LIU-SPS 200 MHz RF upgrade - CERN · 2019. 6. 4. · EN-CV Mauro Nonis, Serge Deleval, Michele Battistin, Alexandre Broche, Mathieu Archambau, Bill Bannister, Glen Mason, Aurelio

LIU-SPS200 MHZ RF UPGRADE

PRESENTATION TO SCK-CEN

[email protected]

OUTLOOK

Brief description of the RF power project & Summary

Building BAF3

Power systems

Transmission Lines

Cavities

FPC

Tunnel Integration

Conclusion

21 May 2109 [email protected] 2

DESCRIPTION OF THE PROJECT

First definition of the project (2011)

Four to become six Travelling Wave Cavities

Four existing amplifiers upgraded to 1.05 MW* feeding four cavities

Two New power amplifiers delivering 1.4 MW* to two cavities (became 1.6 MW* in 2015)

A new building

A new SPS-LSS3 layout

*All RF power levels being peak power operating with a duty cycle at 50% at 42 kHz or 172 kHz


Available RF voltage as a function of Irf

Courtesy Elena Chapochnikova


Three main sub-tasks

New RF Building project

Cavities re-arrangement project

RF Power Amplifiers project


RF amplifier

1 mW

Coaxial transmission line

150 meters

Accelerating cavity

1.7 MW

RF amplifier

1 mW

Accelerating cavity

1.7 MW

New RF Building




LSS3

Coaxial lines

Cavities

Fundamental Power Couplers

RF Power Amplifiers project

Present amplifiers upgrade

New amplifiers



RF BE/RF Eric

BE Space Management BE/ASR Paula

Safety DGS/SEE Enrico

Ventilation and cooling EN/CV Mauro

Electrical Network EN/EL Joël

Transport EN/HE Keith

Integration EN/MEF Yvon

Alarms GS/ASE Christophe

Civil Engineering GS/SE Natasha

New RF Power Amplifiers project

Power BE/RF Eric

LLRF BE/RF Wolfgang, Philippe

Controls BE/RF Andy

HVPS TE/EPC David

Cooling (air/water) EN/CV Mauro

Diacrode

Los AlamosJohn

MICE Andy

SSA

SOLEIL Patrick

TTI (Spain) José

Tetrodes

Thales,E2V EU

CPI, L3comUSA

Thoshiba Japan


RF

Coaxial lines BE/RF Eric

New couplers BE/RF Eric

Spare sections BE/RF Eric

Dampers (LSS2-LSS3) BE/RF Wolfgang

Pickups BE/RF Thomas

Optics BE/ABP Gianluigi

Safety DGS/SEE Enrico

Cooling EN/CV Mauro

Transport EN/HE Catherina

Integration EN/MEF Yvon

Vacuum TE/VSC Miguel

OUTLOOK


Manpower

Schedule

Budget

Building BAF3

Power systems

Transmission Lines

Cavities

FPC

Tunnel Integration

Conclusion


MANPOWERA lot of people from many teams ! (more than 160 directly involved)

All teams involved know the requested manpower regarding their activities


Dep-Group Persons

BE-RF

Eric Montesinos, Charles Julie, Frederic Killing, Sébastien Calvo, Gino Cipolla, Antoine Boucherie, Simon Rains, James Bibby, Christophe Renaud, Cedrick Grandbois, Pilar Parrado Caballero, Irene

Alonso Romero, Francisco Sauba Esteban, Morgan Wigham, Julien Novello, Sebastien Mutuel, Patrice Girod, Michel Ferrone, Jean-Marie Angonin, Romuald Terry, Sidi Chikhi, David Bastard, Lancelot

Brechignac-Denis, Thomas Henry, Elena Shaposhnikova, Thomas Bohl, Christine Vollinger, Nasrin Nasresfahani, Patrick Kramer, Rama Calaga, James Mitchell, Wolfgang Höfle, Philippe Baudrenghien,

Gregoire Hagmann, Luca Arnaudon, Carlos Oliveira, Diego Barrientos Turrion, Emile Grospelier, Thomas Kaltenbacher, Ester Sancho Cabrera, Débora Aguilera, Jose Enrique Varela Campelo, Paola

Mazzotta, Toon Roggen, Urs Wehrle, Philip Hofer

BE-ABP Benoit Salvan, Hannes Bartosik, Ghislain Roy, Yannis Papaphilipou

BE-ASR Marc Tavlet, Christelle Gaignant, Anne Funken, Lisa Kobzeva, Axelle Deleu, Paola Carvalho Correia

BE-BI Christian Boccard, Patrick Ogier

BE-ICS Denis Raffourt

BE-OP James Ridewood

DG-LS Florence Jacobs

HSE-SEE Olivier Tison, Cécile Pinto, Jonathan Gulley, Laurent Colly, Guillaume Fontana

IPT-PIThierry Lagrange, Anders Unnervik, Ivo Lobmaier, Bjorn Jenssen, Fatima Najeh, Dante Gregorio, Laszlo Abel, Sandrine Magnan, Nordine Azizi, Alexandre Tabary, Sandra Benoit-Godet, Boi-Lan

Nguyen-Lemoine

IT-CS Stephane Casenove

EN-ACE Katy Foraz, David McFarlane, Emmanuel Paulat, Patrick Bestmann, Julie Coupard, Sonia Bartolome Jimenez, Bertrand Nicquevert, Simon Cherault, Tobias Dobers, Yannick Beraud

EN-CV Mauro Nonis, Serge Deleval, Michele Battistin, Alexandre Broche, Mathieu Archambau, Bill Bannister, Glen Mason, Aurelio Berjillos Barranco, Michel Obrecht

EN-ELNicolas Bellegarde, Guillaume Gros, Nuno Dos Santos, Thierry Bourrel, Jean-Claude Guillaume, Stefano Bertolazi, Georgy Georgiev, Gerardo Velasquez Gutierrez, Joel Lahaye, Denis Ribiollet,

Simon Baird, Gérard Cumer, Davide Bozzini, Jérôme Pierlot, Juan Gomez, Thierry Octave, Christophe Crombez, François Duval, Jean-Pierre Sferruzza

EN-HECaterina Bertone, Jean-Baptiste Bonnamy, Pascal Brunero, Serge Pelletier, Yann Seraphin, Patrick Vallet, Gilles Roche, Helder Lorenco, Roberto Rinaldesi, Jean-Pierre Grandchelli, Jean-Louis

Grenard

EN-MEF Yvon Muttoni, Frédéric Galleazzi, Scharif Mehanneche, Antoine Kosmicki

EN-MME Gilles Favre, Stefano Sgoba, Alessandro Dallocchio, Jean-Marc Malzacker, Laurent Deparis, Alession D’Andrea, René Claret, Thierry Tardy, Pierre Moyret, Laurent Prever-Loiri, Jean-Marie Geiser

SMB-SE Luz-Anastasia Lopez-Hernandez, Christophe Biot, Laurent Faisandel, Mathieu Fontaine

TE-EPC Jean-Paul Burnet, Gilles LeGodec, Davide Aguglia, Karsten Kahle, Christophe Coupat, Clément Bovet

TE-MSC Jérémie Bauche

TE-VSC Paolo Chiggiato, Antonio Mongelluzzo, Sergio Calatroni, Wilhelmus Vollenberg, Ciara Pasquino, Jose Ferreira Somoza, Antonio Mongelluzzo

SCHEDULE


OUTLOOK


Building BAF3

Power systems

Transmission Lines

Cavities

FPC

Tunnel Integration

Conclusion


BAF3

Design completed by end of October 2011 to allow Civil engineering studies and authorisation requests to be launched

Goal to have the bare building completed by end 2014 (taking advantage of LS1 to minimize accident impacting SPS operation during construction)

Even if we did not know what amplifier technology will be selected !


2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

Bare building

BAF3

Point 3 is the best area even if we need a new building

New building between BA3 and BB3 in front of 929 RF workshop :

Ground floor

20m x 25m = 500 m2

Mezzanine:

10m x 25m = 250 m2


RF workshop

Siemens

Philips

800 MHz

Faraday Cage

New RF building

BAF3

Amplifier tendering process opened to several technologies

2 x 16 tetrodes (well known)

2 x 2048 SSPA (Solid State Power Amplifiers)

4 x Diacrodes (new tube)

4 x IOT (Inductive Output Tube, almost new)

Answer of the selected technology (volume needed) after the building approval

Hybrid combiners and coaxial lines will be similar to the ones in use with present systems


4.7 m4.7 m

2.3 m

4 tours (320 kW) = 33 m2

LVPS = 72 m2

total 64 towers = 600 m2

1 tube (160 kW) = 4 m2

HVPS = 192 m2

Total 32 tubes = 320 m2

Total combiners = 200 m2

Total combiners = 200 m2

Courtesy

Patrick Marchand

(SOLEIL)

BAF3

All main RF equipment around

Close to RF workshop

Take advantage of ‘nearly empty’ GT10 gallery to install 350 mm RF coaxial transmission lines Easiest path to the pit

Access through 929 RF workshop

Reserved area for BB3 transformers if needed in the future to replace oil transformers to

cast resin transformers


Reserved area for

new BB3 transformers

28m x 4m

BAE3 Philips

BA3 Siemens

RF Faraday Cage

BB3

800 MHz

929 RF

workshop

BC3 New RF Amplifiers

GT10 Gallery

BAF3

Total surfaces:

Basement : 19.5 m x 36.5 m = 710 m2

Mezzanine : 475 m2

Total = 1185 m2

Total surfaces for RF:

Basement = 550 m2

Mezzanine = 475 m2

Total = 1025 m2


36.5 m

19.5 m

BAF3


BAF3 with Tetrodes BAF3 with SSPA

BAF3

2011 Integration studies completed

2012 Enquiry ‘Etude Genie Civil’ sent out

2013 Construction

2014 Bare building delivered

2015 Ready for services integration


OUTLOOK


Building BAF3

Power systems

New amplifiers

Present amplifiers upgrade

Transmission Lines

Cavities

FPC

Tunnel Integration

Conclusion


FUTURE POWER SYSTEMS IN THE SPS


BAF3

BAE3

CCC

BA3

BB3

NEW SYSTEMS 2 x 2.0 MW @ 200 MHZ


One line

(input cavity ~120 to 180 m away) From Beam Control

1.6 MW at cavity input

4 stages of 3 dB combiners = - 0.6 dB

120 to 180 m Coaxial lines = - 0.2 dB

Final Amplifier output = 1.6 MW + 0.8 dB = 2.0 MW / 16 = 125 kW

1/16 splitter

Three contracts

Drivers :

2 x 16 x SSPA

Finals :

Tetrode : 2 x 16 x 110 kW

IOT : 2 x 16 x 110 kW

SSPA : 2 x 16 x (110 x 1 kW)

Diacrode : 2 x 2 x 850 kW

No klystron at 200 MHz

Combiners + lines :

3 dB hybrids

850 kW power loads

PURCHASING STRATEGY

Two contracts

IT-3842 Drivers

IT-3841 Finals

A first contract for the Drivers (IT-3842)

SSPA only (best technology for a few kW amplifier)

Will be a first input for a predefined cost for the Finals

Combining systems

Done in house or subcontracted

Will be a second input for a predefined cost for the Finals

Once Drivers contract adjudicated, a second contract for the Finals

Drivers IT-3842 cost

+ Combiner cost (defined by CERN)

+ Finals IT-3841 offer

_______________________________________

IT-3841 adjudication to the lowest compliant


IT-3842, DRIVERS

72 companies consulted

20 selected

10 offers

Defined a 1.25 kW unit Compatible with all Finals technologies

32 for SSPA & IOTS, 256 for Tetrodes, 192 for Diacrodes

12 pre-series for qualification (end of contract clause in case of any failure without any payment)

One to six batches of 50 (total 62 to 312) regarding result of future Finals IT-3841

TTI Norte, Spain, awarded the contract (3.7 €/W)


2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

November 2011 March 2014

Consulted

Selected

0

5

10

15

20

25

30

Sp

ain

Ita

ly

Sp

ain

Germ

any

Ita

ly

Franc

e

Ita

ly

Franc

e

Belg

ium

Isra

el

€ / W peak

IT-3842, DRIVERS

RF design is impressively robust

Double circulators !

Sustained the CERN Fast Short-Circuit test !

Successfully performed the 1000 hours test with five units (not a single failure)

Many broken transistors after 6 months of operation (first half 2017)

Very quick reaction of the company (TTi Norte, Spain) that repaired at no cost all the already produced units

64 units in operation since mid-2017 without very few failures !

300 units total delivered and successfully tested


2011 2012 2013 2014 2015 2016 2017 2018 2019 2020


August 2015

IT-3842, DRIVERS










2011 2012 2013 2014 2015 2016 2017 2018 2019 2020


August 2015

IT-3842, DRIVERS










2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

November 2011 March 2014 January 2017

September 2017

2020201920182017

IT-3841, FINALS

Technical Specification to be finalized taking into account Drivers outcome

Power level request increased

Cavity 1.4 to 1.6 MW

Amplifier from 1.6 to 2.0 MW !


2011 2012 2013 2014 2015 2016

December 2014

Drivers

TSMS TS

IT-3841, FINALS ADDITIONAL COSTS

Drivers IT-3842 cost 5500 CHF per 1.25 kW unit

SSPA & IOT 176 kCHF

Tetrodes 1’408 kCHF

Diacrodes 1’056 kCHF

Combiner cost (defined by CERN) SSPA & IOT 2’760 kCHF

Tetrode 3’160 kCHF

Diacrode 800 kCHF

Total additional cost per technology SSPA & IOT 2’936 kCHF

Tetrode 4’568 kCHF

Diacrode 1’856 kCHF


IT-3841, FINALS BIDDERS CONFERENCE

Defined the scope of the contract being as fair as possible regarding the

technology

Defining a quite costly Demonstrator in order to disqualify ‘non serious’ companies (we do not want to be R&D at low cost)

Not a single CHF paid in case of failure of the demonstrator

Taking into account tubes on an as long as possible period (over 5 years)

Including spares in order to operate during 20 years

Answered 102 questions from the suppliers


20202019201820172011 2012 2013 2014 2015 2016

20 January 2015

IT-3841, REQUIREMENTSRequirements Integration within the given building

Repetition rate 0.1 Hz to 500 kHz (require a CW and a pulsed amplifier)

Full reflection all phases 100 ms (equivalent to 4 time the power level along the lines)

Non conventional way to measure the BW (required by LLRF and TWC)

Very good linearity

Two tone at many power levels

A lot of tests to qualify the Finals Supercycle test, short circuit test, BW, linearity, …

Short duration tests to qualify an Amplifier within one week

Long duration tests to check reliability within one month


IT-3841, REQUIREMENTS


Only 10 kW in-between pulses !

2020201920182017

IT-3841


19 selected

8 declined

7 offered

No discussion about the Drivers neither the combiners costs


2011 2012 2013 2014 2015 2016

Consulted

Selected

Unable to submit a competitive bid due to quantity being beyond our production capacity and we could not provide installation support

Dear all, We are sorry but we are not able to finish every documents within deadline. So we must decline to participate with our offer. Thank you for your opportunity. Best regards

We are not on time with the documents required

We believe that the chances are too low to get the contract by bidding Solid State Amplifier solutions. Additionally, the known dumping price structure of competitors in the field of Solid State Amplifiers, which get development provided free of costs by public institutes (already known due to the preceding call for tender for preamplifiers of the same frequency) also makes the chance to win the bid too small for the required work load for bid preparation

13 March 2015, bids opening

IT-3841


19 selected

8 declined

7 offers

March 2015 lowest bid is Thales Communication & Security for 8.002 MCHF

Very careful verification of the offer

September 2015 CERN FC approval


2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

13 March 2015, bids opening

Consulted

Selected

0

5

10

15

20

SSPA

- F

R

Dia

crode -

CH

/FR

Dia

crode -

FR/SP

SSPA

- S

P

SSPA

- S

P

Tetr

ode -

SP

SSPA

- G

B

€ / Wpeak

Offered17 September 2015, FC approval

1.75 €/Wp

(2019 rates)

IT-3841, FINALS

One Transmitter will be composed of

16 x 150 kW RF amplifiers

One RF amplifier will be composed of

2 x 40:1 cavity combiner

One Cavity combiner will be composed of

40 x 1 kW RF blocs

In total

Two transmitters

32 RF amplifiers

64 cavity combiners

5120 RF blocs


2 x 16 x 150 kW

RF Amplifiers

IT-3841, SCHEDULE


20202019201820172016

Contract

FC Sep 15 Start contract negotiation

8 weeks Nov 15 Contract signed

10 weeks Feb 16 Design Report

36 weeks Sep 16 Demonstrator FAT report completed

44 weeks Nov 16 Demonstrator SAT report

94 weeks Oct 17 1st Transmitter SAT report

120 weeks Apr 18 2nd Transmitter SAT report

144 weeks Oct 18 All spares delivered

DR

Demonstrator FAT

Demonstrator SAT

1st Transmitter SAT

2nd Transmitter SAT

Ready for LLRF

TRUE LIFE


20202019201820172016

#10 Demonstrator SAT

1st Transmitter SAT

2nd Transmitter SAT

Ready for LLRFFirst Demonstrator SAT

20202019201820172016

Contract

DR

Demonstrator FAT

Demonstrator SAT

1st Transmitter SAT

2nd Transmitter SAT

Ready for LLRF

VISIT AND TECHNICAL DETAILS

Several technical details are still under a NDA

I will answer your questions during the visit as much as within the respect of the NDA

Thanks for your visit to CERN


Documents

LIU-SPS 200 MHz RF upgrade - CERN · 2019. 6. 4. · EN-CV Mauro Nonis, Serge Deleval, Michele Battistin, Alexandre Broche, Mathieu Archambau, Bill Bannister, Glen Mason, Aurelio