Proton Improvement Plan (FY12 PMG Q4). William Pellico, Fermilab PMG,October 25 2012 2 FY12 Summary Q4 Task(s) Summary – Highlights RFQ Injector Budget.

Proton Improvement Plan (FY12 PMG Q4)

William Pellico, Fermilab PMG ,October 25 20122

FY12 Summary

Q4 Task(s) Summary – Highlights

RFQ Injector

Budget and Labor Review Summary

Outstanding Issues

Near Term Plans - ScheduleFY13 Budget

FY13 Goals/Issues

Controls - RLS (Elmie Peoples)

PAC – Beam projections and startup

Additional PIP Items

RLS - An accelerated schedule/benefits

University Support

Q4 Task(s) Summary – Highlights

PIP FY12 Q4 (0,1,2) Milestone Summary

WBS Action Milestone Level

Description Base lined Date Jan 2012

New Planned DateJul 2012

1.1.1.1 High Level RF

Determine course of action

1 Select the best option. Jul 2012 Aug 2012

1.3RFQ Injector

Beam ready for operations

0 Reliably deliver beam to downstream machines.

Oct 2012 Nov 2012


WBS Action Milestone Level Description DateCompleted

New Planned Date

1.2.1.7 New Cavities 2 Initial cavity design DelayedBudget Delay FY15

1.2.7.1 Solid State Power Amplifier 2 Assemble and test 10 power amplifiers Jul-12NA

1.2.7.2 Solid State Driver Module 2 Assemble and test driver amplifiers Jul-12NA

1.2.7.4 Solid State Installation 2 Upgraded all east gallery stations Jul-12NA

1.1.1.2 Linac Modulator 2 Options identified and screened by management Sep-12

NA

WBS 1.1 LINACSummary Tasks at a Glance

= Task expected to be complete during shutdown= Significant progress but not complete

= Non-shutdown activity = Task de-scoped

WBS Task Name1.0 PIP1.1 Linac1.1.1 200MHz RF Power Systems1.1.1.1 High Level RF1.1.1.2 Linac modulator1.1.1.3 7835 procurement1.1.2 Accelerator Physics1.1.2.1 Simulations and Studies1.1.2.3 Linac notch creation1.1.3 Instrumentation1.1.3.1 Beam position monitors1.1.5 Utilities1.1.5.1 Power Distribution1.1.5.1.1 L1 transformer1.1.5.1.2 Motor controller center (MCC) 1.1.5.1.3 480Vac harmonic filter1.1.5.3 Vacuum System1.1.5.3.1 Blowers1.1.5.3.2 A-0 dewar repair1.1.5.3.3 400MeV area valve replacement1.1.5.3.4 400MeV area turbo/rougher replacement

= Task status changed since last report

Highlights since last reportUtilities L1 transformer

Installation delayed to later yeardue to complication with installation plan MCC upgrade – to be complete this week! Vacuum

blowers received and installed complete A0 dewar repair complete beam valves ordered (waiting delivery)

Instrumentation Receiving partial deliver new PCB boards All new NIM crates and cables installed in all 5

different locations

5 William Pellico, Fermilab PMG ,October 25 2012


WBS 1.1.1 200MHZ RF Power SystemWBS 1.1.1.1 HLRF

Detailed analyses of 4 possible options Maintain 7835 triode tubes 200 MHz klystron upgrade Thales tube upgrade (quasi LANL design) 400 MHz front-end Linac

Write-up complete in August PIP management recommends

a) That the lab should invest in the 200 MHz klystron (~$8.5M)b) That the PIP team should continue with effort in WBS 1.1.1.2 for

new tube base modulator (~ $5M) Specification was written and finalized (Specification Number:

MBK201FERMI Rev. 1) Bid process complete and awarded to CPI with quotation type

CPFF & ROM NRE and prototype ~ $2M Production price ~ $1M ETD: 12/1/2014


WBS 1.1.1 200MHZ RF Power SystemWBS 1.1.1.2 Modulator

3 different modulator designs, each with detailed simulations, costing and timeframe

CEC – Solid State Modulator with 48 stages coupled via HV transformer

• Total cost between $5.9 - 9.6M SLAC – Marx Modulator with two different 4kV stage types (10 Main

stages & 5 vernier stages, both 4kV) • Total cost ~ $4.5M

Fermilab – Marx Modulator with three different 950 Volt stage types (40 Main stages, 12 regulating stages, and one adjustable stage)

• Total cost ~$4.36M

Technical design reviewed in August 2012 special consideration given for the modulator slew rate (15kV/us),

beam tilt (+/-10kV), and flat top regulation (+/- 25 Volts)

Based on cost, ability to strength multi-lab collaborations, adaptability to powering a multi-beam klystron, overall design and scheduling, the CEC design was dropped in favor of continuing engineering effort on both the SLAC and Fermilab Marx modulators during FY13

SLAC proposes engineering study to build a lower voltage two cell prototype for design testing $75k

Fermilab proposed and started the design of a lower voltage 10 cell modulator prototype ($40k materials plus labor)



Initial Check ofTuner Connection –Gap Size

Welding on filling

After grinding downwelding fill - sanding

After Tin electroplating

Each tuner will have a tin gasket to help make a good RF seal to the cavity

Tuner &Stem

Cavitywith tuner stem

Cavity with tuners removed WBS 1.2Booster Cavity Refurb.


WBS 1.2Tuner RebuildCooling Loop Leaks

New DisksDented/Restricted Cooling

Disassembly of Tuners Damaged Tuner RF Fingers

The tuner repair isa long process andinvolving manysteps and skilledlabor.

RFQ WBS 1.3


Cockcroft-Walton Retirement Ceremony (August 2012) WBS1.3


Shutdown I-

Shutdown H-

Removal of 750KeV Line

WBS 1.3 RFQ Q4 Activities

The Q4 RFQ effort has been substantial and very successful. The milestone of Cockcroft-Walton decommissioning was met and work is proceeding with the installation of the new RFQ injector line. The schedule set in July has been met with no notable delays thus far.


RFQ Install – WBS1.3RFQ/LEBT

New Source SuppliesPower Supplies For LEBT AND MEBT

Under Platform

RFQ in place for Testing

Budget and Labor Review Summary

2011 Plan Design Handbook (Jan. 2012)

Present Plan with FY12-13 cuts

Direct M&S (M$)

Labor (FTE)

Direct M&S (M$)

Labor (FTE)

Direct M&S (M$)

Labor (FTE)

FY 2012 6.2 45 5.6 48 5.6 33

FY 2013 6.2 35 6.0 35 1.9 23

FY 2014 13.3 30 10.7 32 10.7 ? 32 ?

FY 2015 12.3 30 11.4 31 11.4 ? 31 ?

FY 2016 6.4 30 6.1 32 6.1 ? 32 ?

FY 2017 0 0 0 5 3.6 ? 28 ?

FY 2018 0 0 0 0 ? 5 ?

Total 44.4 170 39.8 183 39.5? 184?

15

Current PIP Budget Profile / RLS (Being Updated)


Limited Labor in FY12Reduction of FY13 by > 50%Forecasted FY14 reduction = delaysOutlying years – better but uncertain

Fully Burdened Costs


Missing RFQRIP (1.4M)

Issues FY12

Issues • WBS 1.3 RFQ – Task completes when commissioning starts

FY12 was end of M&S – looks like we do not need additional funds Only labor remaining – about 10 people until mid November

• WBS 1.1 Linac Transformer did not get installed due to complexity with size

• Will need to add some funding for install• Will need to find a good install date once solution is decided

Klystron was partially paid for – still need to move 600k into task Still pursuing new modulator (7835) effort until HLRF path is defined Linac Optics – loss of people – need committed long term effort

• WBS 1.2 Booster Cavity Refurbishment – Labor & Time constraints Booster shielding still needs resolution Booster Rep rate limit – still unresolved and require testing Booster has not found a ferrite that meets our High μ need Booster Optics – need to replace Grad student and additional work


Near Term Plans - Schedule

Required for 12 Hz Required for FluxRequired for 15 Hz Required for Reliability

Com

plet

ion

Dat

e B

efor

e F

Y13

Bud

get

Red

uctio

n


Task identified as a goal requirement but many of these overlap.Recent Budget guidance still being worked through the planning and RLS process.

20

PIP Gant (Using FY12 Estimates)

PIP – Previous and Projected Cycle Rate


2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 20190

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16 Ave Rep Rate(Hz)

Ave Rep Rate(Hz)

Hz

CycleRange

12 HzBooster Cavity RefurbishmentCurrent limit - not sure what is safe but likely <9 Hz

Booster Solid State UpgradeTask completes in FY13 Q4

Utilities that are required to support the higherRF cycling rateTask completes (for this use) in FY13 Q2

After shutdown – rates will be exploredbut limited by RF upgrade work, failuresand program planning.A beam cycle rate between 7 and 9 Hz will be tested.

15 Hz Booster Anode SuppliesPurchase Planned for FY14Install In FY15

Booster Bias Supply transformer upgradePurchase hardware in FY13Installation will occur as units are completed


5/5/

2003

12/5

/200

3

7/5/

2004

2/5/

2005

9/5/

2005

4/5/

2006

11/5

/200

6

6/5/

2007

1/5/

2008

8/5/

2008

3/5/

2009

10/5

/200

9

5/5/

2010

12/5

/201

0

7/5/

2011

2/5/

2012

9/5/

2012

4/5/

2013

11/5

/201

3

6/5/

2014

1/5/

2015

8/5/

2015

3/5/

2016

10/5

/201

6

5/5/

2017

12/5

/201

7

7/5/

2018

2/5/

2019

0

50

100

150

200

250

Protons Per HourBefore Shutdown and PIP Goal

Protons Per Hour

Booster beam flux willbe limited by cycle rate and loses. Cycle intensity will be pushed higher as allowed by loss limits and user requests.

Range

Loss Remediation:

New Notch Beam AbsorberTwo parts to task – Absorber completes in FY13 Q1New Short Kickers in FY14 Q2

Collimation system – improvementTask completes in FY14 Q1

Lattice correction/workTask is expected to end FY17This effort is never-ending and isBased upon beam requirements

Linac Laser Notching SystemTask end date is FY15 Q2

Booster Cogging upgradeTask end date is FY15 Q1(Most likely FY14Q1)

Radiation Safety Task end date FY13 Q3Penetrations issue unresolved


Proton Source/PIP – FY13 Calendar

Flux will scale with Cycle Rate

Additional PIP Items

Budget Impact Mitigation / Collaboration

• It has been proposed that the budget impacts could be mitigated with help from institutions involved with experiments

Easiest way is to just transfer a whole lot of money, but we realize that is unlikely

• We have identified two concrete ways contributions could be made Students/postdocs on beam physics issues

• RFQ commissioning, linac optics, booster optics & instabilities, dampers, laser notcher, rf system development, rf instrumentation

• Need volunteers who are at Fermilab and can contribute at least ~ 0.5 FTE-yr to be useful

University machining• Some success with this in the past• University shops can be available at an inexpensive rate• Many PIP areas require various levels of machining / fabrication• Need volunteers and a streamlined method for processing the work (MOUs? POs?

Bidding?)

Model – Outside Involvement

• Previous model – mid 00s One liaison on lab side (Prebys)

• Projects in Linac, Booster, Main Injector One liaison on experimental side (Michael)

• Activity form MINOS & MiniBooNE institutions

• Model for this interaction PIP only? AD-wide?

• Liaison from PIP? Numerous experiments

• Single liaison? One from each experiment?

• Mutual benefit PIP: Inexpensive machining and scientific help Universities: business for their shops, topics for students

• Also need to develop some reward structure within experiments (service tasks, shift credit)


RF StationCavity LCW

Valves Solid State StatusRefurbishmnet

OrderExpected

Finish Certified Re-Installed

1 New Upgraded 6 03/06/13




5 New in 2012 Upgraded 3 09/24/12

6 New in 2012 Upgraded 4 11/06/12

7 New in 2012 Upgraded 2 07/17/12 07/24/12

8 New in 2012 Upgraded 1 02/27/12 05/02/12

9 Old Cables pulled & terminated 8 06/27/13



12 Old Upgraded 16 10/03/14





17 Old Cables pulled 11 12/18/13

18 Old Cables pulled 19 03/30/15


Booster RF Work Timetable

Additional 2-3 techs will allow two tasks going in parallel.A total of 5 skilled techs, we could reasonably turn cavities around in the ~6-7 week range.

Currently we are planning for 10 weekper cavity refurb. The first three cavitiestook much longer – thebest took 11 weeks.

EXTRA

NuMI POT GoalsFY13• Assumptions:

3 months commissioning start April 1, 2013

“Linear” ramp from pre-shutdown power level to full power (350 kW to 700kW)

• Goals Design = 1.4E20 Base = 1.0E20 DOE Metric = 1.1E20

FY14• Assumptions

Operate at nominal NOvA parameters 6 week summer shutdown

• Goals Design = 6.5E20 Base = 4.6E20 DOE Metric = 5.2E20


Providing 2E20 to BNB by Summer 2014 Shutdown (A Scenario)

• Assumptions Begin sending 1.5 Hz

Booster beam to BNB May 2013 while MI/Recycler are brought up

Ramp up to 1.8 Hz to BNB on average for FY2014

• Protons Delivered: Design = 2.0E20 Base = 1.4E20


Impact on NuMI POT

Total POT in FY13&FY14

• Without BNB Program: Design = 7.9E20 Base = 5.6E20

• With BNB Program: Design = 6.7E20 Base = 4.7E20


Proton Improvement Plan (FY12 PMG Q4). William Pellico, Fermilab PMG,October 25 2012 2 FY12 Summary Q4 Task(s) Summary – Highlights RFQ Injector Budget.

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