1. 1 BROOKHAVEN SCIENCE ASSOCIATES Vacuum Systems H.C. Hseuh, Vacuum Group Leader 8 th ASAC Meeting for NSLS-II Project May 10-11, 2011

2. 2 BROOKHAVEN SCIENCE ASSOCIATES 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

3. 3 BROOKHAVEN SCIENCE ASSOCIATES 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 chambers B1 chamber

4. 4 BROOKHAVEN SCIENCE ASSOCIATES 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

5. 5 BROOKHAVEN SCIENCE ASSOCIATES Cell Vacuum Chamber Layout BM Beamline ID Beamline L.S. S.S. S2S3 S4 S5 S6 Short aluminum chambers 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 S5A BM-A BM-B FC S4A FC

6. 6 BROOKHAVEN SCIENCE ASSOCIATES Cell Chamber Cross Sections RF screen NEG BPM Stick absorber Pump port Crotch absorber Multipole Dipole ID / 3PW fans 3m long, 6 o bend, ρ = 25 m

7. 7 BROOKHAVEN SCIENCE ASSOCIATES Chamber Extrusion and Bending Extrusion ➾ bending ➾ machining ➾ cleaning ➾ welding ➾ assembly V #1,2 BNLV # 3 - 7APS BNL Inspection Multipole Bending at BNL 50 ton press w 45 cm throat 3 m, 6 o (ρ = 25m) accuracy to < 1.5 mm / 3m before after Shims Spacer All extrusion completed in Dec All bending completed in Feb ~ 20% extra extrusions available

8. 8 BROOKHAVEN SCIENCE ASSOCIATES 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

9. 9 BROOKHAVEN SCIENCE ASSOCIATES S4A, S5A & FC Chambers S4A changed from inconel to aluminum Relocated BLW, added two flange ABS Three 1 st articles met requirements Production of 31 S4A is underway S4A ~ 500 watts BM-A BM-B S5A for 3PW FC S5A S4A FC are made by BNL Shop and brazed to flanges S5A changed from stainless to aluminum Orders for 34 S5A placed with vendors New design Old design

10. 10 BROOKHAVEN SCIENCE ASSOCIATES Cell Chamber Production Status

11. 11 BROOKHAVEN SCIENCE ASSOCIATES Absorber locations and quantity S S S C,F F S > 8 ABS per cell, ~ 300 ABS for storage ring

12. 12 BROOKHAVEN SCIENCE ASSOCIATES 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 S C 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

13. 13 BROOKHAVEN SCIENCE ASSOCIATES Production of RF shielded bellows RF bellows requirements Max mis-alignment: ± 2 mm Max extension: -15/+10 mm Max angle deviation: ±10 mrad Low impedance Outside finger design wide fingers, n o 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

14. 14 BROOKHAVEN SCIENCE ASSOCIATES 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) – 1 st 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) – 1 st article next week All metal gate valves (40) – order being placed Right angle valves (270) – 35% ordered and received

15. 15 BROOKHAVEN SCIENCE ASSOCIATES Gauges, RGA and PLC Vacuum gauges and controllers (100 sets) 1 st 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

16. 16 BROOKHAVEN SCIENCE ASSOCIATES 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