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Vacuum Systems

Vacuum Systems. H.C. Hseuh, Vacuum Group Leader 8 th ASAC Meeting for NSLS-II Project May 10-11, 2011. Outline. Injector Vacuum Systems Storage Ring Vacuum Chambers Cell vacuum chamber layout Cell chamber cross sections Cell chamber fabrication and assembly

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Vacuum Systems

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  1. Vacuum Systems H.C. Hseuh, Vacuum Group Leader 8th ASAC Meeting for NSLS-II Project May 10-11, 2011

  2. Outline • Injector Vacuum Systems • Storage Ring Vacuum Chambers • Cell vacuum chamber layout • Cell chamber cross sections • Cell chamber fabrication and assembly • S4A, S5A and fast corrector chambers • Production of Absorbers and RF Shielded Bellows • Procurement of Pumps, Valves and Instruments • Summary

  3. Injector Vacuum Systems (1) • Linac • Vacuum details agreed upon with Research Instruments (RI) • RI will purchase identical vacuum gauges, pumps and controllers • RI will use different PLC modules and interlock logics • Linac-Booster Transport Line • Layout finalized, detail component design is underway • B1, B3 & B4 chambers fabricated • B2 design done, being fabricated • All pumps, pump controllers, gauges and valves purchased B3 & B4 chambers B2 chamber model B1 chamber

  4. Injector Vacuum Systems (2) • Booster Ring • Arc chamber fabrication started at Budker after FDR in Feb • Straight section details & interface to TL are underway • Pumps, valves, gauges and controllers were purchased by BNL • PLC layout and logic were developed • Same PLC chassis/modules will be used for Booster and Transport Lines • All six PLC wiring will be done by Budker • Booster-Storage Ring Transport Line • General layout is completed • Detail design of four bending chambers is underway • B1 and B3 will have Booster arc chamber profile • B2 and B4 will have exit port to dump and SLM B1/B3 chamber B2/B4 chamber

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

  6. Cell Chamber Cross Sections Dipole Multipole Pump port Stick absorber Pump port Crotch absorber ID / 3PW fans BPM RF screen 3m long, 6o bend, ρ = 25 m 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 All extrusion completed in Dec All bending completed in Feb ~ 20% extra extrusions available after

  8. Chamber Fabrication and Assembly Adaptor plate Robotic welding at APS Machined extrusion Bi-metal flanges Vacuum certification ~ 10 chambers per month at APS and at BNL Completed chamber

  9. S4A, S5A & FC Chambers Old design BM-B BM-A S5A for 3PW FC New design S4A ~ 500 watts S4A changed from inconel to aluminum Relocated BLW, added two flange ABS Three 1st articles met requirements Production of 31 S4A is underway FC S5A changed from stainless to aluminum Orders for 34 S5A placed with vendors S4A S5A FC are made by BNL Shop and brazed to flanges FC

  10. Cell Chamber Production Status

  11. Absorber locations and quantity S S F C,F S C,F S > 8 ABS per cell, ~ 300 ABS for storage ring

  12. Production of BM Photon Absorbers • All ABS are made of GlidCop • Re-design stick and crotch ABS after Sept review • To improve cooling, reliability and corrosion resistance • To make them easier to fabricate • Added 90 flange ABS to protect d/s BLW from large beam deviations • Production of 60+ ABS underway by two vendors and at BNL Shop C S F C Flange ABS Crotch ABS w/ wide opening (170C/107C) Crotch ABS w/ Cu tube (180C/127C) Stick ABS w/ Stainless tube (130C/119C)

  13. Production of RF shielded bellows RF bellows requirements Max mis-alignment: ± 2 mm Max extension: -15/+10 mm Max angle deviation: ±10 mrad Low impedance Outside finger design wide fingers, no brazing, water cooling @ d/s flange RF fingers assembled in-house • Improved after Sept review and APS beam test • Better thermal contacts with fewer parts • One sleeve, longer RF fingers, electroplating • Stronger inconel springs for higher contact force • Eight(8)1st articles completed by BNL Shop • Order of 240 bellows housings by vendor being placed • All internal parts by BNL Shop • Assembly by Vacuum staff • APS beam test resumes in June

  14. Vacuum Pumps and Valves • Ion pumps (350) - 40% delivered • Dual ion pump controllers (200) - 80% delivered • Titanium sublimation pumps (300) - 70% delivered • TSP power supplies (280) – 1st article received • Custom NEG strips and supports (1500m) • All strips delivered, 40 % assembled into chambers • All NEG power supplies purchased • Turbopump stations – compact design, 18 assembled • RF shielded gate valves (62) – 1st article next week • All metal gate valves (40) – order being placed • Right angle valves (270) – 35% ordered and received

  15. Gauges, RGA and PLC • Vacuum gauges and controllers (100 sets) • 1st articles accepted, production has started • Residual gas analyzers (53 sets) – bids are due in mid May • Bakeout controllers – 4 needed for each cell bakeout • 4 available now, order placed for 9 more BC • Order for 3 mobile power distribution transformers placed • All cables identified – low smoke, zero halogen, tray rated… • Cables for pentent 1 ordered and most delivered • Pentent 1 cable run lists provided to EE Group • Programmable logic controllers (36) • Booster and TL PLC layouts generated and approved • Six(6) PLC chassis and code to be done by Budker • Storage ring PLC layout and chassis generated

  16. Summary • Fabrication of transport line and Booster chambers has started • Storage Ring cell chambers - 40% completed • ~ 10 chambers per month • Production of FC and S4A/S5A aluminum chambers started • Production of RF bellows and absorbers started • Procurement of pumps and controllers is ahead of schedule • Procurement of vacuum gauges and RGA is underway • Detail design of straight sections and exit pipes has started • RFP for DW chambers is underway • Girder and chamber integration has started • Ready to start tunnel/mezzanine installation FE S6 & exit pipe DW chamber layout Cross section

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