Experience Fabricating the Storage Ring Vacuum Chambers for NSLSII July 12 th, 2011Prepared by:...
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Transcript of Experience Fabricating the Storage Ring Vacuum Chambers for NSLSII July 12 th, 2011Prepared by:...
Experience Fabricating the Storage Ring Vacuum Chambers for NSLSII
July 12th, 2011Prepared by: Charles Hetzel
Facility and Cell Overview.
Pumps and Valves.
Instrumentation and Absorbers.
RF bellows.
Chamber Cross Sections and Fabrication.
Chamber Assembly and Production Status.
Vacuum Instrumentation Rack Overview.
1- Accelerator Tunnel
2- Experimental Floor
3 - 200MeV LINAC
4 - Booster (C=158m)
5 - RF Building, liquid He Plant
6 - Service Buildings
1
2
3
4
56
6
6 6
6
Nominal energy: 3GeV
Nominal current: 500mA
30 cells (DBA) in 5 pendants
Ring circumference: 792m
Long straight sectionRF gate valve
S3Dipole
S4Multipole S5
Dipole
S2Multipole
S6Multipole
ID photon extraction
Dipole and 3PWphoton extraction
3 pole wiggler (3PW)
Each section of the cell is composed of girders assemblies. 3 focusing and 2 bending segments (DBA). Alternating long and short straights (9.3m and 6.6m).
Photon extraction takes place at S3 and G6.
The ring is divided into 60 vacuum sections. Sectors can be isolated with RF gate valves. Design pressure (beam on): 10-9 torr.
Fast corrector
Short straight sectionRF gate valve
200 l/s ion pump (8” or 6”)TSP cartridge
Right angle valve
100 l/s ion pumpTSP cartridge
NEG strips (St707)1500m
Turbo pump cart18 units
All metal RF gate valves isolate cells and ID straights. Double position indicators (to vac PLC and to EPS PLC). Radiation resistant and bakeable. Two first articles received. Additional RF gate valves used to isolate SC cavities.
All metal gate valves used in transport lines and font ends.
Right angle valves Rough pumping. Instrumentation isolation.
RF gate valve62 units
All metal gate valve40 units
Right angle valve270 units
Instrumentation located in dipole chambers.
CCG and RGA in S3
CCG and TCG in S5
Gauge tree with isolation valve.
Flange absorber21mm X 64mm
90 units< 200 W (< 16 W/mm2)
Absorbers intercept unused dipole fan radiation.
Intercepting surfaces are made GlidCop Al15.
Stick absorber20mm, 22mm, 25mm
130 units< 700W (< 5 W/mm2)
Glidcop: 130°C, Tube: 119°C
Crotch absorber21mm
60 units< 1800W (< 57 W/mm2)
GlidCop: 180°, Tube: 127°C
Requirements:
Misalignment: +/- 2 mm
Stroke: +10/-15 mm
Angular deviation: +/-10 mrad
Low impedance
RF fingers(GlidCop)
Finger retainer(316L)
Bellows weldment(316L)
Contact springs(Inconel 718)
Sleeve(316L)
Water cooled flange
Storage ring will require ~ 220 units
100 piece order in process
Weldment purchased, assembly @ BNL
Coil spring(Be-Cu)
Multipole cross sectionDipole cross section
Fast corrector sectionS4A cross section
Only 2 vendors were willing and able to produce our extrusion.
180 multipole extrusions.
140 dipole extrusions.
Extrusions were fabricated over ~18 months.
Incoming extrusions were inspected.
Dipole chambers. Bent into shape.
Thermally cycled.
Re-measured.
Packaged and shipped for machining.
Welding of flange-adapter sub assemblies. Out of tolerance flanges.
Sub assemblies to chamber welding.
Bake out and vacuum certification. Leaky flanges (21 flanges, 10 chambers)
Currently producing 10 chambers per month.
Note: Pictures taken at Argonne National Laboratory
Measurement description Target Avg. Measured Values
Absorber flange to beam center 290.6mm 289.0 +/- 1.5mm
Flatness of machined surface +/- 1mm +/- .6mm (1.8mm max)
Flange angle perpendicular to the orbit plane 9 mrad max +/- 3 mrad (7 mrad max)
Transition flange twist 9 mrad max +/-3 mrad (7 mrad max)
Minimum wall thickness in machined area 3mm 2.5mm (1.9mm min)
Measurement description Target Avg. Measured Values
Absorber flange to beam center 252.0mm 251.5 +/- 1.4mm
Chamber flatness near magnet pole cut outs +/- 1mm +/- .56mm (1.4mm max)
Flange angle perpendicular to the orbit plane 9 mrad max +/- 3 mrad (10 mrad max)
Transition flange twist 9 mrad max +/- 5 mrad (6 mrad max)
Exit port survey point X 332.2mm 332.4 +/- 1.5mm
Exit port survey point Y 7.1mm 7.1 +/- .5mm
BPM
rf shield
NEG assembly
Bake out and conditioning Cal rod heater
Currently assembling 10 chambers/month
Removal of surface contamination.
400ppm ozone in oxygen @ 70°C for 6 hours. NEG activation 35 A@120 C. Cool down and reprocess.
Treatment performed on 9 out of 90 chambers.
P = 1.3 x 10-9 Torr3X bake 6 h@120 C.
P = 8.5 x 10-10 Torr
Chamber Ordered Machined Welded Assembled
S2 34 32 (94%) 32 (94%) 30 (88%)
S4 33 18 (54%) 18 (54%) 16 (47%)
S6 34 24 (71%) 12 (35%) 12 (35%)
35 mm Dipoles 62 62 (100%) 36 (58%) 27 (44%)
Totals 163 136 (83%) 98 (60%) 85 (52%)
Install after magnet pre-alignment (100µm).
BPMs positioned using laser tracker (mechanical center).
Adjustment may be required after magnetic alignment (30µm).
Pumps and bake out wiring added after final alignment.
Final leak check and vacuum signoff.
Three racks/cell located on mezzanine IPPS, TSP power supplies Gauge controllers (CCG, Pirani)PLC chassis, MOXA
Cables: Low smoke, zero halogen, tray rated
Computer system w touch screen
Joe Gagliano, George Goeppner (APS)
Vacuum techs
C. Longo
S. Sharma
L. Doom
V. Ravindranath
T. Dilgen
B. Kosciuk
Gao-Yu Hsiung and June-Rong Chen (NSRRC)
Many others in and out of NSLS-II