Martin Dommach TDR ART Review, Hamburg, September 14, 2012 Vacuum System Martin Dommach TDR ART Review, Hamburg, September 14, 2012 How to edit the title slide Upper area: Title of your talk, max. 2 rows of the defined size (55 pt) Lower area (subtitle): Conference/meeting/workshop, location, date, your name and affiliation, max. 4 rows of the defined size (32 pt) Change the partner logos or add others in the last row.

Cleaning of components Pump down procedure Outline Overview Mechanical design Cleaning of components Pump down procedure Calculation of pressure profiles and pump failure analysis Interface to accelerator vacuum and to instruments Vacuum control system WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

More than 3 km of vacuum system to be installed Overview More than 3 km of vacuum system to be installed Installation starts in October 2013 Installation order: SASE1, SASE3, SASE2 ≈ 9 months installation time per beamline WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

All vacuum parts are made of stainless steel Mechanical design All vacuum parts are made of stainless steel Standard pipe length is 6 m Only use of CF-flanges with copper gaskets All-metal angle valves between air and vacuum (roughing and venting valves) Viton sealed gate valves to separate different vacuum sections All-metal gate valves at the interfaces to the instruments and to the linear accelerator Installation of an 75 l/s Ion pump roughly every 30 m and larger pumps on optical and diagnostic elements WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

All vacuum parts have to be hydrocarbon free Cleaning All vacuum parts have to be hydrocarbon free Pressure of mass 45-100 has to be less than 10-3 of total pressure Lab washer to clean parts up to 60 x 60 x 70 cm size Industrial partner for cleaning of larger pipes and vessels RGA-Test setup to proof cleanness RGA-setup Lab washer, installed at HERA Süd lab WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Particle free areas ±30 m around mirrors and gratings Assembly in cleanroom class ISO 5 Small cleanroom tents for installation in the tunnel Installation of fast safety valves upstream the distribution mirrors To prevent venting Only one instrument of a beamline will be affected in the case of an air inrush To avoid particle transport towards the mirror WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Main components DN100 gate valve DN16 all metal venting valve with particle filter 75l/s ion pump DN40 all-metal rough pumping valve tube support DN100 vacuum pipe Main components for beam transport Long tubes WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

On site orbital welding 18 m sections made of three prefabricated parts For long distances (at SASE2 several 100 m) Purchase of the pipes cleaned and sealed in foils, ready for orbital welding in the tunnel Good experience at LCLS Used for beam transport between near and far hall Less potential leaks Less installation work Less expensive WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach LCLS, May 2011

Mobile pumping station Used to pump down beam transport sections before starting the ion pumps Hydrocarbon free – no lubricants 80 l/s turbo pump 10 m3/h scroll pump Rough pumping via bypass, to get better conductance Reducing of scroll pump run-time by using a buffer volume Optional RGA or leak test unit Beckhoff PLC with touch panel, remote controllable WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Mobile pumping station Status: Prototype is ready for use Design of a smaller version is finished Small “series production” of pumping carts is ongoing 3 small carts 3 lager ones WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Estimation of pump down time Assumption: One pump station DN100 vacuum pipe 67 m long pipe Outgassing: Pump down using one mobile pump station shown on previousslide Graph shows pressure at the end of the 67m long tube After 2-3 days its possible to switch on ion pumps An other development is the SASE3 gas attenuator… WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Pumping down and venting For initial pump down the pump stations are used for ≈60 h to reach 10-5 mbar pressure to start the ion pumps Further maintenance breaks require less pump down time due to controlled venting and use of more pump stations The operation and control of the process is done manually The exhaust gas of the pump stations will be discharged into the tunnels Venting the vacuum system will be done using dry Nitrogen All venting valves are equipped with particle filters to avoid contamination WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Calculation pressure profiles Example: straight section of 240 m Stainless steel tube, inner diameter 100 mm (DN100) CF-flanges, metal gaskets Outgassing assumption 1 x 10-10 8 ion pumps 75 l/s, one pump every 30 m At 10-6 mbar the pump lifetime will be 80000 h (≈ 9 years) What happens if one or more pumps fail? Calculations made with CalcVac software (M. Hoffmann, M. Seidel, DESY) WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

All 8 ion pumps operational WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

1 pump failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

2 pumps failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

3 pumps failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

4 pumps failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Pump failure analysis - summary Worst case included: failure of four pumps Only the pumps adjacent to the failed pumps experience an increase in pressure, but the pressure will be still in the 10-7 mbar range They can be used like this at least for a few weeks Exchange of the faulty pumps can be shifted to next maintenance period Mobile pumping stations can be connected to the beam pipe as a backup Assumptions on achievable end pressure will be tested in HERA south lab WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Interface to WP-19 (accelerator vacuum system) V0 all-metal gate valve Operated by WP-73 Two sets of limit switches Fast safety valve Fast safety valve controller Redundant pair of vacuum sensors 100m away from safety valve Getter pump and Vacuum gauge WP-19 Getter pump WP-73 Getter pump WP-19 Line represents the vacuum pipe V0 – valve as a hand over position WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Interface to the instruments WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Modular system, easy to extend Vacuum control system Based on Beckhoff PLC: EtherCAT technology Ring topology Modular system, easy to extend Racks in the tunnels every 100m, provided by WP-76: Water cooled 230V power outlets Computer network connection PLC software & user interface by WP-76 WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Vacuum control system - devices Components operated by the vacuum control system Vacuum pumps Gate valves Pressure gauges Fast safety valves Gas attenuator Residual gas analyzers Differential pumping units Other sensors (temperature, air pressure, Cooling water flow…) User interface Archive Machine Protection System Main PC (XHQ) PLC- software … Rack 1 (Tunnel) I/O, controllers getter pumps gauges …   Rack 2 (Tunnel) I/O, controllers getter pumps gauges gate-valve … Rack n (Tunnel) I/O, controllers WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Vacuum control system – interfaces Accelerator Vacuum System (WP-19) Instrument Control System MID Instrument Control System HED Instrument Control System SPB Instrument Control System FXE Instrument Control System SQS Instrument Control System SCS Personal Interlock Injector Machine ProtectionSystem V0 and fast safety valve close or error Vacuum OK All valves open? Beckhoff online? Error? Mode 1-5 Inst. ready, vacuum OK Different interfaces To machine protection system Instruments More detailed the interface to WP-19 WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach

Thank you for your attention! WP-73 TDR ART Meeting, Hamburg, September 14, 2012 Martin Dommach