Geoff Waldschmidt RF Engineer ASD / RF DOE Lehman CD-2 Review of APS-Upgrade 4-6 Decem ber 2012

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


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


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


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


RF Window Designs

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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


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

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LOM damper

HOM: RF return loss

HOM damper: Four-wedge design

HOM: Thermal profile


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


*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


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


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


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


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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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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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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Damper / Window ES&H


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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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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


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


SPX Dampers and Windows Summary Schedule U1.02.01.03 & U1.03.03 (incl. R&D Cavity/Tuners)

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SPX Dampers and Windows BOE Contingency U1.02.01.03 & U1.03.03 (incl. SPX R&D Cavity/Tuners)

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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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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


Geoff Waldschmidt RF Engineer ASD / RF DOE Lehman CD-2 Review of APS-Upgrade 4-6 Decem ber 2012

Documents

review of aps

aps upgrade project

shemelindoe lehman cd

ghzdoe lehman cd

aps personnelg

cavity portsdoe lehman

windows scope

power coupling