3841, requirements • Requirements • Integration within the given building • Repetition rate 0.1 Hz to 500 kHz (require a CW and a pulsed amplifier) • Full reflection all phases 100 ms (equivalent to 4 time the power level along the lines) • Non conventional way to measure the BW (required by LLRF and TWC) • Very good linearity • Two tone at many power levels • A lot of tests to qualify the Finals • Supercycle test, short circuit test, BW, linearity, … • Short duration tests to qualify an Amplifier within one week • Long duration tests to check reliability within one month eric.montesinos@cern.ch

  29. IT-3841, requirements Only 10 kW in-between pulses ! eric.montesinos@cern.ch

  30. IT-3841 Consulted Selected • Unable to submit a competitive bid due to quantity being beyond our production capacity and we could not provide installation support • Dear all, We are sorry but we are not able to finish every documents within deadline. So we must decline to participate with our offer. Thank you for your opportunity. Best regards • We are not on time with the documents required • We believe that the chances are too low to get the contract by bidding Solid State Amplifier solutions. Additionally, the known dumping price structure of competitors in the field of Solid State Amplifiers, which get development provided free of costs by public institutes (already known due to the preceding call for tender for preamplifiers of the same frequency) also makes the chance to win the bid too small for the required work load for bid preparation • 74 companies consulted • 19 selected • 8 declined • 7 offered • No discussion about the Drivers neither the combiners costs 13 March 2015, bids opening 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 eric.montesinos@cern.ch

  31. IT-3841 Consulted Selected Offered 17 September 2015, FC approval • 74 companies consulted • 19 selected • 8 declined • 7 offers • March 2015 lowest bid is Thales Communication & Security for 8.002 MCHF • Very careful verification of the offer • September 2015 CERN FC approval 13 March 2015, bids opening 2012 2013 2014 2015 2016 2017 2018 2019 2020 2011 1.75€/Wp (2019 rates) eric.montesinos@cern.ch

  32. IT-3841, Finals • One Transmitter will be composed of • 16 x 150 kW RF amplifiers • One RF amplifier will be composed of • 2 x 40:1 cavity combiner • One Cavity combiner will be composed of • 40 x 1 kW RF blocs • In total • Two transmitters • 32 RF amplifiers • 64 cavity combiners • 5120 RF blocs 2 x 16 x 150 kW RF Amplifiers eric.montesinos@cern.ch

  33. IT-3841, Schedule Demonstrator FAT Ready for LLRF 1st Transmitter SAT Contract 2016 2017 2018 2020 2019 DR Demonstrator SAT 2nd Transmitter SAT eric.montesinos@cern.ch

  34. True life Demonstrator FAT Ready for LLRF 1st Transmitter SAT Contract 2016 2017 2018 2020 2019 DR Demonstrator SAT 2nd Transmitter SAT First Demonstrator SAT 1st Transmitter SAT Ready for LLRF 2016 2017 2018 2020 2019 #10 Demonstrator SAT 2nd Transmitter SAT eric.montesinos@cern.ch

  35. Visit and technical details • Several technical details are still under a NDA • I will answer your questions during the visit as much as within the respect of the NDA • Thanks for your visit to CERN eric.montesinos@cern.ch

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