1 BROOKHAVEN SCIENCE ASSOCIATES Production of Vacuum Components H.C. Hseuh NSLS-II ASAC Review...

1 BROOKHAVEN SCIENCE ASSOCIATES

Production of Vacuum Components

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


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


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

.


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


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


Multipole Chamber Cross Section

RF screenNEGBPM

CHM in SextupoleStick absorber

Pump port


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


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


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


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


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


BM Photon Absorbers

Stick ABS

BM Absorber Position and Power

GlidCop 15 for ABS

Crotch ABS

PrototypesStick location & quant.

Crotch openings


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


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


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


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


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


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 ….


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….


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

1 BROOKHAVEN SCIENCE ASSOCIATES Production of Vacuum Components H.C. Hseuh NSLS-II ASAC Review...

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