Proton Improvement Plan (FY13 PMG Q4). William Pellico, Fermilab PMG, Nov 27 2013 2 PIP FY13 Q4 Summary Task Highlights Budget and Labor Review Summary

Proton Improvement Plan (FY13 PMG Q4)

William Pellico, Fermilab PMG, Nov 27 20132

PIP

FY13 Q4 Summary

Task Highlights

Budget and Labor Review Summary

Outstanding Issues

Plans - ScheduleFY14 Goals

FY14 Budget

Additional PIP Items


FY13 Q4 Task Summary – Highlights

PIP FY13 Milestone Summary


LVL TASK MILESTONE DESCRIPTION Due

3 1.02.02.03.01.01.04 Notched Beam absorber design complete Q1

3 1.01.03.01.02.14 Linac BPM board production complete Q1

2 1.00.04 Linac Beam Q1

3 1.03.03.07 RFQ Inj Equipment installed, vacuum ready, beam ready Q1

2 1.00.03 NTF Beam Q1

3 1.03.03.12 RFQ Installation Complete - Beam extracted to Linac Q1

3 1.01.03.01.03.03 Linac BPM Production Module Testing Complete Q2

3 1.01.03.01.04.05 Linac BPM Module Installation & Commissioning Complete Q2

3 1.02.03.02.01.02 Specifications doc. for Booster longitudinal dampers complete Q2

3 1.02.02.03.02.15 L12 Long Notcher Installation & Commissioning Complete Q2

3 1.01.02.03.06.09 Linac Notch Optical Cavity Prototype Certification w/IR Optics Q2

3 1.01.02.03.06.10 Linac Notch Prototype optical cavity certified Q2

3 1.02.03.01.01.03 Booster BPM Specification Complete Q2

3 1.02.01.01.02 Specifications for Anode Power Supply Documented Q2

1 1.02.07.01 Solid State Upgrade Complete Q2

2 1.00.05 Booster Beam Q2

2 1.02.02.03.01.12 L13 Beam Absorber Complete Q2

3 1.01.02.03.02.13 Certify Operation of Linac Notch OPG Q2

1 1.02.07.06.02.15.05 Last Solid State Installation Complete Q2

3 1.01.02.03.04.08 Linac Notch Complete 1st & 2nd stage Fiber Amplifier Q2

2 1.02.07.05.02.15 SS Modulator Production Complete Q2

3 1.02.03.02.01.07 Booster Damper prototype board for transverse system complete Q3

3 1.02.01.02.01.04 First 6 Bias Supply Transformers Received Q3

3 1.02.03.02.01.10 Booster Damper prototype board testing complete Q4

3 1.01.01.01.03.06 Receive Klystron Dimensions & Power Requirements Q4

3 1.01.02.03.05.03 Linac Notch Laser Amplifier Technology Chosen Q4

The current RLS is outof date and is being updated. Effort to adjustRLS when changes tobudget and labor occuris challenging.

Not Completed

Completed

FY13 Q1

FY13 Q2

FY13 Q3

FY13 Q4

WBS 1.1 LINAC FY13 Q4Summary Tasks at a Glance

5 William Pellico, Fermilab PMG, Nov 27 2013

Linac WBS Task FY13 Q4 Progress Summary

WBS 1.1.1.1 High Level RF MBK design has been abandoned and substituted by a SBK specification. New bid process complete. Finalizing FP contract negotiation (warranty, T’s & C’s , etc…)

WBS 1.1.1.2 Linac Modulator EE support completed 3 cell testing system. Implemented modifications to the design and initiated building 9 cell modulator

WBS 1.1.1.3 7835 Procurement Waiting tube delivery procured in FY13

WBS 1.1.2.1 Simulations and Studies Small progress on this task during this quarter

WBS 1.1.2.3 Linac Notch Creation Purchased of waveform generator and laser technology was chosen (1064nm Nd:YAG amplifier)

WBS 1.1.5.1 Power Distribution Awaiting next long shutdown for L1 transformer installation

WBS 1.1.5.3 Vacuum System Some equipment procured with Supplemental funds have been already delivered. Ongoing installation plans

6 William Pellico, Fermilab PMG, Nov 27 2013

WBS 1.1 LINAC (Highlights)WBS 1.1.2.3 Linac Notch Creation

Linac Notch – Beam Shaping

• Laser technology chosen• 1064nm technology based upon Nd:YAG

amp offered by Northrop Grumman Cutting Edge Optical (NGCEO)

•Started with Notcher installation plans and stand design

Old

New

3-cell simultaneous turn-on at 300 amps.

WBS 1.1.1.2 Modulators

9-CELL UNDER CONSTRUCTION

• No problems with 3-cell operation as long as initial turn on timing is done properly.

• Simultaneous turn-on yields 2700 volts with 250 ns rise time (10% - 90%).

• 9-cell construction under-way



WBS 1.1 LINACWBS 1.1.1.1 High Level RF

Klystron Timetable• MBK 2012

• Evaluated LE Linac RF power situation (wrote document - recommending Klystron option)

• Wrote specifications• Bid process (1 bid – CPI)• End of year funding issue• Contract (CPFF)

• MBK 2013• Carryover funding issue• Late 2013 – carryover approved• Contract type causes concern

• Lots of negotiations• Re-issue bid for SBK

• SBK 2014• New bid received• Fix Cost• Negotiating contract issues (CPI)

WBS Task Highlight

1.2.1.1 Anode Supply Supplemental funding allowed initial engineering to start with purchase of internal transformer

1.2.1.5 Cavity Refurbishment

8th & 9th cavities refurbished & certified (Aug 30 & Oct 21); however, 1st refurbished cavity removed due to RF leak – replaced a tuner and refurbished flange connections

1.2.1.6 New Tuners Delivery of nearly 200 low mu cores – passAwait delivery latest round of high mu cores – hope is that vendor will have increased mu

1.2.1.8 Spare RF Cavity Old rejected pieces reworked with some new components to make a vacuum certified cavity; requires 3 tuners

1.2.2.1 Simulations & Studies

Team working on optics software process/procedure

1.2.2.3 Notcher System Operational – working on short kickers/PS

1.2.5.2 Power Distribution Supplemental funding moved ordering new transformer earlier

1.2.5.3 Vacuum Systems Supplemental funding moved ordering replacement vacuum equipment earlier


WBS 1.2 Booster FY13 Q4Summary Tasks at a Glance


WBS 1.2 Booster (Highlights)1.2.2.3 Notcher System1.2.1.5 Cavity Refurbishment (more later)

Notcher System

Testing of Short Kickers:• Magnets passed

impedance testing

• Supply nearing completion

Repair of 9th cavity

Repair LCW cone leakRefinished outer flange

Center tube, fingers (not shown) and stem burnt

New short kicker pulser

Two short kickers

Low mu ferrites cores for new tuners

1 15 29 43 57 71 85 99 11312714115516910

10.5

11

11.5

12

12.5

Measured mu

mu

1 15 29 43 57 71 85 99 1131271411551691900

1950

2000

2050

2100

2150

2200

2250

2300

Mass (g)

grams

185 cores from National Magnetics has been received in three different shipments; in Sept, Oct and Nov.The following data was taken for all cores including a low power ƒo measurement.

Core # mu OD (cm) ID (cm)Thickness

cm gramsvolume cm^3

density gm/cm^3 Qo fo MHz f low f high

M4-2013-100 11.17 20.32 12.70 2.54 2111 503.02 4.20 274.1 43.588 43.509 43.668

M4-2013-101 11.76 20.31 12.70 2.54 2179 502.25 4.34 285.3 43.079 43.004 43.155

M4-2013-102 11.55 20.31 12.70 2.54 2158 501.78 4.30 292.3 43.265 43.192 43.340

M4-2013-103 11.65 20.31 12.70 2.54 2172 502.04 4.33 282.2 43.175 43.099 43.252


High Power Test• 30 cores from across all lot numbers were tested in the high power

test jig with 10,000 Amps of DC bias and driven with a 5-KW RF amplifier.

• Had very consistent results.• No high loss effect (HLE) in any of the cores.

M4-2013-107 Lot 56371-1

Bias Current

(A)Setting (dBm)

Res. Freq. (MHz)

Forward Power (V)

Reverse Power (V)

Forward Power (kW)

Reverse Power (W)

Cavity Voltage

0 7.0 41.012 1.200 0.260 3.599 169 6.330

3000 7.0 42.330 1.200 0.300 3.599 225 9.200

5000 7.0 42.607 1.220 0.270 3.720 182 10.500

10000 7.0 42.910 1.180 0.350 3.480 306 11.150

Q measurement

Bias Current (A) 3000 10000

SG setting (dBm) 7.0 7.0

Max Cavity Voltage (V) 9.2 11.15

Resonant frequency (MHz) 42.330 42.910

f1 42.291 42.879

f2 42.376 42.940

Q 498.0 703.4



14William Pellico, Fermilab PMG, Nov 27 2013


Budget and Labor Review Summary



PIP Labor Usage (FTE)

Planned Actual


Planned Actual

Supplemental Spending – Direct M&S

19

ID PIP Tasks Task Code

1 DTI switches and controller for extractor (and spare for Einzel Chopper) 2103.01.01.02.02.AD

2 Booster Transformer (MCC and spare breaker) 2103.02.05.02.01.AD

3 Buncher Solid State RF power 2103.01.01.02.02.AD

4 12 Scroll Pumps for Booster 2103.02.06.01.AD

5 Linac Roughing Station 2103.01.05.03.AD

6 Laser Amp for Linac Notcher 2103.01.02.03.AD

7 1st Linac 7835 20.17.1.1.1

8 RFQ Turbo and Roughing station/controls 2103.01.06.01.AD

9 400 MeV line pumps 2103.01.05.03.AD

10 2nd Linac 7835 20.17.1.1.1

11 14 Booster roughing and turbo pumps stations 2103.02.06.01.AD

12 Replace 5 Booster valves 2103.02.06.01.AD

13 Linac Modulator (SLAC Version) 2103.01.01.02.01.AD

14 SS amp for Linac Driver system 2103.01.01.02.02.AD

15 Booster Anode Supply Transformers 2103.02.01.01.02.AD

16 Laser notch pulser 2103.01.02.03.AD

17 201 MHz Circulator 2103.01.01.01.02.AD

18 Linac 55 chilled water pump and plumbing 2103.01.05.02.AD

19 3rd Linac 7835 2103.01.01.04.AD

20 Injector Solenoid and trim PS 20.17.1.1.8

21 RF test ‘cave’ or shielded room 2103.02.01.05.02.AD

Supplemental funds wereprovided in July –

This is a significant $$ andwill have a positive effect on the schedule.

Part of funds will be usedto remedy the recent PSbudgets which impactedPIP goals (7835 tubes).

Part of funds will be usedto put back track PIP itemsimpacted from previousreductions (e.g. laser notcher).

Part of funds will be used tomove tasks forward (Refurb)

Some small items already delivered – all should be in FY15



PIP M&S

Notes/CommentsThis includes carryover and the supplemental funding received in August.

Plans - Schedule

Row Labels M&S Overhead M&S Personnel Costs Overhead SWF Grand Total

2103 Proton Improvement Plan (PIP) 4,629,952 835,577 2,825,481 2,708,990 11,000,000

2103.00.01.AD AD-PIP Prgm Mgmt 56,000 11,952 141,868 139,215 349,036

2103.00.01.APC APC-PIP Prgm Mgmt 68,235 66,959 135,194

2103.01.01.00.APC APC-LnPIP PSPLnOS 97,292 95,473 192,765

2103.01.01.01.01.AD AD-Lin PSPA PDsgn 26,355 25,862 52,217

2103.01.01.01.02.AD AD-LnPIP PSPA Proto 460,000 107,300 27,656 27,139 622,095

2103.01.01.02.01.AD AD-LnPIP PSModPDsgn 237,000 55,814 100,816 98,931 492,561

2103.01.01.02.02.AD AD-LnPIP PS Proto 76,000 17,898 224,716 220,514 539,128

2103.01.01.04.AD AD-LnPIP 7835 Acq 600,000 0 600,000

2103.01.02.01.AD AD-LnPIP APStudies 2,340 2,296 4,636

2103.01.02.01.APC APC-LnPIP APStudies 30,050 29,488 59,538

2103.01.02.03.AD AD-LnPIP NtchSyst 285,000 67,118 24,922 24,456 401,495

2103.01.05.01.AD AD-LnPIP PwDstPlnDsn 3,446 3,382 6,828

2103.01.05.02.AD AD-LnPIP DT/LCW M&R 5,000 2,740 7,740

2103.01.05.03.AD AD-LnPIP VacSysRepl 160,000 37,680 14,827 14,550 227,056

2103.02.01.01.01.AD AD-BstPIP AnPSPLnOS 58,350 57,259 115,609

2103.02.01.01.02.AD AD-BstPIP AnPSFab 700,000 164,850 95,989 94,194 1,055,034

2103.02.01.02.01.AD AD-BstPIPBiasSuPlnOS 31,485 30,896 62,381

2103.02.01.02.02.AD AD-BstPIPBiasSupUpg 180,000 42,390 229,956 225,656 678,002

2103.02.01.04.AD AD-BstPIP Tst Stnd 5,865 5,755 11,620

2103.02.01.05.02.AD AD-BstPIP RF CavTRW 310,087 73,025 291,583 286,130 960,825

2103.02.01.06.01.AD AD-BstPIPNwRFTnPO 22,307 21,890 44,198

2103.02.01.06.01.TD TD-BstPIPNwRFTnPO 146,591 122,286 268,877

2103.02.01.06.02.AD AD-BstPIPNwRFTnDes 36,759 36,071 72,830

2103.02.01.06.03.AD AD-BstPIP NwRFTnFab 510,000 0 33,195 32,574 575,770

2103.02.01.07.01.TD TD-BstPIPNwRFCavPO 230,591 192,359 422,950

2103.02.01.07.02.AD AD-BstPIPNwRFCvPD 50,711 49,762 100,473

2103.02.01.07.02.APC APC-BstPIPNwRFCvPD 38,426 37,708 76,134

2103.02.01.07.03.AD AD-BstPIP NwRFCvPT 843,865 206,063 25,296 24,823 1,100,047

2103.02.02.01.AD AD-BstPIP APStudies 7,500 1,766 64,847 63,634 137,747

2103.02.02.01.APC APC-BstPIP APStudies 66,067 64,831 130,898

2103.02.02.01.CD CD-BstPIP APStudies 24,650 16,939 41,589

2103.02.02.02.AD AD-BstPIP AperAlign 49,484 48,558 98,042

2103.02.02.02.PPD PPD-BstPIP AperAlign 3,839 2,846 6,685

2103.02.02.03.AD AD-BstPIP NtchSyst 13,500 3,179 77,804 76,349 170,831

2103.02.02.03.APC APC-BstPIP NtchSyst 56,750 55,688 112,438

2103.02.02.04.AD AD-BstPIP BmCog Sys 105,017 103,053 208,070

2103.02.02.05.01.AD AD-BstPIP CollSysImp 80,000 18,840 43,070 42,265 184,175

2103.02.02.06.AD AD-BstPIP RadShldg 15,654 15,361 31,015

2103.02.03.01.AD AD-BstPIPBmInstPlDsg 48,976 48,060 97,036

2103.02.03.02.AD AD-BstPIPDprSysImprv 50,000 11,775 52,221 51,244 165,241

2103.02.03.03.AD AD-BstPIPBmInstUpgr 107,649 105,636 213,284

2103.02.04.01.AD AD-BstPIPBmCtrlPDsgn 25,037 24,568 49,605

2103.02.05.02.02.AD AD-BstPIP Trsf Inst 11,518 11,302 22,820

2103.02.05.03.AD AD-BstPIP VacSysRepl 56,000 13,188 13,272 13,024 95,485

Grand Total 4,629,952 835,577 2,825,481 2,708,990 11,000,000William Pellico, Fermilab PMG, Nov 27 201322

Uploaded FY14PIP Budget

Notable Items:Linac Klystron (CO)

Linac ModulatorLinac 7835 (2)Booster Bias PSBooster AnodesBooster TunersBooster Cavity (new)


Operations with refurbishment means the voltage and loses are always a concern – medium intensities. Batch intensity will track the voltage sum – mostly due to transition loses.

Same scales for 2011 operationsand present operations. Average voltage is about 817 KV compared to 917 two years ago. This is likely to continue with occasional unplanned downtime to fix RF stations.

PIP FY13 Q4 Summary & ConcernsWBS 1.1 Linac

Linac WBS efforts are in good shape• Klystron effort continues – Business Services/CPI/PIP

• Switching from MBK to SBK Modulator efforts continue with both SLAC and AD/EE support Simulation and Studies-> continue development code for DTL lattice,

WBS 1.2 Booster Cavity Refurbishment – Labor & Time constraints

• Contract Employees• Dosage (ALARA) – will need to rotate personnel• Need to deal with operations vs. repair (MI startup)

Booster shielding – progressing Booster has not found a ferrite that meets our High μ need

• A order has been placed for 10 high u ferrites – getting close to a usable ferrite FY14? Booster High Intensity/rep rate: Up to 7 Hz – MiniBooNE, Recycler and NoVA

• Booster Rep rate limit – RF has had more downtime (rep rate or operating time?)

Supplemental Funding – Big Boost and will help PIP/FY14


Documents

Proton Improvement Plan (FY13 PMG Q4). William Pellico, Fermilab PMG, Nov 27 2013 2 PIP FY13 Q4 Summary Task Highlights Budget and Labor Review Summary