1 brookhaven science associates production of vacuum components h.c. hseuh nsls-ii asac review...

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Production of Vacuum Components

H.C. HseuhNSLS-II ASAC ReviewOctober 14-15, 2010

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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

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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• (beam-gas) > 40 hrՇ

• 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

NSLS-II Vacuum Requirement

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Cell Vacuum Chamber Layout

BM Beamline

ID Beamline

L.S.

S.S.

S2 S3S4 S5

S6

Stainless chambers

S1

S1

• 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

BLW BLW BLWBLW

BLW

BLW

S4AS5A

BM-ABM-B

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Dipole Chamber Cross Section

< 3 mm wall

Adequate V gap (~15 mm)Sufficient H width for SR fans Extrusion width of 320 mm Bending effortAdequate wall thickness after machining

ID / 3PW fan

Pump port Crotch absorber2 mm gap

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Multipole Chamber Cross Section

RF screenNEGBPM

CHM in SextupoleStick absorber

Pump port

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Chamber Extrusion and Bending

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

Only two vendors are interested Width, quantity and tight tolerance Straightness ≤ 1 mm / 5 m Cross sections to < 0.5 mm/5 m

InspectionMultipole

Bending at BNL50 ton press w 45 cm throat

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

before

after

Shims

Spacer

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Chamber Machining and Welding

Robotic welding at APS

Completed chamber

Vacuum certification

Bi-metal flanges

Machined extrusion

12 Dipole and 24 multipole chambers completed (~ 20%)

Adaptor plate

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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…

• → 905 clean 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

• → 905 for 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

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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

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Locations for BM Photon Absorbers

BM+3PW fans

ID fan(s)

Crotch absorber

Stainless pipe / absorber

Stick absorber

Short Straight Long

Stra

ight

5 Stick ABS, 2 Crotch ABS & 1 S4A ABS (+ 3 Flange ABS)

Stick absorber

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BM Photon Absorbers

Stick ABS

BM Absorber Position and Power

GlidCop 15 for ABS

Crotch ABS

PrototypesStick location & quant.

Crotch openings

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Re-design of AbsorbersAfter 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

Stick ABS w/ Stainless cooling tube

Day-1 Crotch ABS w/ Cu cooling tube

Crotch ABS w/ wide opening

APS Flange ABS

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S4A Stainless Chamber / Absorber

Stainless CHM & distributed ABS:

Multipole CHM is too narrow for ID fans

Limited hor. space for stick ABS

Impedance of flange ABS

Intercept ~ 500 watts BM fan at 1.5o

BM-A BM-B

Prototypes

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S4A Chamber Re-design - aluminumStainless prototypes were:

Difficult to manufacture – tapers, inconel, …

Welding zone at mid plane

Can’t protect BLW from large beam deviation

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

Extruded Aluminum

Uniform cross section

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Chose outside finger design wide fingers

no brazing water cooling

RF Shielded Bellows

Inside fingers $$, simple

Outside fingersLower impedance, $$$

RequirementsMax mis-alignment: ± 2 mm Max extension: -15/+10 mm Max angle deviation: ±10 mradLow impedance ohmic loss, HOM heating

Two options

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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

Modified design

Before

Before

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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 assembledPump procurements are ahead of scheduleAll contracts cover procurements for injectors, FE, BL ….

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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….

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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