Production of Vacuum Components

1. Production of Vacuum Components H.C. Hseuh NSLS-II ASAC Review October 14-15, 2010

2. Outline • Storage Ring Vacuum Chambers • Vacuum Parameters and Cell Layout • Aluminum chamber cross sections • Chamber fabrication and assembly • Absorbers, S4A and RF Bellows • Absorber locations, design and prototyping • S4A stainless chamber and absorbers • RF bellows design and prototyping • Vacuum Pumps and Other Components • Summary

3. NSLS-II Vacuum Requirement . • Vacuum Chambers • Beam aperture – 25 mm (V) x 76 mm (H) • Ante-chamber for pumping and photon exit • Chamber straightness - < 1 mm / 5 m • Tapers - 10:1 ratio; steps or cavities < 1 mm • Precision alignment of BPMs: ± 0.2mm (H) and ± 0.1mm (V) • Discrete absorbers for BM fan • Clear aperture for ID fan toward front end • P(avg) < 1 nTorr • Շ (beam-gas) > 40 hr • no pressure bumps at straight sections • ➾minimize bremsstrahlung radiation and shielding for BL • Fast conditioning after intervention • In-situ bakeout to 130oC, NEG strip pumping • η (PSD) < 1 x10-5 molecules/hv after 100 A.hr beam dosage

4. Cell Vacuum Chamber Layout ID Beamline S2 S3 S1 BM Beamline S4 BM-A S5 L.S. BM-B S6 S1 BLW BLW S.S. BLW BLW BLW S4A S5A Stainless chambers BLW • 191 aluminum chambers, 3 – 5.5 m long • Extrusion w ante-chamber • > 12 types (length, magnet cutouts, etc.) • 60 stainless steel chambers (S4A and S5A) • 30 x 1.5 m after BM-A; 30 x 0.6 m for 3PW • 90 short inconel sections for fast correctors (FC) • ID chambers: 6 DW, 1 EPU, 4 IVU, …. • Special ones for Diag, Inj., RF… Dipole Multipole

5. Dipole Chamber Cross Section ID / 3PW fan < 3 mm wall Crotch absorber Pump port 2 mm gap Adequate V gap (~15 mm) Sufficient H width for SR fans Extrusion width of 320 mm Bending effort Adequate wall thickness after machining 3m long, 6o bend, ρ = 25 m

6. Multipole Chamber Cross Section Pump port Stick absorber CHM in Sextupole BPM RF screen NEG

7. Chamber Extrusion and Bending Extrusion ➾ bending ➾ machining ➾ cleaning ➾ welding ➾ assembly BNL V # 3 - 7 APS APS BNL V #1,2 Bending at BNL 50 ton press w 45 cm throat 3 m, 6o (ρ = 25m) accuracy to < 1.5 mm / 3m Spacer Multipole Shims Inspection before Only two vendors are interested Width, quantity and tight tolerance Straightness ≤ 1 mm / 5 m Cross sections to < 0.5 mm/5 m after

8. Chamber Machining and Welding Robotic welding at APS Adaptor plate Machined extrusion Bi-metal flanges Vacuum certification Completed chamber 12 Dipole and 24 multipole chambers completed (~ 20%)

9. Chamber Assembly and Testing at BNL • Extrusion to Weldment • BNL Measure → bend → measure → bake → measure • → machining vendors → APS for welding → vacuum certification →BNL • → 905 for measuring ports for BPM, absorber, flanges… • → 905clean room for chamber assembly • Install RF screen, BPM buttons, NEG strips, absorber • Install ion pump, gauge and roughing valve • → 905 for vacuum certification • Bake 130oC, UHV certification • Rogue mode measurement • Remove ion pump and gauges; install vibration wire support tube • →902 annex for girder integration/magnet measurement • → 905for wiring, bake and certification • Assemble large ion pump/TSP, pump down and LC, bake to 130oC • →740 (SR tunnel) for installation and testing Process developed

10. Aluminum Chamber Production Status • Extrusion machined: ~ 30% • Chamber welded: ~ 20% • Chamber assembled: ~ 6% • Chamber ready for integration: ~ 5% • APS welding: < 8 chambers per month • Need >10 chambers per month • BNL assembly and bake: 1-2 per wk • Increase to 3 per week to meet girder integration / installation schedule

11. Locations for BM Photon Absorbers 5 Stick ABS, 2 Crotch ABS & 1 S4A ABS (+ 3 Flange ABS) ID fan(s) Stainless pipe / absorber BM+3PW fans Long Straight Short Straight Crotch absorber Stick absorber Stick absorber

12. BM Photon Absorbers Stick ABS GlidCop 15 for ABS Stick location & quant. Prototypes BM Absorber Position and Power Crotch ABS Crotch openings

13. Re-design of Absorbers • After review of ABS on Sept 8-9: • Re-design stick and crotch ABS • To improve cooling, reliability and corrosion resistance • To make them easier to manufacture • Add ~ 90 flange ABS to protect BLW from large beam deviation Crotch ABS w/ wide opening APS Flange ABS Stick ABS w/ Stainless cooling tube Day-1 Crotch ABS w/ Cu cooling tube

14. S4A Stainless Chamber / Absorber BM-B BM-A Intercept ~ 500 watts BM fan at 1.5o Stainless CHM & distributed ABS: Multipole CHM is too narrow for ID fans Limited hor. space for stick ABS Impedance of flange ABS Prototypes

15. S4A Chamber Re-design - aluminum Stainless prototypes were: Difficult to manufacture – tapers, inconel, … Welding zone at mid plane Can’t protect BLW from large beam deviation Extruded Aluminum Uniform cross section New design: Add two flange absorbers Relocate d/s bellows to u/s Separate Inconel chamber for FC Aluminum extrusion for S4A No taper, easier to machine/weld Meet dimension tolerances 2-3 month effort

16. RF Shielded Bellows Two options Requirements Max mis-alignment: ± 2 mm Max extension: -15/+10 mm Max angle deviation: ±10 mrad Low impedance ohmic loss, HOM heating Inside fingers $$, simple Chose outside finger design wide fingers no brazing water cooling Outsidefingers Lower impedance, $$$

17. Re-design of RF shielded bellows • Six prototypes completed and tested • Electrical test OK; mechanical test w/ some dust • Beam test at APS gave high finger temperature • Being re-designed after review on Sept 8-9 • Reduce the number of components • Combine sleeve and RF fingers at one end • Improve thermal/electrical contacts • One sliding joint, fewer coil springs • Electroplating of fingers and sleeves • Increase contact force on RF fingers • Multiple-prong springs Before Before Modified design

18. Vacuum Pumps • Ion pumps, 100 l/s (150) & 200 l/s (200) • Order placed in Feb 2010, 20% delivered • Dual ion pump controllers (200) • Order placed in June 2010, 10% delivered • NEG strips w custom holes and supports (1500m) • All strips delivered, 10% assembled into chambers • 30% NEG power supplies purchased • Titanium sublimation pumps (300) • Order placed in July 2010, 10 1st articles delivered • TSP power supplies (270), 50 A x 13 V • PS from 3 vendors evaluated, order to be placed in Nov • Turbopump stations – 8 available, 8 more being assembled Pump procurements are ahead of schedule All contracts cover procurements for injectors, FE, BL ….

19. Vacuum Valves and Gauges • RF gate valves (60) RFQ in process, place order in Nov • FE gate valves (20) and fast shutters (10) – FY11 • Right angle valves (~ 270), vendor selected – FY11 • Vacuum gauges and controllers (100 GC sets) • Gauges and controllers from 4 vendors evaluated • Draft specification done, RFQ in Nov • Residual gas analyzers (60) – FY11 • RGA from several vendors are being evaluated, RFQ in 2011 • Bakeout controllers • One 24-zone done, and two 12-zone ones being assembled • Eight 24-zone are to be assembled by vendors Contracts will cover procurements for Injectors, FE, BL….

20. Vacuum Production Summary • Vacuum system design is ‘almost’ completed • Chamber production/assembly started w ~ 20% available • Need to ramp up the production rates to meet schedule • Re-design and fabrication of S4A ‘aluminum’ chambers started • Procurement of other vacuum components • Vacuum pumps are ahead of schedule • TSP PS, VG, GV to be placed in a month • Absorbers and RF bellows are re-designed and prototyped • Following the recommendations from expert review on Sept 8-9 • Needed by May 2011 for ring installation