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Superconducting Undulators WBS: APS-U1.03.04.03

Superconducting Undulators WBS: APS-U1.03.04.03. Yury Ivanyushenkov Physicist, SCU Project Technical Leader ASD/Magnetic Devices Group DOE Lehman CD-2 Review of APS-Upgrade 4-6 Decem ber 2012. Outline. Science / Technical Significance WBS Scope of this System Staff / Org Chart

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Superconducting Undulators WBS: APS-U1.03.04.03

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  1. Superconducting UndulatorsWBS: APS-U1.03.04.03 Yury Ivanyushenkov Physicist, SCU Project Technical Leader ASD/Magnetic Devices Group DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

  2. Outline • Science / Technical Significance • WBS Scope of this System • Staff / Org Chart • Requirements • Design • ES&H • Cost • Schedule • Previous Reviews Responses • Summary DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  3. Superconducting Undulators (SCUs) Motivation Brightness Tuning Curves Superconducting undulators generate extremely high photon brightness above 40 keV DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  4. SCU Scope SCU0 – Test device SCU1 SCU2 SCU2 will use a longer cryostat with a 2-m long magnet. The device is built and tested stand alone. SCU1 will use a modified cryostat from SCU0 and a new 1-m long magnet. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  5. SCU Cost Summary DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  6. SCU Requirements DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  7. SCU Org Chart Y. Ivanyushenkov (ASD) Technical Leader M. White (APS-U) Associate Project Manager Core Team Management: E. Gluskin*(ASD-MD) Simulation: R. Dejus (ASD-MD) S. Kim (ASD-MD) R. Kustom (ASD-RF) E. Moog (ASD-MD) Y. Shiroyanagi (ASD-MD) Design: D. Pasholk (AED-DD) D. Skiadopoulos (AES-DD) E. Trakhtenberg (AES-MD) Cryogenics: J. Fuerst (ASD-MD) Q. Hasse (ASD-MD) Measurements: M. Abliz (ASD-MD) C. Doose (ASD-MD) M. Kasa (ASD-MD) I. Vasserman (ASD-MD) Controls: B. Deriy (ASD-PS) M. Smith (AES-C) J. Xu (AES-C) Tech. support: K. Boerste (ASD-MD) *Group Leader Budker Institute Collaboration (Cryomodule and Measurement System Design) • N. Mezentsev • V. Syrovatin • V. Tsukanov • V. Lev Technical Support M. Borland (ASD-ADD) J. Collins (AES-MD) G. Decker* (ASD-D) P. Den Hartog* (AES-MD) L. Emery* (ASD-AOP) R. Farnsworth* (AES-C) J. Gagliano* (AES-VS) G. Goeppner* (AES-MOM) K. Harkay (ASD-AOP) V. Sajaev (ASD-AOP) J. Penicka* (AES-SA) J. Wang* (ASD-PS) A. Zholents (ASD-DD) *Group Leader FNAL Collaboration (Resin Impregnation) • A. Makarov UW-Madison Collaboration (Cooling System) J. Pfotenhauer D. Potratz D. Schick DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  8. SCU Design – Major Challenges • High field quality requirements: • low phase error: • < 8 deg. rms • low field integrals*: • SCU0: 1st field integrals (Bx, By) ≤ 470 G-cm, 4700 G-cm, • 2nd field integrals (Bx, By) ≤ 4.32x104 G-cm2, 1.3x105 G-cm2 • SCU1/SCU2 : TBD • measurement of SCU performance before installation into storage ring • Superconducting coils cooling in presence of heat load from the beam: • heat load on the beam chamber of ~10 W • * Requirements for maximum possible change of absolute first- and second-field integral errors (based on local orbit modeling with x-ray BPMs participating in orbit correction) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  9. SCU Design – Strategy to Solve Challenges SCU0 goal: Verify design concept by building and testing in the beam a full-scale device. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  10. SCU Design – Conceptual Points • Magnetic structure: • Two identical magnet jaws separated by a gap of 9.5 mm • Superconducting (SC) coils are wound with NbTi round wire • A correction coil at each end of the main coil • No magnetic ‘shimming’ • Beam vacuum chamber: • Thin-wall Al beam chamber with the vertical aperture of 7.2 mm • Cooling scheme: • SC coils are cooled by liquid helium (LHe) flowing through the channels in the cores • LHe is stored inside the cryostat in the LHe tank above the magnet that together with the cores and LHe piping forms a closed system • He vapor is re-condensed in the LHe tank that is cooled by two cryocoolers DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  11. SCU Design – Conceptual Points (2) • Cooling scheme (continued): • Beam chamber is thermally insulated from 4-K circuit • Beam chamber is cooled by two cryocoolers and is kept at 10-20 K • Cryostat: • Contains a cold mass (SC magnet, LHe tank, beam chamber, and a support frame) • 20-K and 60-K thermal shields • Current lead assemblies • Four cryocoolers DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  12. He fill/vent turret SC magnet LHe vessel LHe piping 20 K radiation shield 60 K radiation shield Beam chamber Beam chamber thermal link to cryocooler SCU Design – Cryostat Structure SCU design concept is implemented in the SCU0 design Design of SCU0 is based on the APS experience of making short SC magnetic structures and on experience by a team from Budker Institute, Novosibirsk, of making cryostats for their SC wigglers. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  13. SCU0 Manufacture - Magnet • SCU0 magnet design is based on the design developed at the APS during the R&D phase of the project • The steel coil formers (cores) are manufactured by Hi-Tech, Chicago • The coils are wound at the APS on a precise computer-controlled winder • Resin vacuum impregnation is done at the APS • Completed cores are tested in a vertical LHe bath cryostat Completed single magnet core Completed magnet assembly DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  14. SCU0 Manufacture - Cryostat • SCU0 cryostat design follows the design of superconducting wigglers developed by Budker Institute, Novosibirsk, Russia • Conceptual and detailed design of the SCU0 cryomodule is done at the APS • The cryostat package, including vacuum vessel, two radiation shields, and LHe tank, was manufactured by PHPK Technologies, Columbus • Internal components of the cryomodule were manufactured by Hi-Tech, Chicago Radiation shields fit test at PHPK Completed cryostat package at PHPK DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  15. SCU0 Assembly • SCU0 was assembled at the APS in a new facility located in Bldg. 314 • Several sub-systems were first assembled including cold mass and current lead blocks • Current lead assemblies were tested in a dedicated cryostat before installation into the SCU0 cryostat • LHe tank with He circuits were leak checked • Several fit tests were done • SCU0 assembly was completed in May 2012 SCU0 being assembled in the new facility Fully assembled cold mass Cold mass and current lead assemblies fit test DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  16. SCU Horizontal Measurement System • SCU warm-sensor measurement system is based on a concept developed at Budker Institute for characterizing superconducting wigglers. • Scanning Hall probe: • Specially developed three-sensor Hall probe (attached to carbon fiber tubing and driven by linear stage) to measure By and Bx simultaneously and determine the mid-plane field regardless of sensor vertical offset from magnetic mid-plane. • On-the-fly Hall probe measurements (2 cm/s, z 0.2 mm, typical z range ±35 cm) to determine local field errors and phase errors. • Stretched Wire Coil • Stretched wire rectangular, delta and ‘figure-8’ coils to determine static and dynamic 1st and 2nd field integrals. • Rotary stages on upstream end of cryostat as well as on the Z axis linear stage to provide synchronized rotary motion for stretch coils. • Coils can be translated along x axis approximately ±1 cm to measure integrated multipole components. SCU warm-sensor concept SCU0 horizontal measurement system DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  17. SCU Control System • SCU0 control system is a fully working prototype for the SCU1 and SCU2 control systems • Two versions of the SCU0 control system are being developed: • LabVIEW-based system (stand alone system) • EPICS-based system (final system) • Cold tests of the SCU0 heavily use the LabVIEW system • SCU0 in the storage ring will be controlled by EPICS system SCU0 hardware rack with power supplies, NI crate, temperature sensors, and other hardware Temperature window of the LabVIEW SCU0 control system DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  18. SCU0 Cold Test – Cryogenic Performance: Cool down • A design concept of cooling the undulator down with compact cryocoolers has been confirmed. • The system achieved cool-down during a day, using cryocooler power alone requiring total three days to stabilize at LHe temperature. The temperatures of the 4-K cryocoolers during initial cool-down of SCU0. The cryocoolers are 2-stage devices, with the 1st stage providing shield cooling and the 2nd stage cooling the liquid helium reservoir and superconducting magnet. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  19. SCU0 Cold Test – Cryogenic Performance: Steady state operation • Steady state cryogenic performance of the SCU0 has met all design goals. • The observed temperatures in the system are below the design temperatures. Temperature window of the LabVIEW control system DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  20. SCU0 Cold Test – Cryogenic Performance: Helium circuit operation • Stable operation of superconducting magnet coils indirectly cooled by LHe: • A concept of using horizontal thermal syphon loop was proven. • Helium loss-free operation for 1.5 months • Cooling power exceeds the heat load: • Ability to liquefy warm helium supplied from a gas bottle instead of using a liquid helium Dewar. • Ability to operate below 4.2 K – • Operation at 700 A (140% of the maximum operating current) at the temperature of 3.8 K in the LHe tank was demonstrated. • This opens a way to higher fields. This figure shows increasing liquid helium level achieved by using the excess 4 K capacity of the system to re-liquefy helium gas added from an external cylinder to increase the LHe inventory in the reservoir. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  21. SCU0 Cold Test – Cryogenic Performance:Heat load tests • Beam heat load was simulated by using a heater attached to the cold part of the SCU0 beam chamber. • A heat load of 0-45 W was applied to the beam chamber at full operating current of 500 A • The beam chamber temperature raised from 11 K to 30 K • The LHe circuit temperature raised from 4.3 K to 4.4 K indicating a very good thermal insulation between the two circuits • The magnet did not quench during the heat load tests DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  22. SCU0 Cold Test – Magnetic Field Performance • The SCU0 magnet exceeds most of the design parameters • The magnet reached the maximum operating current of 500 A without quench • The design peak field of 0.64 T is achieved • The magnet operated stably at the elevated current of 600 A • The 1st field integrals typically change less than 30 G-cm from 100 to 600 A for both fixed currents and dynamic changes in current. • The 2nd field integrals change by less than 8000 G-cm2 from 100 to 600 A dependent on the corrector current lookup table. • Phase errors are typically 1 degree rms or less from 100 A to 600 A. SCU0 magnet excitation curves More details are in the presentation by Chuck Doose Typical By field with main coil current of 500 A and correction current of 51.7 A DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  23. SCU0 Cold Test Results Summary • The SCU0 is cryogenically stable. • Since the initial cool-down and then filling the SCU0 with liquid helium on July 3, the device was kept cold until August 20. • The SCU0 magnet is working at full design current. • The SCU0 magnet coils achieved the design excitation current of 500 A upon the first current ramp without quenching. • The magnet has at least 20% margin in operation current. • The magnet has continuously been energized for up to a week at the maximum design current of 500 A, and for several days at 600 A without inadvertent quenching. At the LHe temperature of 3.8 K the magnet operated at a current of 700 A. • The device has successfully passed a thermal load test. • SCU0 did not quench at 500 A with 45 W of heat applied to the beam chamber for at least 1.5 hours. SCU0 being tested in July-August 2012 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  24. SCU0 – Status and Next Steps • SCU0 is re-assembled in September-October with a new beam chamber • This new beam chamber has a larger aperture cold-to-room temperature transitions • The SCU0 is being cold tested • Installation of SCU0 into the APS storage ring is planned for December-January shutdown DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  25. SCU ES&H • Integrated Safety Management System (ISMS) • APS-U Project following Argonne’s ISMS program requirements • Argonne Integrated Safety Management System (ISMS) Description recently revised and submitted to DOE ASO • Describes framework for integrating ESH requirements with mission objectives • References Argonne LMS procedures which implement specific portions of the ISMS • Design, manufacture, commissioning, and operation of superconductor undulators are aligned with the laboratory standards and policies: • ES&H-4.10 Cryogenic Liquid Safety • ES&H-13.1 Pressure Systems Safety • APS_000031 APS Design Review Procedure • Vacuum Systems Consensus Guideline for DOE Accelerator Laboratories • 10 CFR 851 – Worker Safety and Health Program DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  26. SCU Risks / CEDU Contingency Most of the risks in the SCU design and operability in the ring are mitigated by building and testing the first undulator – SCU0. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  27. WBS U1.03.04.03 SCU BOE Contingency DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  28. SCU Cost Summary Chart • SCU1 and SCU2 costs are estimated based on the experience of fabricating the SCU0 • Cost drivers: • High-precision magnetic structures including engineering development of magnet fabrication; • High-quality thermal links to minimize temperature gradients in the system; • Thin-wall beam chamber assembly to minimize the magnetic gap; • Cryostat including vacuum vessel, LHe tanks and two radiation shields. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  29. WBS U1.03.04.03 SCU Cost Summary by FY DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  30. WBS U1.03.04.03 SCU Summary Schedule DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  31. Previous Reviews Responses • CD-2 Director’s Review (September 11-13, 2012) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  32. Work between CD-2 and CD-3 • Between CD-2 and CD-3 our work will be concentrating on • monitoring Programmatic activities on SCU0; • study of SCU0 performance; • magnetic design of the SCU1 and SCU2 magnets; • design modifications of the SCU1; • conceptual design of the SCU2. • Reviews: • SCU0 beam test review; • SCU1 magnetic design review. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

  33. Summary • This system includes delivery of two superconducting undulators - SCU1 and SCU2 • The superconducting undulators will produce extremely high photon brightness above 40 keV • The conceptual design is complete because the first test undulator SCU0 has successfully passed a stand alone cold test • The cost is $3,942k • We are readyto begin final design of the superconducting undulators required by APS-U • We are ready for CD-2! DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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