Superconducting Undulators WBS: APS-U1.03.04.03

Superconducting UndulatorsWBS: APS-U1.03.04.03

Yury IvanyushenkovPhysicist, SCU Project Technical LeaderASD/Magnetic Devices Group

DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

Outline

Science / Technical Significance WBS Scope of this System Staff / Org Chart Requirements Design ES&H Cost Schedule Previous Reviews Responses Summary

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Superconducting Undulators (SCUs) Motivation

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Superconducting undulators generate extremely high photon brightness above 40 keV

Brightness Tuning Curves

SCU Scope

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WBS Programmatic Funds U1.03.04.03

SCU0 SCU1 SCU2

SCU1 will use a modified cryostat from SCU0 and a

new 1-m long magnet.

SCU0 – Test device SCU1 SCU2

The device is built and tested stand alone.

SCU2 will use a longer cryostat with a 2-m

long magnet.


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SCU Cost Summary

k$Labor Nonlabor TOTAL

U1 03.04 - Super Conducting Undulators 1,307 1,770 444 420 3,942 03.04.03.01 - SCU1 - 1.8-CM Period 144-pole 1-M Magnetic Structure in 2-M Cryostat 828 478 94 235 1,635 03.04.03.02 - SCU2 - 1.8-CM Period 2-M Magnetic Structure in 3-M Cryostat 479 1,292 350 186 2,307

WBSDIRECT (k$) ESCALATION

($k)DIV OH + ANL

G&A ($k)

SCU Requirements

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SCU0 SCU1 SCU2

Energy at 1st harmonic, keV 20-25 12-25* 12-25*

Period length, mm 16 18 18

Magnet length, m 0.340 1.140 ~2.3*

Cryostat length, m 2.063 2.063 ~3.0*

SCU Org Chart

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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. MezentsevV. SyrovatinV. Tsukanov

V. Lev

FNAL Collaboration(Resin Impregnation)

A. Makarov

UW-Madison Collaboration (Cooling System)

J. PfotenhauerD. PotratzD. 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

SCU Design – Major Challenges

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High field quality requirements:– low phase error:

< 8 deg. rms– low field integrals*:

SCU0: 1st field integrals (Bx, By) ≤ 470 G-cm, 4700 G-cm, 2nd field integrals (Bx, By) ≤ 4.32x104 G-cm2, 1.3x105 G-cm2

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)

SCU Design – Strategy to Solve Challenges


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Challenges Strategy to find a solution Project phase Status

High quality field Develop magnetic design that achieves low field errors

R&D Completed

Verify design by building and testing prototypes R&D Completed

Scale design to longer structures SCU0 – SCU2 Completed for SCU0

Build a high-quality horizontal measurement system

SCU0 Completed

Cooling of superconducting coils in presence of beam heat load

Estimate heat load from beam R&D – SCU0 Completed

Develop cooling scheme that minimizes heat load on superconducting coils

SCU0 Completed

Verify the design in a test device – stand alone test

SCU0 Completed

Check test device performance in the ring SCU0 Installation into the SR is scheduled for January 2013

SCU0 goal: Verify design concept by building and testing in the beam a full-scale device.

SCU Design – Conceptual Points


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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

SCU Design – Conceptual Points (2)


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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

SCU Design – Cryostat Structure


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SCU design concept is implemented in the SCU0 design

LHe vessel

SC magnetHe fill/vent turret

20 K radiation shield

60 K radiation shield

Beam chamber

Beam chamberthermal 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.

SCU0 Manufacture - Magnet


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• 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

SCU0 Manufacture - Cryostat


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• 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

SCU0 Assembly


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• 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

SCU Horizontal Measurement System


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• 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 By and Bx 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 CoilStretched wire rectangular, delta and ‘figure-8’ coils to determine static and dynamic 1st and 2nd 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

SCU Control System


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• 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

SCU0 Cold Test – Cryogenic Performance: Cool down


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• 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 1st stage providing shield cooling and the 2nd stage cooling the liquid helium reservoir and superconducting magnet.

SCU0 Cold Test – Cryogenic Performance: Steady state operation


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• 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

Component Observed temperature, K

60-K shield 32-33

20-K shield 8

Beam chamber 8-11

LHe circuit 4.2

SCU0 Cold Test – Cryogenic Performance: Helium circuit operation


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• 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.

SCU0 Cold Test – Cryogenic Performance:Heat load tests


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• 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, W 0 10 20 45

Main coil current, A 500 500 500 500

Beam chamber temperature, K

10.6 13.5 16.3 30.0

LHe tank temperature, K

4.29 4.30 4.30 4.44

SCU0 Cold Test – Magnetic Field Performance


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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 1st field integrals typically change less than

30 G-cm from 100 to 600 A for both fixed currents and dynamic changes in current.

The 2nd field integrals change by less than 8000 G-cm2 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 By field with main coil current of 500 A and correction current of 51.7 A

More details are in the presentation by Chuck Doose

SCU0 Cold Test Results Summary


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• 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

SCU0 – Status and Next Steps


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• 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

SCU ES&H


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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

SCU Risks / CEDU Contingency

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Most of the risks in the SCU design and operability in the ring are mitigated by building and testing the first undulator – SCU0.

Specific Risk Mitigation

Excessive beam heat load Beam 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 integrals Two correction coils are implemented in each half-magnet core; additional beam correctors might be employed.

Large phase error Tight 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.

WBS U1.03.04.03 SCU BOE Contingency


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SCU Cost Summary Chart

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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.

k$

Labor Nonlabor TOTALU1 03.04 - Super Conducting Undulators 1,307 1,770 444 420 3,942

03.04.03.01 - SCU1 - 1.8-CM Period 144-pole 1-M Magnetic Structure in 2-M Cryostat 828 478 94 235 1,635 03.04.03.01 - ACWP 135 - - 32 167 03.04.03.01.01 - SCU0 Cryomodule Modification - SCU1 312 51 23 83 468 03.04.03.01.02 - Magnets - SCU1 152 346 37 53 588 03.04.03.01.03 - Measurement System Modifications - SCU1 65 26 9 19 119 03.04.03.01.04 - Area Preparation - SCU1 61 51 11 18 140 03.04.03.01.05 - Integration & Installation - SCU1 104 4 15 30 152

03.04.03.02 - SCU2 - 1.8-CM Period 2-M Magnetic Structure in 3-M Cryostat 479 1,292 350 186 2,307 03.04.03.02 - ACWP 5 - - 1 6 03.04.03.02.01 - Engineering Development Unit - SCU2 230 172 59 69 530 03.04.03.02.02 - Cryomodule - SCU2 88 739 175 55 1,057 03.04.03.02.03 - Magnets - SCU2 5 265 56 11 337 03.04.03.02.04 - Power Supplies & Controls & Cabling - SCU2 30 50 18 11 109 03.04.03.02.05 - Area Preparation - SCU2 26 62 19 10 117 03.04.03.02.06 - Integration & Installation - SCU2 94 4 24 29 151

WBS

DIRECT (k$) ESCALATION ($k)

DIV OH + ANL G&A

($k)

WBS U1.03.04.03 SCU Cost Summary by FY

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WBS U1.03.04.03 SCU Summary Schedule

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Previous Reviews Responses


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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)

Work between CD-2 and CD-3

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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.

Summary

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• 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!

Documents

Superconducting Undulators WBS: APS-U1.03.04.03