1. 1 BROOKHAVEN SCIENCE ASSOCIATES Production of Vacuum Components H.C. Hseuh NSLS-II ASAC Review October 14-15, 2010

2. 2 BROOKHAVEN SCIENCE ASSOCIATES 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

3. 3 BROOKHAVEN SCIENCE ASSOCIATES 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 Շ (beam-gas) > 40 hr no pressure bumps at straight sections ➾ minimize bremsstrahlung radiation and shielding for BL Fast conditioning after intervention In-situ bakeout to 130 o C, NEG strip pumping η (PSD) < 1 x10 -5 molecules/hv after 100 A.hr beam dosage NSLS-II Vacuum Requirement.

4. 4 BROOKHAVEN SCIENCE ASSOCIATES Cell Vacuum Chamber Layout BM Beamline ID Beamline L.S. S.S. S2S3 S4 S5 S6 Stainless chambers 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 S4A S5A BM-A BM-B

5. 5 BROOKHAVEN SCIENCE ASSOCIATES Dipole Chamber Cross Section < 3 mm wall Adequate V gap (~15 mm) Sufficient H width for SR fans Extrusion width of 320 mm Bending effort Adequate wall thickness after machining ID / 3PW fan 3m long, 6 o bend, ρ = 25 m Pump port Crotch absorber 2 mm gap

6. 6 BROOKHAVEN SCIENCE ASSOCIATES Multipole Chamber Cross Section RF screen NEG BPM CHM in Sextupole Stick absorber Pump port

7. 7 BROOKHAVEN SCIENCE ASSOCIATES Chamber Extrusion and Bending Extrusion ➾ bending ➾ machining ➾ cleaning ➾ welding ➾ assembly V #1,2 BNLV # 3 - 7APS BNL Only two vendors are interested Width, quantity and tight tolerance Straightness ≤ 1 mm / 5 m Cross sections to < 0.5 mm/5 m 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

8. 8 BROOKHAVEN SCIENCE ASSOCIATES 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

9. 9 BROOKHAVEN SCIENCE ASSOCIATES 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 130 o C, 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 130 o C → 740 (SR tunnel) for installation and testing Process developed

10. 10 BROOKHAVEN SCIENCE ASSOCIATES 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

11. 11 BROOKHAVEN SCIENCE ASSOCIATES Locations for BM Photon Absorbers BM+3PW fans ID fan(s) Crotch absorber Stainless pipe / absorber Stick absorber Short Straight Long Straight 5 Stick ABS, 2 Crotch ABS & 1 S4A ABS (+ 3 Flange ABS) Stick absorber

12. 12 BROOKHAVEN SCIENCE ASSOCIATES BM Photon Absorbers Stick ABS BM Absorber Position and Power GlidCop 15 for ABS Crotch ABS Prototypes Stick location & quant. Crotch openings

13. 13 BROOKHAVEN SCIENCE ASSOCIATES Re-design of Absorbers After 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

14. 14 BROOKHAVEN SCIENCE ASSOCIATES 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 1.5 o BM-A BM-B Prototypes

15. 15 BROOKHAVEN SCIENCE ASSOCIATES S4A Chamber Re-design - aluminum Stainless 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

16. 16 BROOKHAVEN SCIENCE ASSOCIATES Chose outside finger design wide fingers no brazing water cooling RF Shielded Bellows Inside fingers $$, simple Outside fingers Lower impedance, $$$ Requirements Max mis-alignment: ± 2 mm Max extension: -15/+10 mm Max angle deviation: ±10 mrad Low impedance ohmic loss, HOM heating Two options

17. 17 BROOKHAVEN SCIENCE ASSOCIATES 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

18. 18 BROOKHAVEN SCIENCE ASSOCIATES 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 1 st 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 assembled Pump procurements are ahead of schedule All contracts cover procurements for injectors, FE, BL ….

19. 19 BROOKHAVEN SCIENCE ASSOCIATES 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….

20. 20 BROOKHAVEN SCIENCE ASSOCIATES 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