1. Martin Dommach TDR ART Review, Hamburg, September 14, 2012
Vacuum System
Martin Dommach
TDR ART Review, Hamburg, September 14, 2012
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2. 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

3. 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

4. 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

5. All vacuum parts have to be hydrocarbon free
Cleaning
All vacuum parts have to be hydrocarbon free
Pressure of mass 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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 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

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

15. 1 pump failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012
Martin Dommach

16. 2 pumps failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012
Martin Dommach

17. 3 pumps failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012
Martin Dommach

18. 4 pumps failing WP-73 TDR ART Meeting, Hamburg, September 14, 2012
Martin Dommach

19. 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

20. 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

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

22. 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

23. 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

24. 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

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