1. Accelerator Systems
F. Willeke, Director Photon Sciences Accelerator Division
NSLS-II Project Advisory Committee Meeting
March 29-30, 2012

2. Outline Overview Injector Status
Magnet Production and Girder Integration
Other Production
Vacuum Components
Power Supplies, Electrical Utilities
Mechanical Utilities
Installation and Testing
Insertion Devices
Commissioning with Beam
Plans for Start-up of Operations

3. Overall Status of NSLS-II Accelerator Systems
Significant progress has been made since the last PAC.
The large production contracts have all been placed by now
Production
RF power systems (LINAC, Booster, Storage Ring) is complete.
Production well advanced for magnets (78%), vacuum chambers (90%), utilities (~75%), and power supplies (55%).
Frontend & instrumentation production starting up
Superconducting 500MHz cavities & cryo-plant are in production.
Installation: progressing well
Overcoming initial challenges due to difficulties in taking over buildings, under estimated labor, additional installation tasks identified, late utility installations by vendors
Commissioning
The LINAC commissioning with beam has started
The Authorization Base for commissioning of the booster synchrotron is well under way, and Storage Ring effort has begun.
Good progress made on commissioning software and database.

4. Overall Status of NSLS-II Accelerator Systems cont’d
Insertion Devices
Damping Wiggler: Production started and first article expected to be delivered in June
EPU: Vendor design nearly complete
IVU: Contracts placed for two IVU20, one IVU21, and one IVU21 undulator
ID’s for NEXT and ABBIX Projects: Design, production, installation and commissioning plan being integrated with the NSLS-II Project.
Schedule Performance
Cumulative schedule variance for Accelerator Systems: being ~3 1/2 months late
Detailed installation schedule is being continuously optimized on weekly basis based on latest progress and production information
Additional labor resources being provided to reduce the schedule variance

5. LINAC 200MeV s-band LINAC was delivered on schedule last fall
Installation now complete
LINAC frontend successfully tested with beam and demonstrated that it met all specifications (charge, pulse length)
LINAC RF power units (solid state modulators) successfully tested
LINAC with beam commissioning started this week

6. Magnetic Measurements Equipment received at BNL
Booster Progress
Magnet Production
Girder Integration
Completed large PS
Production of 3GeV booster synchrotron components (magnets, vacuum, girders, power supplies) at BINP and their subcontractors has progressed very well
Shipping of components to BNL started in November. Containers with components are arriving since December 2011.
Close coordination with BINP for installation and commissioning plan
Installation of utilities in service building and booster tunnel has begun
Booster on track for start of commissioning in February 2013
Magnetic Measurements
Prepare for Shipment
Vacuum Chambers
Assembly
Packaging (Girders)
Equipment received at BNL

7. Booster Magnet Girders at BINP - Ready for Shipment

8. Storage Ring Magnets
Storage ring magnet production well underway at all manufacturer’s.
~80% of the production complete;
63% of the magnets delivered to BNL.
All technical issues resolved at this point.
Quadrupoles: BINP Production of 120 magnets nearing completion (April).
TESLA Production of 120 magnets ramping up (10 magnets /month, 16 received)
Sextupoles: Danfysik production: 169 sextupoles proceed. steadily,14 magnets /month, 87% complete) IHEP Production rate is no issue, 89% complete, however quality needs to be watched Large Aperture Quadrupoles and Sextupoles:
Buckley Production of 60 quadrupoles and 30 sextupoles going well, ~93% of the production complete, quality ok
Dipoles: Technical issues resolved, production picking up speed,
Buckley Production of 60 magnets at rate of 1 magnet / week, 8 units received
Correctors: Production of 189 units close to completion (>95% )
Fast correctors: Production of 90 units started in February.
 Production of Storage Ring Magnets no longer a limiting factor for accelerator schedule.

9. Magnet Production Summary

10. Fabrication Results and Magnetic Data
Sextupole transfer function uniformity
Typical lower order terms
Typical systematic terms
Magnetic measurement data:
1. Transfer function and harmonic data for each
quadrupole and sextupole
2. Hall probe scan for one magnet per type
3. By mapping at three vertical planes for all the
main dipole magnets
Saturation in strong quad
Current dependence of first
systematic harmonic

11. Girder Status
Magnet Production not limiting girder integration anymore
Magnet Girder Vacuum Integration fully developed
Alignment of better than 30 micron routinely achieved
2 Shift 6 days/week operation established
Rate 2 girders /week (goal)
Girder installation will be completed Dec 2012
Present Status:
27 Girders installed
9 Girders being integrated

12. Vacuum production on track for installation, no technical issues
Vacuum Systems
The production of vacuum chambers for multi-poles and dipoles (150 units) nearing completion (welding at APS was completed in February, chamber assembly will be completed in July).
Production of 27 “day-1/2” chambers for ID straights started
Design of injection straight vacuum completed; finalizing of drawing packages while injection kicker and injection septum design is being completed; RF straight vacuum system design underway
Gate valves in production (40% complete)
Shielded Bellows in production, sufficient units for P1 and P2 ready
Absorbers: production well underway, most units for P1 and P2,
crotch absorbers delayed due to manufacturing issues.
Ion and TSP pumps are in hand, in-house assembly of integrated NEG pumps keep up with chamber production.
Vacuum instrumentation and infrastructure: pump controllers and HV supplies, RGA, cables, TSP power supplies and cables and termination; production far advanced or complete
Vacuum production on track for installation, no technical issues

13. Power Supplies Power supply production has progressed well.
Overall, about 55 % of the production is at hand.
In-house testing of components set up
Integration in progress
Main Dipole PS will be completed end of 2012
PSC
Regulator
Controls Interface
Excellent performance: 2.5 ppm << 10 ppm (spec)
Power Converter

14. Utilities Electrical Utilities:
All 575 equipment enclosures at hand, 65% installed, 40% fully functional
All cable at hand, a significant fraction already installed
(P1:100%, P2: 60%, P3: 10%)
All UPS units received, 40% installed
All cable tray installed (99% complete)
Electrical Utilities Hardware at hand, significant fraction already installed.
Mechanical Utilities:
Process chilled water, compressed air systems and central DI-water systems either already in operation or ready for operation
Di-Water secondary systems, all 13 pump skids delivered,
RF and Injector systems are complete and operational
DI-Water piping installation underway ~75% complete
Mechanical utilities available for start-up of testing and commissioning

15. Beam-line Frontends
Final Drawing packages released after numerous revisions and design changes
Materials such as GLIDCOP at hand
Production of components has started
Tables for installing components have been delivered
Vacuum components such as pumps at hand
Contracts placed for brazing of absorbers and masks
Materials for safety shutters available
Integration and assembly of components started
Beamline frontends are delayed with respect to the project baseline schedule, but are not near the critical path.

16. RF Systems
Storage Ring RF Transmitter Systems are complete, installed, and tested
The IOT transmitter for the Booster is complete and partially installed
The design of superconducting cavity completed, construction started.
The 3rd harmonic niobium cavity and its cryostat is complete, the design of auxiliary systems in progress
The liquid Helium cryogenic plant vendor design phase is completed (FDR) and manufacturing of the systems started.
Liquid Nitrogen system contract awarded in February.
The low level RF controls have been successfully tested at CLS which demonstrated the superiority of the FPGA based system  compared to conventional systems.
NSLS-II
CLS

17. RF Systems HV PS HV Transformer Circulator, loads,
Klystrons
HV Transformer
Circulator, loads,
Water manifolds and waveguides

18. Instrumentation Production of BPM buttons completed this month.
BPM electronics development successful, 200 nm resolution and stability confirmed with beam tests at ALS, full production started
Transverse Damper System in production, electronics tested
Beam Current monitors have been received
Optical-,X-ray- monitors (emittance, bunch length ) designed and components are on order.
The design of photon BPMs has started.
Injector Instrumentation well advanced, systems for the first step of commissioning installed and tested

19. Pulsed Magnets
The NSLS-II Storage Ring injection septum being built in industry, design complete, production started
The NSLS-II kicker systems are being built in-house.
A prototype kicker and pulser has been produced.
Long lead items such as coated ceramic chambers and IGBT based switching elements are on order.
Pulsed magnets for booster injection and extraction are part of the BINP booster scope. The systems have been built and bench tests have demonstrate that they meet requirements.
Prototype
Kicker-Pulser
Assembly
Test: 3 x 10-5 amplitude reproducibility

20. Controls
Controls Software for accelerator systems developed, built and tested  ready for use in integrated testing and commissioning.
Controls hardware (VME crates, digital I/O output modules, network hardware, computers) at hand and partially installed
Optical fiber cables for connecting the network hardware
available, being installed
Timing system hardware at hand, software well developed
Cell controller hardware (real time control) is in production.
The IRMIS data base system developed, semi automated link of data from component testing
High level application programs well advanced commissioning will start with full suite of high level applications
C Controls efforts are on schedule

21. Status NSLS-II Project Beamline Insertion Devices
Damping Wiggler (DW) Contract was issued on Nov.7, FDR was completed on June 6th, 2011; PM & hi-m materials available, production started, first article in May’12.
In-Vacuum Undulators IVU 21(SRX), IVU20 for HXN & CHX and & IVU22 (IXS) IVU20, IVU21 contract awarded in November/December 2011, vendor design in progress, IVU22 award in March’12
Elliptically Polarized Undulator (EPU) Contract was issued on April 28, CDR was completed on June 9th, 2011, FDR October 2011, production has started
Three Pole Wiggler (3PW) Contract was issued on March 25, FDR was completed on May 20th, 2011, in production

22. ID-Magnetic Measurement Facility
State of the Art Facility Completed:
Clean Room has been completed
Hall probe bench in operation
Calibration Dipole in operation
Flip/long coil system (IFMS) received
Helmholtz Coil System in place
Hall Probe Bench
Calibration Dipole System
Flip/Long Coil System

23. Installation Installation had a late start (~3 months)
Start-up slow, but speeded up significantly now
After injector building BORE Aug’11, concentration on injector installation LINAC complete, Booster well underway
Challenging Coordination issues resolved : Building contractors, AD contractors, AD technicians, temporary labor, laboratory services now work together closely
At present: ~4 months behind schedule, we have added some 12 FTE’s (electricians, cable pullers, surveyors, electrical technicians to catch up with the work)

24. Installation Progress
completed LINAC installation
Completed LINAC to Booster Transfer line Part 1

25. Installation Progress
Di-ionized Controls Computer rooms equipped with Water distribution systems and pumps sealed electronic racks, servers, network
Skids for Injector and Injector Complex hardware completed and installed
Completed and installed

26. Installation Progress
Personal Protection System PLC Cabinet with the 2 redundant Safety PLCs

27. Integrated Testing and Hardware commissioning
Integrated testing is the demonstration of the proper functioning of the hardware systems in the final, installed configuration, in presence of the neighboring systems and by using the computer control system for extensive test of the full functionality of the systems.
Plans for integrated testing have been developed, they will happen module by module, a module being as small as one of the 30 cells
Resources have been revisited and revised by adding labor.
Integrated testing started with the completion of the 1st storage ring cell (#25) in February: First cell pumped down,

28. Commissioning with Beam
LINAC and LtB-Transfer-line beam commissioning started benefiting from well developed plans and all software systems in place and tested.
The ASE and SAD for the booster synchrotron have been reviewed by the lab safety committee with no major concerns raised
The documentation for the Storage ring has been started
Data-base for commissioning and operations has been developed. Many of the needed data are already available. Commissioning data taskforce continues with a more pragmatic approach making sure that all needed data exist and are accessible.
Commissioning plan is concentrating on creating high level controls software in support of commissioning.

29. Accelerator Schedule DESIGN Production Installation Testing
Commissioning
now

30. (from Apr-9-Dec12: 3 months, Mar 12 3.5 months)
Cost and Schedule Performance &
Cost index
Schedule Index
Forecasted and realized SV based on 3.5 months delay
Accelerator schedule performance continues to be explained by an overall delay
(from Apr-9-Dec12: 3 months, Mar months)

31. NSLS-II Start-Up of Operations Schedule
Float could become user operation

32. First Part of Commissioning Goals
Beam Stored
Injection set-up for beam accumulation
Beam Orbit Corrected to 30 microns
Beam Vacuum Conditions checked and compared with expectations
Beam Optics Verified and Corrected, confirm 2nm horizontal emittance
RF Parameters measured, confirmed and RF loops tested and optimized
Alignment of Quadrupoles and Sextupoles confirmed/corrected
Dynamic Aperture measured, compared with Simulations and improved
Orbit Feedback commissioned and turned on, differential orbits control with submicron precision
Injection Optimized for low loss and high efficiency
Top-Off Injection Mode set-up and top-off interlocks tested
Beam Loss Control and Monitoring, commissioned, interlock tested
Local Orbit interlock at ID locations, implemented and tested
Active Damper Systems Tested and Commissioned
Single Bunch limitations explored and Touschek Lifetime measured vs Bunch Intensity
Radiation Monitoring Tested with Increased Beam Currents
Vacuum Component Temperatures Monitored vs Beam Current and Compared with expectations
Beam Current Increased to 50 mA - 200mA
Vacuum conditioning with high Beam intensity
Accelerator ready for Insertion Device/Frontend Commissioning

33. Insertion Device Installation
Schedule for Installation of 12 Project IDs: 6 DW, 2 EPU, 1 IVU21, 2 IVU20, 1 IVU22
Serial Activities: Rigging, Installation in the Tunnel, survey, cabling, electrical connections
Parallel Activities: Vacuum installation and connections, pump-down, vacuum conditioning, installation of instrumentation, testing of operations software

34. Time for ID, Frontend & Beamline Commissioning
Time Needed for Insertion Device Commissioning
ID integration into the lattice h
Implementation of feed forward corrections h
Vacuum conditioning h
High Beam Intensity tests, temperature monitoring and check h
Total shifts
Time Needed for Frontend Commissioning
Frontend functionality test with beam: XBPM, shutters, slits: h
EPS interlock settings h
Temperature monitoring and heating tests h
Vacuum Conditioning h
Top-off safety tests h
Total shifts
Time Needed for Beamline Commissioning (dedicated non-parasitic times only)
2 shifts
Note: Commissioning of Insertion Devices and Frontend is interleaved
First beam to Exp. Floor could be delivered after 1st ID and FE is fully accommodated

35. High Intensity Commissioning
High Intensity studies and commissioning will continue during 1st year of operations
High Intensity Commissioning has to be taken in small steps
Need to be careful not to damage vacuum and frontend components
RF systems are very delicate, there is the possibility of damaging the superconducting cavity
The impact of high intensity operations on radiation levels needs to be carefully monitored and inacceptable conditions must be first corrected
Vacuum conditions are expected to improve slowly, we need to keep the pressure always under control
We will not rush to get to high intensity early on
During the first year(s) of operation we will regularly work on improving intensity
Step by step procedure, increase from mA (established at end of project) to 300mA
in 6 modules of 50mA each, allocated time: X 12 shifts
- radiation monitoring with beam loss h
- LCM adjustments h
- injection optimization h
- feedback and RF adjustments h
- monitoring of critical FE components, special set-up h
- trouble shooting h
- recovery from trips h
 Intensity Ramp-up
1st Year mA
2nd Year mA
3rd Year mA

36. NSLS-II Availability
NSLS-II is designed for high reliability and availability >95%
DOE definition: Reliability User time delivered at scheduled time/ total scheduled user time
However: during the first years of operation the reliability is expected to suffer from teething problems.
Expectation:
FY14 70%
FY15 85%
FY16 90%
FY17 95%
FY18 >95%

37. Analysis

38. Environmental Impact: Dust, Humidity, Temperature
NSLS-II Electronics/PS Rack Solution
Dust causing frequent failures on TEVATRON QP electronics )copied from H. Edwards/P. Czarapata, FNAL, Groemitz Miniworkshop 2005
Lifetime of film capacitors vs int.temperature C. Chen et al IEEE PESC, Aachen 2004

39. NSLS-II Performance Simulation
2 years

40. Operation Cycle

41. Summary
NSLS-II Accelerator made good progress; overall about 65% complete
LINAC is being commissioned
All large construction contracts placed
There are no major technical issues with construction any more
Keeping pace with Installation schedule to start storage ring commissioning by mid 2013 is the largest challenge
Labor for installation has been increased by ~12 FTE already, project EAC accounts for additional labor that will be most likely be necessary to maintain schedule
Integrated testing started
Cost performance is good, schedule performance well understood
- and so are the required measures for keeping pace with the schedule
Plans for start-up and operations well developed

42. ID type, incl. period (mm)
NSLS-II Project, NEXT, and ABBIX Insertion Devices BL
ID straight type
ID type, incl. period (mm)
Length
Kmax
FE type
# of ID's (base scope)
# FE's
Project
CSX
lo-β
EPU49 (PPM) x2
4m (2 x 2m)
4.34
canted 2 1
NSLS-II
IXS
hi-β
IVU22 (H) x2
6m (2 x 3m)
1.52
std
HXN
IVU20 (H) 3m
1.83
CHX
SRX
IVU21 (H)
1.5m
1.79
XPD
DW100 (H)
6.8m (2x3.4m)
~16.5 DW
ESM
EPU56 (PPM) & EPU180 (EM) 4m
3.64
6.8
NEXT
SIX
7m (2 x 3.5m)
3.5
ISR
IVU23 (H)
3.0m *
canted**
SMI
IVU22 (H)
1.3m
2.05
ISS
FXI
FMX
ABBIX
AMX
0 (joint w/FMX)
LIX
Same device
PPM: Pure Permanent Magnet
EM: Electro Magnet
H: Hybrid Magnetic Design
* Depending on location within ID straight section
** Off-center canting magnet location in ID straight section