Vacuum Systems

1 BROOKHAVEN SCIENCE ASSOCIATES

Vacuum Systems

H.C. Hseuh, Vacuum Group Leader8th 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

• S4A, S5A and fast corrector chambers

• Production of Absorbers and RF Shielded Bellows

• Procurement of Pumps, Valves and Instruments

• Summary


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

B2 chamber model B3 & B4 chambersB1 chamber


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


Cell Vacuum Chamber Layout

BM Beamline

ID Beamline

L.S.

S.S.

S2 S3S4 S5

S6

Short aluminum chambers

S1

S1

• 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

BLW BLW BLWBLW

BLW

BLW

S5A

BM-ABM-B

FC

FC

S4A

FC


Cell Chamber Cross Sections

RF screenNEGBPM

Stick absorber

Pump port Pump port Crotch absorber

Multipole Dipole

ID / 3PW fans


Chamber Extrusion and Bending

Extrusion bending ➾ ➾ machining ➾ cleaning ➾ welding assembly➾V #1,2 BNL V # 3 - 7 APS APS BNL

Inspection

Multipole

Bending at BNL50 ton press w 45 cm throat

3 m, 6o (ρ = 25m) accuracy to < 1.5 mm / 3m

before

after

Shims

Spacer

All extrusion completed in DecAll bending completed in Feb~ 20% extra extrusions available


Chamber Fabrication and Assembly

Robotic welding at APS

Vacuum certification

Bi-metal flanges

Machined extrusion

~ 10 chambers per month at APS and at BNL

Adaptor plate

Completed chamber


S4A, S5A & FC Chambers

S4A changed from inconel to aluminumRelocated BLW, added two flange ABSThree 1st articles met requirementsProduction of 31 S4A is underway

S4A ~ 500 watts

BM-A BM-B

S5A for 3PWFC

FC

FC

S5AS4A

FC are made by BNL Shop and brazed to flanges

S5A changed from stainless to aluminumOrders for 34 S5A placed with vendors

New design

Old design


Cell Chamber Production Status


Absorber locations and quantity

SS

S

C,F

C,F FS

> 8 ABS per cell, ~ 300 ABS for storage ring


Production of BM Photon Absorbers

Stick ABS w/ Stainless tube (130C/119C)

Crotch ABS w/ Cu tube (180C/127C)

Crotch ABS w/ wide opening (170C/107C)

Flange ABS

SC

C

F

• 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


Production of RF shielded bellows

RF bellows requirementsMax mis-alignment: ± 2 mm Max extension: -15/+10 mm Max angle deviation: ±10 mradLow 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


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


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


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

S6 & exit pipe

DW chamber layout

FE

Cross section

Documents

Vacuum Systems