geoff waldschmidt rf engineer asd / rf doe lehman cd-2 review of aps-upgrade 4-6 decem ber 2012
DESCRIPTION
Short Pulse X-ray Dampers U1.02.01.03.07 / U1.03.03.07 (U1.02.01.03.05). Geoff Waldschmidt RF Engineer ASD / RF DOE Lehman CD-2 Review of APS-Upgrade 4-6 Decem ber 2012. Outline. Technical Significance WBS Scope Team Requirements - PowerPoint PPT PresentationTRANSCRIPT
Short Pulse X-ray DampersU1.02.01.03.07 / U1.03.03.07
(U1.02.01.03.05)
Geoff WaldschmidtRF EngineerASD / RF
DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012
Outline
Technical Significance WBS Scope Team Requirements Design Interfaces Value Engineering Risks ES&H Cost Schedule
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Technical Significance
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Dampers (LOM / HOM)– Maintains beam stability – In-vacuum HOM dampers (within cryomodule)– High-power handling: LOM (2kW) / HOM (0.5kW)
Rf Windows (LOM / Input Coupler)– Double windows for redundant vacuum barrier– Wide bandwidth for mode damping– Transmission power handling: LOM (2kW) / input
coupler (10kW) Waveguides (LOM / Input Coupler / HOM)
– Required for power coupling and mode damping in the cavity
– Designed to meet rf and thermal performance requirements
Cavity assembly
HOM Damper
RF window
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Dampers and Windows Scope and WBSU1.02.01.03 & U1.03.03 (incl. SPX R&D Cavity/Tuners)
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Labor Non-Labor TOTAL ($k)
U1 Short Pulse X-Ray (SPX) 1,227 2,276 173 410 4,085 U1 02.01.03 - SPX R&D 583 1,360 24 202 2,168
02.01.03.07 - Cavity/Tuner/Damper System R&D 583 1,360 24 202 2,168 U1 03.03 - SPX Production 644 916 150 208 1,917
03.03.07 - Dampers & Windows 644 916 150 208 1,917
WBS DIV OH + ANL
G&A ($k)ESCALATION
($k)
DIRECT ($k)
LOM window
HOM damper
Input Coupler window
LOM damper
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
The Team
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APS Personnel– G. Waldschmidt – RF Engineering– B. Brajuskovic – Mechanical Engineering– D. Bromberek – RF testing– J. Fuerst – Mechanical Engineering– J. Liu – Mechanical Engineering– M. Middendorf – Test Stand Manager– G. Wu – Physicist
Cornell performed testing of rf parameters of the SiC material – led by V. Shemelin
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Designed for a total beam-induced power of 2.25 kW
PRD outlines longitudinal and transverse damping requirements for beam stability
SPX RF Window / Damper Requirements
LOM power spectrum
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Bandwidth (GHz)
Power Requirements
(kW)Type
HOM Damper
2.9 - 8.0 0.5Ultrahigh vacuum
LOM Damper
~ 2.3 2Out-of-vacuum
Input Coupler Window
Broadband 10Pilbox
(WR284)
LOM Window
Broadband 2Pillbox
(WR340)
FPC: 160 W
HOM: 265 W
Beam pipe: ~15W
LOM: 1.53 kW
Beam-induced losses through cavity ports
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
RF Window Designs
7
Windows are procured from CML Engineering– Input coupler windows are “identical” to standard
WR284 APS Linac windows– LOM windows are a WR340 version of the input
coupler window with optimizations across critical bandwidth
Windows have compact profile for cryomodule envelope Windows have an average power rating of 15 kW
LOM prototype: VSWR (2.2 - 2.4 GHz)
LOM prototype: VSWR (2.9 – 3.9 GHz)
APS Linac window
Pillbox resonance
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Critical frequency range: 2.3 GHz and 2.9 – ~4.0 GHz
LOM damper is commercially available 5kW load HOM damper is designed at ANL (based on PEP-II
and KEK designs) and fabricated by industry HOM dampers consist of a four-wedge design to
reduce stresses Water-cooled Located inside the cryomodule at 300K
Damper Designs
8
LOM damper
HOM: RF return loss
HOM damper: Four-wedge design
HOM: Thermal profile
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Prototype Dampers
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RF test port
SiC test fixture
Five prototype HOM dampers were successfully fabricated (prior to SPX0 dampers)
Damping material is Hexoloy SA Silicon Carbide (SiC) from St. Gobain - similar material used in ARES cavities at KEK*
Extensive tests were used to pre-qualify material– Particulate and Lifetime – Soldering / Brazing– UHV, ME, and RF properties
Improvements were incorporated into SPX0 design
– Expanded eBeam welding and machining– SiC tile soldering– Fixturing enhancements and plasma etching
HOM prototype damper
High-power test setup
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
*Operational Experience of HOM Absorbers at KEKB”, International Workshop on Higher-Order-Mode Damping of Superconducting RF Cavities, 2010.
SPX0 Damper Production Identical SiC material was procured for
SPX0 dampers– Material failed during cutting (July 2012)– Tomography analysis showed volumetric
sub-surface fractures Recovery plan is being implemented
– Multiple SiC materials have been procured
– Alternate vendor being developed– Materials are being tested for rf,
mechanical, and vacuum properties– Plan was accepted by APS-U (Oct. 2012)– Delivery date has moved from Dec. 2012
to June 2013 Copper damper waveguide bodies and
flanges are being fabricated
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Failed SiC plate
SPX0 damper waveguide body
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Waveguide Requirements (U1.02.01.03.05)
Primary requirement of waveguide is to transmit power to the cavity and dampers
Waveguide geometry must maintain broadband rf performance for HOM / LOM suppression
RF loading of the dampers at 2.815 GHz must be limited
Thermal leak to cooling circuits must be minimized
The waveguide designs achieve these guidelines
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Cavity with waveguide, helium vessel, and tuner
HOM damper
HOM waveguide
LOM waveguide
Input coupler waveguide
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Dynamic RF Loading
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Input power vs. Qext for different beam offsets
RF simulation geometry
Surface loss density
Operating point
Dynamic loading of waveguides is due to rf input power and parasitic mode damping
1.86 kW of input power produces 0.5 MV deflecting voltage– Dynamic loss in cavity is 7 W with Qo of 109 – Evanescent field decays slowly in end-group waveguides
HOM and LOM waveguides are designed for 300W and 2kW of traveling-wave rf power, respectively
Electric field Location of
helium vessel
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Waveguide Heat Load
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Waveguide CaseRF Surface Loss (W)
2K (W)
80K (W)
300K (W)
Input Coupler
Static --- -1.14 -3.74 4.88
Dynamic + Static
5.97 -1.61 -4.18 -103.55
HOM Static --- -0.38 -0.71 1.09
Dynamic + Static
4.321 -2.07 -1.65 -0.59
LOM STATIC --- -1.36 -7.09 8.46
Dynamic + Static
2.81 -1.57 -7.28 -15.30
Input Coupler
HOM
LOM
Dynamic loading: (1) 300W @ 3GHz (2) Cavity evanescent field
Dynamic loading: 2
kW @ 2.3 GHz
Dynamic loading: (1) 1.86 kW @ 2.815 GHz (2) Cavity evanescent field
Heat load to 2K due to waveguides: ~7.3W (each cavity)
80K2K
300K
300K80K
2K
300K
80K2K
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Interfaces
LOM loads and RF windows are supplied by industry HOM loads will be fabricated by industry with additional support
from ANL RF windows and HOM dampers will be supplied by ANL to JLAB for
assembly onto the cavity string Diagnostics, heating elements for each window / damper, water
cooling, and vacuum pumping will be handled by AES group at the APS
Diagnostic signals will be setup by the Controls group in Epics for remote access and data logging
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Damper / Window Value Engineering
Standard WR284 and WR340 waveguide sizes were used for the HOM / LOM dampers and windows
Modifications of existing designs– Developed WR340 LOM rf window based on the APS Linac
WR284 pillbox window– Bellows for both FPC and HOM waveguides were modified from
existing WR284 bellows (Darmstadt)
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Damper / Window Risks and Mitigation Particulate generation of the HOM dampers– HOM damper design was adapted to reduce particulates– SiC surface is processed to reduce particulate generation– Particulate testing is being performed Performance and durability of the HOM dampers
– SiC material has high thermal conductivity and low permittivity– Manufacturing process is carefully controlled – Soldering of SiC produces consistent and strong bonding
Water freezing in the rf windows / dampers due to 80K thermal intercepts– Water temperature is monitored– Redundant heating elements are located on each component– N2 gas-purging of water lines is under consideration in case of system power loss Cavity venting due to RF window vacuum leak– Double window design is used for both the LOMs and input couplers– RF window diagnostics include IR cameras and arc detectors
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Damper / Window ES&H
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
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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 General Safety Requirements
– Follow ASD/RF group safety policies – High-power (4 kW) rf testing is performed in 400A at the APS– Personnel and equipment safety interlocks are implemented– Test permits are required to document each experiment and outline the
hazards and mitigation steps that are required
SPX Dampers and Windows Scope and WBSU1.02.01.03 & U1.03.03 (incl. SPX R&D Cavity/Tuners)
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Labor Non-Labor TOTAL ($k)
U1 Short Pulse X-Ray (SPX) 1,227 2,276 173 410 4,085 U1 02.01.03 - SPX R&D 583 1,360 24 202 2,168
02.01.03.07 - Cavity/Tuner/Damper System R&D 583 1,360 24 202 2,168 02.01.03.07 - ACWP (includes ANL and JLAB) 269 741 - 102 1,112 02.01.03.07.01 - Damper 301 257 16 83 657 02.01.03.07.02 - Tuner (JLab #21372) - 84 1 3 88 02.01.03.07.03 - Window 13 175 5 9 203 02.01.03.07.04 - Cavity Design (JLab #21374) - 100 2 4 107 02.01.03.07.06 - Helium Vessel (JLab #21376) - 2 0 0 2
U1 03.03 - SPX Production 644 916 150 208 1,917 03.03.07 - Dampers & Windows 644 916 150 208 1,917 03.03.07 - ACWP 203 - 12 50 264 03.03.07.01 - HOM Dampers 49 419 48 26 543 03.03.07.02 - Windows - 348 35 12 395 03.03.07.03 - LOM Dampers - 123 12 4 140 03.03.07.04 - RF Testing 392 25 43 116 576
WBS DIV OH + ANL
G&A ($k)ESCALATION
($k)
DIRECT ($k)
Damper (U1.02.01.03.07.01): $657k– HOM detailed design / Fabrication for (2) cavities for SPX0 / SiC / Ebeam welding / Testing– LOM dampers / External waveguide
HOM Dampers (1.03.03.07.01): $543k– HOM damper fabrication for (8) cavities (Design work on dampers is primarily incorporated into
WBS U1.02)DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Dampers and Windows Obligation ProfileU1.02.01.03 & U1.03.03 (incl. SPX R&D Cavity/Tuners)
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX R&D and Production Milestones U1.02.01.03 & U1.03.03
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u START: Preliminary Design - SPX0 4/10
u START: Preliminary Design - SPX 2/12
u COMP: PDR - SPX0 7/12
u COMP: PDR - SPX 1/13
u SHIP: SPX0 Cryomodule to ANL 4/14
u COMP: SPX0 Cryomodule Test 6/14
u START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)
u COMP: SPX0 Installation 10/14
u AVAIL: SPX0 Ready for Operation 1/15
u START: Final Design - SPX 6/14
u COMP: Final Design 9/15
u START: Major Procurement 10/15
u AWARD: Cryoplant Contract 10/15
u START: Cryoplant Installation 9/17
u COMP: Cryoplant 3/18
SHIP: Cryomodule #1 to ANL 10/17 uSTART: Cryom #1 Installation 5/18 u
COMP: Cryom #1 Installation 6/18 uAVAIL: Cryomodule #1 Ready for Operation 8/18 u
SHIP: Cryomodule #2 to ANL 8/18 uSTART: Cryom #2 Installation 12/18 u
COMP: Cryom #2 Installation 1/19 uAVAIL: Cryomodule #2 Ready for Operation 3/19 u
SPX SYSTEM
FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Dampers and Windows Milestones U1.02.01.03 & U1.03.03 (incl. SPX R&D Cavity/Tuners)
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q COMP: Prototype Dampers - SPX0 7/12 (Note: this was part of LDRD)
q COMP: LOM Prototype Windows - SPX0 8/12
q COMP: LOM Dampers Initial Test 12/12
q START: Test and Evaluate - Conditioning of (3) WR340 LOM Loads 3/13
q SHIP: SPX0 Dampers to Jlab 6/13
q START: Final Design Dampers and Windows 6/14
q COMP: Final Design 10/14
q AWARD: HOM/LOM Components 10/14
q START: RF Testing 2/15
q COMP: RF Testing 4/17
q SHIP: Windows / Dampers to JLAB 5/17
DAMPERS
FY16 FY17 FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Dampers and Windows Summary Schedule U1.02.01.03 & U1.03.03 (incl. R&D Cavity/Tuners)
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
SPX Dampers and Windows BOE Contingency U1.02.01.03 & U1.03.03 (incl. SPX R&D Cavity/Tuners)
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Work after CD-2
Complete HOM damper fabrication for SPX0 Procure LOM dampers, LOM windows and input coupler
windows Perform low-power and high-power testing / conditioning of
dampers and windows Perform tests on copper prototype cavity to characterize
damping Create design of external waveguide transmission lines for LOM
damper and input coupler
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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012
Summary
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The scope and cost of the dampers and windows are understood.
The damper and window system is based on requirements defined in the PRD for beam stability and the ESD for power handling.
The preliminary design is complete and the dampers and windows are in the process of procurement.
Resolution of issues with Hexoloy SA damping material for the SPX0 dampers is progressing.
Extensive testing of the dampers and windows will be performed.
Delivery to JLAB for SPX0 is 6/2013 and for SPX is 5/2017 The cost is $4,085k We are ready for CD-2
DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012