1. Superconducting Undulators WBS: APS-U1.03.04.03 Yury Ivanyushenkov Physicist, SCU Project Technical Leader ASD/Magnetic Devices Group DOE Lehman CD-2 Review of APS-Upgrade 4-6 December 2012

2. Outline  Science / Technical Significance  WBS Scope of this System  Staff / Org Chart  Requirements  Design  ES&H  Cost  Schedule  Previous Reviews Responses  Summary 2 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

3. Superconducting Undulators (SCUs) Motivation 3 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Superconducting undulators generate extremely high photon brightness above 40 keV Brightness Tuning Curves

4. SCU Scope 4 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 WBSProgrammatic FundsU1.03.04.03 SCU0SCU1SCU2 SCU1 will use a modified cryostat from SCU0 and a new 1-m long magnet. SCU0 – Test deviceSCU1SCU2 The device is built and tested stand alone. SCU2 will use a longer cryostat with a 2-m long magnet.

5. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 5 SCU Cost Summary

6. SCU Requirements 6 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 SCU0SCU1SCU2 Energy at 1 st harmonic, keV20-2512-25* Period length, mm1618 Magnet length, m0.3401.140~2.3* Cryostat length, m2.063 ~3.0*

7. SCU Org Chart 7 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Core Team Management: E. Gluskin*(ASD-MD) Simulation: R. Dejus (ASD-MD) S. Kim (ASD-MD) R. Kustom (ASD-RF) E. Moog (ASD-MD) Y. Shiroyanagi (ASD-MD) Design: D. Pasholk (AED-DD) D. Skiadopoulos (AES-DD) E. Trakhtenberg (AES-MD) Cryogenics: J. Fuerst (ASD-MD) Q. Hasse (ASD-MD) Measurements: M. Abliz (ASD-MD) C. Doose (ASD-MD) M. Kasa (ASD-MD) I. Vasserman (ASD-MD) Controls: B. Deriy (ASD-PS) M. Smith (AES-C) J. Xu (AES-C) Tech. support: K. Boerste (ASD-MD) * Group Leader Budker Institute Collaboration (Cryomodule and Measurement System Design) N. Mezentsev V. Syrovatin V. Tsukanov V. Lev FNAL Collaboration (Resin Impregnation) A. Makarov UW-Madison Collaboration (Cooling System) J. Pfotenhauer D. Potratz D. Schick Y. Ivanyushenkov (ASD) Technical Leader Technical Support M. Borland (ASD-ADD) J. Collins (AES-MD) G. Decker* (ASD-D) P. Den Hartog* (AES-MD) L. Emery* (ASD-AOP) R. Farnsworth* (AES-C) J. Gagliano* (AES-VS) G. Goeppner* (AES-MOM) K. Harkay (ASD-AOP) V. Sajaev (ASD-AOP) J. Penicka* (AES-SA) J. Wang* (ASD-PS) A. Zholents (ASD-DD) *Group Leader M. White (APS-U) Associate Project Manager

8. SCU Design – Major Challenges 8 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012  High field quality requirements: –low phase error: < 8 deg. rms –low field integrals*: SCU0: 1 st field integrals (Bx, By) ≤ 470 G-cm, 4700 G-cm, 2 nd field integrals (Bx, By) ≤ 4.32x10 4 G-cm 2, 1.3x10 5 G-cm 2 SCU1/SCU2 : TBD –measurement of SCU performance before installation into storage ring  Superconducting coils cooling in presence of heat load from the beam: –heat load on the beam chamber of ~10 W * Requirements for maximum possible change of absolute first- and second-field integral errors (based on local orbit modeling with x-ray BPMs participating in orbit correction)

9. SCU Design – Strategy to Solve Challenges DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 9 ChallengesStrategy to find a solutionProject phaseStatus High quality fieldDevelop magnetic design that achieves low field errors R&DCompleted Verify design by building and testing prototypesR&DCompleted Scale design to longer structuresSCU0 – SCU2Completed for SCU0 Build a high-quality horizontal measurement system SCU0Completed Cooling of superconducting coils in presence of beam heat load Estimate heat load from beamR&D – SCU0Completed Develop cooling scheme that minimizes heat load on superconducting coils SCU0Completed Verify the design in a test device – stand alone test SCU0Completed Check test device performance in the ringSCU0Installation into the SR is scheduled for January 2013 SCU0 goal: Verify design concept by building and testing in the beam a full-scale device.

10. SCU Design – Conceptual Points DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 10  Magnetic structure: –Two identical magnet jaws separated by a gap of 9.5 mm –Superconducting (SC) coils are wound with NbTi round wire –A correction coil at each end of the main coil –No magnetic ‘shimming’  Beam vacuum chamber: –Thin-wall Al beam chamber with the vertical aperture of 7.2 mm  Cooling scheme: –SC coils are cooled by liquid helium (LHe) flowing through the channels in the cores –LHe is stored inside the cryostat in the LHe tank above the magnet that together with the cores and LHe piping forms a closed system –He vapor is re-condensed in the LHe tank that is cooled by two cryocoolers

11. SCU Design – Conceptual Points (2) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 11  Cooling scheme (continued): –Beam chamber is thermally insulated from 4-K circuit –Beam chamber is cooled by two cryocoolers and is kept at 10-20 K  Cryostat: –Contains a cold mass (SC magnet, LHe tank, beam chamber, and a support frame) –20-K and 60-K thermal shields –Current lead assemblies –Four cryocoolers

12. SCU Design – Cryostat Structure DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 12 SCU design concept is implemented in the SCU0 design LHe vessel SC magnet He fill/vent turret 20 K radiation shield 60 K radiation shield Beam chamber thermal link to cryocooler LHe piping Design of SCU0 is based on the APS experience of making short SC magnetic structures and on experience by a team from Budker Institute, Novosibirsk, of making cryostats for their SC wigglers.

13. SCU0 Manufacture - Magnet DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 13 SCU0 magnet design is based on the design developed at the APS during the R&D phase of the project The steel coil formers (cores) are manufactured by Hi-Tech, Chicago The coils are wound at the APS on a precise computer-controlled winder Resin vacuum impregnation is done at the APS Completed cores are tested in a vertical LHe bath cryostat Completed single magnet core Completed magnet assembly

14. SCU0 Manufacture - Cryostat DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 14 SCU0 cryostat design follows the design of superconducting wigglers developed by Budker Institute, Novosibirsk, Russia Conceptual and detailed design of the SCU0 cryomodule is done at the APS The cryostat package, including vacuum vessel, two radiation shields, and LHe tank, was manufactured by PHPK Technologies, Columbus Internal components of the cryomodule were manufactured by Hi-Tech, Chicago Radiation shields fit test at PHPK Completed cryostat package at PHPK

15. SCU0 Assembly DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 15 SCU0 was assembled at the APS in a new facility located in Bldg. 314 Several sub-systems were first assembled including cold mass and current lead blocks Current lead assemblies were tested in a dedicated cryostat before installation into the SCU0 cryostat LHe tank with He circuits were leak checked Several fit tests were done SCU0 assembly was completed in May 2012 SCU0 being assembled in the new facility Fully assembled cold mass Cold mass and current lead assemblies fit test

16. SCU Horizontal Measurement System DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 16 SCU warm-sensor measurement system is based on a concept developed at Budker Institute for characterizing superconducting wigglers. Scanning Hall probe: Specially developed three-sensor Hall probe (attached to carbon fiber tubing and driven by linear stage) to measure B y and B x simultaneously and determine the mid-plane field regardless of sensor vertical offset from magnetic mid-plane. On-the-fly Hall probe measurements (2 cm/s,  z 0.2 mm, typical z range ±35 cm) to determine local field errors and phase errors. Stretched Wire Coil Stretched wire rectangular, delta and ‘figure-8’ coils to determine static and dynamic 1 st and 2 nd field integrals. Rotary stages on upstream end of cryostat as well as on the Z axis linear stage to provide synchronized rotary motion for stretch coils. Coils can be translated along x axis approximately ±1 cm to measure integrated multipole components. SCU warm-sensor concept SCU0 horizontal measurement system

17. SCU Control System DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 17 SCU0 control system is a fully working prototype for the SCU1 and SCU2 control systems Two versions of the SCU0 control system are being developed: LabVIEW-based system (stand alone system) EPICS-based system (final system) Cold tests of the SCU0 heavily use the LabVIEW system SCU0 in the storage ring will be controlled by EPICS system SCU0 hardware rack with power supplies, NI crate, temperature sensors, and other hardware Temperature window of the LabVIEW SCU0 control system

18. SCU0 Cold Test – Cryogenic Performance: Cool down DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 18 A design concept of cooling the undulator down with compact cryocoolers has been confirmed. The system achieved cool-down during a day, using cryocooler power alone requiring total three days to stabilize at LHe temperature. The temperatures of the 4-K cryocoolers during initial cool-down of SCU0. The cryocoolers are 2-stage devices, with the 1 st stage providing shield cooling and the 2 nd stage cooling the liquid helium reservoir and superconducting magnet.

19. SCU0 Cold Test – Cryogenic Performance: Steady state operation DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 19 Steady state cryogenic performance of the SCU0 has met all design goals. The observed temperatures in the system are below the design temperatures. Temperature window of the LabVIEW control system ComponentObserved temperature, K 60-K shield32-33 20-K shield8 Beam chamber 8-11 LHe circuit4.2

20. SCU0 Cold Test – Cryogenic Performance: Helium circuit operation DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 20 Stable operation of superconducting magnet coils indirectly cooled by LHe: A concept of using horizontal thermal syphon loop was proven. Helium loss-free operation for 1.5 months Cooling power exceeds the heat load: Ability to liquefy warm helium supplied from a gas bottle instead of using a liquid helium Dewar. Ability to operate below 4.2 K – Operation at 700 A (140% of the maximum operating current) at the temperature of 3.8 K in the LHe tank was demonstrated. This opens a way to higher fields. This figure shows increasing liquid helium level achieved by using the excess 4 K capacity of the system to re- liquefy helium gas added from an external cylinder to increase the LHe inventory in the reservoir.

21. SCU0 Cold Test – Cryogenic Performance: Heat load tests DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 21 Beam heat load was simulated by using a heater attached to the cold part of the SCU0 beam chamber. A heat load of 0-45 W was applied to the beam chamber at full operating current of 500 A The beam chamber temperature raised from 11 K to 30 K The LHe circuit temperature raised from 4.3 K to 4.4 K indicating a very good thermal insulation between the two circuits The magnet did not quench during the heat load tests Heater power, W0102045 Main coil current, A500 Beam chamber temperature, K 10.613.516.330.0 LHe tank temperature, K 4.294.30 4.44

22. SCU0 Cold Test – Magnetic Field Performance DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 22  The SCU0 magnet exceeds most of the design parameters  The magnet reached the maximum operating current of 500 A without quench  The design peak field of 0.64 T is achieved  The magnet operated stably at the elevated current of 600 A  The 1 st field integrals typically change less than 30 G-cm from 100 to 600 A for both fixed currents and dynamic changes in current.  The 2 nd field integrals change by less than 8000 G-cm 2 from 100 to 600 A dependent on the corrector current lookup table.  Phase errors are typically 1 degree rms or less from 100 A to 600 A. SCU0 magnet excitation curves Typical B y field with main coil current of 500 A and correction current of 51.7 A More details are in the presentation by Chuck Doose

23. SCU0 Cold Test Results Summary DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 23 The SCU0 is cryogenically stable. Since the initial cool-down and then filling the SCU0 with liquid helium on July 3, the device was kept cold until August 20. The SCU0 magnet is working at full design current. The SCU0 magnet coils achieved the design excitation current of 500 A upon the first current ramp without quenching. The magnet has at least 20% margin in operation current. The magnet has continuously been energized for up to a week at the maximum design current of 500 A, and for several days at 600 A without inadvertent quenching. At the LHe temperature of 3.8 K the magnet operated at a current of 700 A. The device has successfully passed a thermal load test. SCU0 did not quench at 500 A with 45 W of heat applied to the beam chamber for at least 1.5 hours. SCU0 being tested in July-August 2012

24. SCU0 – Status and Next Steps DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 24 SCU0 is re-assembled in September-October with a new beam chamber This new beam chamber has a larger aperture cold-to-room temperature transitions The SCU0 is being cold tested Installation of SCU0 into the APS storage ring is planned for December-January shutdown

25. SCU ES&H DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 25  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  Design, manufacture, commissioning, and operation of superconductor undulators are aligned with the laboratory standards and policies: ES&H-4.10 Cryogenic Liquid Safety ES&H-13.1 Pressure Systems Safety APS_000031 APS Design Review Procedure Vacuum Systems Consensus Guideline for DOE Accelerator Laboratories 10 CFR 851 – Worker Safety and Health Program

26. SCU Risks / CEDU Contingency 26 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 Most of the risks in the SCU design and operability in the ring are mitigated by building and testing the first undulator – SCU0. Specific RiskMitigation Excessive beam heat loadBeam chamber is cooled by two cryocoolers instead of one (total cooling power is 40 W at 20 K); low heat conduction support structure minimizes heat leak into superconducting coils. Magnetic structure poor fabrication Three half-magnet cores are fabricated and tested, the best two are used in a cryomodule. Large field integralsTwo correction coils are implemented in each half-magnet core; additional beam correctors might be employed. Large phase errorTight mechanical tolerances, strict QA procedure, core test before installation into cryomodule. LHe cooling circuit does not work properly LHe buffer tank is incorporated into the cryomodule.

27. WBS U1.03.04.03 SCU BOE Contingency DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 27

28. SCU Cost Summary Chart 28 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012  SCU1 and SCU2 costs are estimated based on the experience of fabricating the SCU0  Cost drivers: –High-precision magnetic structures including engineering development of magnet fabrication; –High-quality thermal links to minimize temperature gradients in the system; –Thin-wall beam chamber assembly to minimize the magnetic gap; –Cryostat including vacuum vessel, LHe tanks and two radiation shields.

29. WBS U1.03.04.03 SCU Cost Summary by FY 29 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

30. WBS U1.03.04.03 SCU Summary Schedule 30 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

31. Previous Reviews Responses DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 31 Recommendation Response The cost estimates for the cold mass for SCU1 and SCU2 deserve some clarification; the SCU1 cost apparently includes prototypes. Correct. Development costs are included in SCU1 and SCU2. Multipole requirements should show up on slide 3 of the measurement talk (not just 1st and 2nd integral requirements). The requirements for the multipole components will be shown on slide 3 of the talk on the experimental results. A preliminary plan for skew-quad correction should be provided. According to preliminary magnetic modeling, cross-over wires in the magnetic cores are the source of the measured skew-quad component. Additional correction coils might be used for skew-quad correction. A correction scheme is presented in the magnetic measurement talk.  CD-2 Director’s Review (September 11-13, 2012)

32. Work between CD-2 and CD-3 32 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012  Between CD-2 and CD-3 our work will be concentrating on – monitoring Programmatic activities on SCU0; – study of SCU0 performance; – magnetic design of the SCU1 and SCU2 magnets; – design modifications of the SCU1; – conceptual design of the SCU2.  Reviews: –SCU0 beam test review; –SCU1 magnetic design review.

33. Summary 33 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 This system includes delivery of two superconducting undulators - SCU1 and SCU2 The superconducting undulators will produce extremely high photon brightness above 40 keV The conceptual design is complete because the first test undulator SCU0 has successfully passed a stand alone cold test The cost is $3,942k We are ready to begin final design of the superconducting undulators required by APS-U We are ready for CD-2!