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Technology Department

Frédérick Bordry

8th June 2009

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The Technology Department is responsible for technologies which are specific to existing particle accelerators, facilities and future projects.

The main domains of activities cover: magnets (superconducting, normal conducting, fast pulsed magnets, electrostatic and magnetic septa), their machine integration and protection, power converters, cryogenics, high & ultra-high vacuum systems, coatings and surface treatments.

The Technology Department provides support to the experimental detectors, mainly for cryogenics, vacuum, coatings, surface treatments and power converters.

The dominating part of the activities for the next few years is the operation of the LHC (LHC ring and injectors) and its upgrades (LHC injector consolidation, Linac 4, SLHC phase 1).

The Technology Department is responsible to design equipments, systems and studies where necessary for consolidations, upgrades (SPL, PS2, SLHC phase 2,…) and future CERN projects (CLIC,…)

Technology Department Mandate

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TE-ABT mandate : Accelerator Beam Transfer

The group is in charge of the design, development, construction, installation, exploitation and maintenance of injection and extraction related equipment:

• fast pulsed magnets with associated high voltage pulse generators and transmission lines; • electrostatic and magnetic septa, including high voltage power supplies for electrostatic septa; • extraction related protection devices;• associated equipment-level control systems (hard- and software).

The group is responsible for injection and extraction systems in the entire accelerator complex and for beam transfer lines between accelerators and primary beam lines up to targets, including the full commissioning of the LHC injection and beam dumping systems and their potential upgrade. This responsibility comprises the conception, layout and optics design, equipment specification, technical coordination, commissioning, performance follow-up and beam physics of underlying processes.

51 staff

TE-ABT: Fast pulsed systems (“kickers”)

LHC injection kickers

• very short pulses (from O(100 ns): strip-line kickers … Ferrite cores … up to >100 μs: steel tapes)• high voltage (up to 80 kV), high current (up to 30 kA)• high voltage assemblies and circuitry (switches (gas tubes or semiconductor), cables, connectors)• ultra high vacuum (down to 10-11 mbar), precision mechanics, brazing/welding techniques, various metals, surface coating, ceramic insulators and capacitors (in vacuum)• oil and gas systems for insulation and cooling• simulation and measurements of electric/magnetic fields, pulse forms, beam impedance

GTO basedHV switch

many different shapes/sizes

5 m long L-C network

TE-ABT: Electrostatic and magnetic septa

septum magnet

positioning system

vacuum tank

HV deflector

beam screen thin foil (or wires)

HV electrode

insulatorsfoil tensioners

• high voltage (up to 300 kV) electrostatic devices and accessories (cables, switches, resistors, …)• pulsed (ms to s), high current (up to 40 kA, 100 A/mm2), thin water-cooled septum coils• ultra high vacuum (down to 10-12 mbar), precision mechanics, precision positioning systems, brazing/welding techniques, various metals, surface coating, ceramic insulators• electromagnetic field calculations, mechanical stress analyses, thermal/cooling considerations

typically high radiation levels

many different shapes/sizes

Methodology• Design, construction, operation & maintenance of cryogenic systems for accelerators and detectors» Design, construction, commissioning, operation and

maintenance of the cryogenic systems for CERN accelerators and detectors

» Operation, maintenance and upgrade of cryogenic test facilities

» Support for low-temperature developments & tests at the Central Cryogenic Laboratory

» Supply of cryogenic fluids on the CERN site » Consultancy & support in cryogenic design & cryogenic

instrumentation.

TE-CRG Mandate : Cryogenics 65 staff

Helium Refrigerators

1.8 K refrigeration units(up to 2.4 kW @ 1.8 K)

4.5 K Refrigerators(up to18 kW @ 4.5 K)

Cryogen Storage and distribution

GHe storage LN2 storage

Cryo-magnet Distribution line (QRL) Interconnection box

Vert

ical tr

an

sfer

line

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TE-EPC (Electrical Power Converters) group is responsible for design, procurement or construction, installation, commissioning, operation and maintenance of all:

Electrical Power Converters and static VAR compensators for the present and future accelerators, including experimental areas at CERN.

TE-EPC Mandate

66 staff

[2kA, 8V]

Soft-switching modular power converters

1-quadrant converters:- [13kA,18V] : 5*[3.25kA,18V]- [8kA,8V] : 5*[2kA,8V]- [6kA,8V] : 4*[2kA,8V]- [4kA,8V] : 3*[2kA,8V]

2009-2010: Last year(s) of operation for the PS rotating machine!

Fully static power converter Exchange of energy between capacitor banks and the magnets

First power test: Dec. 2009

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New PS 60 MW power system

PULSETRANSFORMER

(OIL TANK)

Main solid stateswitches

A1

C

KF

1:10

Ca

pa

cit

or

ba

nk

ch

arg

er

po

we

r c

on

ve

rte

r, P

S1

Anode powerconverter, PS3

A - Anode;C - Collector;K - Cathode;F - Filament

Filament powerconverter, PS4

Vout

Droop compensation powerconverter or “bouncer”, PS2

0.1mF

Capacitordischarge

system

VPS1

VPS2

12 kV max

-12

0 k

Vm

ax

KLYSTRON(OIL TANK)

DC

Hign FrequencyISOLATION

TRANSFORMER

DC

K1

PS1, PS3, PS4 - CommercialPS2 - CERN made

120 kV High voltage cables

120 kV High voltage connectors

DIODERECTIFIER

A

DRIVER DRIVER

Pulsed Klystron modulators for LINAC’s (ex. Linac 4)

• Characteristics :- output voltage : 100 kV- output current : 20 A- pulse length : 700 s- flat top stability : better than 1%- 2 Hz repetition rate

Load Voltage

-20

0

20

40

60

80

100

120

0.E+00 2.E-04 4.E-04 6.E-04 8.E-04 1.E-03 1.E-03

time (s)

Vk

(k

V)

Load Current

-5

0

5

10

15

20

25

0.E+00 2.E-04 4.E-04 6.E-04 8.E-04 1.E-03 1.E-03

time (s)

Vk

(k

V) 700 µs

Beam passage

Peak power : 2 MW

- Total of SVC’s / filter inst.: 12- Rated voltage: 18 kV- Total surface: 14’000 m2

- Total value (prices 2007): 45 MCHF

- Total capacitive power: 550 Mvar (=17.6 kA @ 18 kV)

- For comparison:

CERN consumption 2008: 380 MVA peak

(=12.2 kA peak @ 18 kV)

SVC’s and harmonic filters at CERN (status 2009)

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• Design, construction and measurements of Superconducting and Normal conducting Magnets for the CERN accelerator complex.

• Design and construction of cryostats for magnets, SCRF cryomodules and other accelerator equipments.

• Support to operation of the accelerators for magnets, current leads, operation of the magnet and cryostat facilities.

• Development of associated technologies, namely superconductors, insulation and polymers, superconducting electrical devices and magnetic measurements for present and future accelerators.

TE- MSC Mandate: Magnets, Superconductors, Cryostats

94 staff

Superconductivity

T = 4.2 KLHC 400 tonnes of high quality NbTi (47%);Used in 1200 tonnes - 7000 km of Cu/NbTi cable; more than 20,000 measurements at 1.9 K

HTS applications

Present LHC application: Ag/Bi-2223Current : > 15 kA @ 50 KAssembly of short strips (< 50 cm)Rigid conductorSuperconductor expensive

New studies: LHC upgr. new application: MgB2Current : > 15 kA @ 20 KLength : > 60 mFlexible cableCheap SuperconductorFuture : development of >150 m cable 15 kA @ 60-80 K with Ybco

Electromagnetic and thermo-mechanical modeling

Magnet technology: high field in - so far – moderate size

Power test of magnets (1.9K – 13 kA)electronics and device for precise meas.

• Support LHC operation and maintain state-of-the art technology for magnet circuit protection and interlock systems for the present and future accelerators, magnet test facilities and CERN hosted experiments.– Responsibility for the electrical integrity of magnet circuits. – Coordination of the commissioning of the LHC magnet system (“Hardware Commissioning”) and magnet

circuit performance evaluation.– Coordination of the LHC machine protection systems and responsibility for its coherence and overall

performance. – Specific studies related to machine protection for topics that go across different systems.– Responsibility for the functional operation of DFBs, DSLs and their auxiliary equipment. – Responsibility for the electrical quality assurance (ELQA) during magnet interconnections and hardware

commissioning as well as for electrical diagnostics and interventions during operation.

– Responsibility for the magnet protection system and machine interlocks for the CERN accelerator complex, including design, construction and exploitation.

– To guarantee permanence of expertise, follow the state-of-the-art and to develop knowledge for design, construction and operation of failsafe and reliable electronics.

TE- MPE Mandate

Machine Protection and Electrical integrity27 staff

High current, radiation tolerant cold by-pass diodes for LHC main magnets.

High reliability cost effective 600 A energy extraction system.

Compact assembly of 13 kA circuit breakers and dump resistors capable of dissipating 700 MJ.

Electrical systems

Magnet

Power Converter

(Magnet +1)

Status info

Thermo-switches Water Flow meter,Red button…

Thermo-switches

@ 60°C

Power Permit

Warm magnet Interlock Controller

Beam Permit BIS interface

Technical network

Controls Config. DB

PVSS Operator Console

Warm Magnet Interlock system Protects resistive magnets overheating:collects inputs from thermo-switches, flow meters,…and gives the Power Permit,.

In addition: removes beam permit in case of powering failure.

Based on Safety PLC (F series from Siemens)

for fast dump request (few μS):

associated with

Fast Boolean processor

(FM 352 from Siemens)

Beam InterlocksProtects LHC from beam Operation: collects User Permit frominvolved systems (VAC, BLM, RF, Powering Interlocks, Experiments, etc… )

and therefore gives the Beam Permit, or triggers beam dump in case of failure.

Highly reliable (SIL3), Fast (few μS) and “monitorable”

User Interfaces

UserPermit

Beam Interlock Controllerembedded in VME chassis

copper cableUser System #1

Up to 14 User Systems

Beam Permit Loops (F.O.)

Technical network

Controls Config. DB

Operator Console(Java Application) Fibre Optics links between Controllers

~200 connections to User Systems

<< Home made design >> in using Programmable Logic devices from Xilinx: from “small” 288 macro-cells CPLD for the safety part to large* Spartan 3 FPGA for the monitoring part

(*) say 1,000,000 gates + all the built in RAM ,etc.

Optical board

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TE- VSC Mandate: Vacuum, Surfaces & Coatings

Design, construction, operation, maintenance and upgrade of high & ultra-high vacuum systems for Accelerators and Detectors.• Expertise and support on thin-walled vacuum chambers, windows and

bellows compensation systems• Expertise in vacuum sealing and leak-tightness technology• Management of the industrial support contract for vacuum work in

accelerators• Expertise in vacuum control systems, vacuum interlocks and monitoring tools

Surfaces treatments, Coatings, surface and chemical analysis for Accelerators & Detectors. Expertise and support in the fields of:• Coatings, electroplating and surface cleaning techniques• UHV characterization and of material and surfaces• Degassing analysis and treatments

67 staff

Domains of ExpertiseVacuum Engineering for Accelerators

• Vacuum Engineering for Accelerators– Finite element calculations for thin-walled and cantilever structures in

Experimental Areas– Vacuum interconnection design optimized for High Order Modes (HOM) and

beam impedance for RT and cryogenic beam pipes– Advanced material for Detector’s beam pipes– Special supporting structures for Detectors (wires, low-Z supports, etc.)– Design of vacuum systems to prevent beam-induced high voltage breakdowns:

flanges, surface treatments and coatings

Domains of Expertise Coatings and Plasma Processing

• CERN-wide support and expertise to accelerators and detectors in the domain of thin film coatings– Thin film coating facilities with a special focus on physical deposition techniques:

evaporation, diode and magnetron sputtering• Complex shape and all types of materials including a-C and NEG coatings

– Specific techniques for plasma processing of surfaces, including plasma cleaning and glow discharge

• Removal of hydrocarbon contamination on Beryllium beam pipes using an oxygen discharge

– Expertise for numerical simulations of special cases of coatings, vacuum and plasmas

TPB deposition for WArP

Gold deposition for CAST

Domains of Expertise Chemical and Surface Analysis

• CERN-wide support and expertise to accelerators and detectors in the domains of:– Surface and chemical analysis– Expertise in radiation damage of polymeric materials– Outgassing analysis (metals and polymers) and degassing treatments– Permeation in polymers and metals– Gas analysis by chromatographic techniques

Outgassing of amorphous carbon films

Surface analysis: XPS-SIMS-AES

Radiation induced ageing

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Conclusion

TE-ABT: Electronics + controls (for kickers, septa, protection eqpt)

fast kicker timing and interlocks

application program for machine operators

“beam energy meter” card

• high precision fast pulsed timing, high-reliability triggering systems• analogue waveform acquisition and analysis, servo positioning systems, industrial slow controls• power electronics, power supplies for HV charging purposes, thyratron heating, electrostatic septa• equipment-level software, diagnostic tools, interface to main control system, spec. application SW

software for kicker waveform surveillance

energy tracking system for LHC dump

Cold turbo-machines

Cold Compressorsand Pumps

Turbo-expanders

Iref(RB_5TeV) = Iref(RQF_5TeV) = Iref(RQD_5TeV)

Global PM Event

Global PM Event

LHC tracking : Ramp of RB, QF, QD (RB function is copied to QF and QD)

High precision measurement system for large scale online diagnostics and protection of electrical interconnections.

Digital FPGA based radiation tolerant protection system for superconducting magnets.

Heater firing circuitsCB

L77 L78 L79 R79 L153 L15475 mΩ

PC

FWDCB

75 m ΩI

L1 L2 L76

Heater firing circuits

Design of protection systems for large superconducting magnet circuits.

Simplified scheme with individual by-pass diodes for one LHC-Sector.

Digital and analog electronics, design of protection systems

SVC BEQ2 (2002) for SPS

Insulation for cryogenic environment

Development of insulation very fine and capable of 20 kV with strong mechanical robustness;Covered 50 km of LHC cold bore tube

HV Tests on cylindrical geometriesIn addition to standard HV tests (DC and impulse test up to 140 kV) on materials and components, we perform HV tests on cylindrical geometries, as insulated tubes, with specifically designed electrodes.Used for testing the dielectric strength of ITER feeders and as a CERN wide service for example for HV testing ceramic coatings .

Development of new insulation with enhanced porosity for LHC upgrade

SMI2 180

SMA18

SM18

Pit in 181 bldg : prepared for MQ (vertical line)

MQs in 904, waiting to be repaired

Magnet Rescue

Dipoles from 3-4 in bldg 181

Normal Conducting Magnets : LINAC 4 projectType Installation Number

LE Solenoid LEBT 2

LE Corrector LEBT/MEBT 4

Quadrupole Linac 36

Corrector Linac / TL 14 + 5

TL Quadrupole TL 18

TL Bending (V + H) TL 4

BI Bending (V) Booster Inj. 1

LBS Bending Spectrometer Line 1

Transfer Line QuadrupoleCombined Corrector

In total 95 magnets of 8 types•Magnet work package defined•Design work started•First contracts beginning 2009

SSS: integrates key items

Vacuum barrier

Magnet helium

enclosure

LHC SHORT STRAI GHT SECTI ON

(technical service module side)

I nstrumentation connections outlet

Diode

Beam tubes

He phase separator

Thermal shield

Connection to cryogenic

distribution line

Cryogenic tubes &

pressure gauge connection

Vacuum vessel

• BPM and instrumentation feed-throughs• Resistive current leads for orbit corrector dipoles• Link to cryo distribution line• Cryogenic ancillaries and diagnostics (He phase separator, He level gauges, P transducers, ... ) • Vacuum Barriers• ...

SSS: complex in variants and assembly

Vaccum vessel components

Thermal shield components

Cold mass components

Jumper lines

Jumper elbowVacuum barrier

QQS Vac. Vessel

C' line

DCF

Bottom tray

Phase separator

Testing circuit

IFS

IFS cover flange

Connection tube

Line N

Vac. Vessel

Cold mass

Jumper thermal shield

QQS thermal shield

Standard section thermal shield

(main components only)

No.units

CM variants SSS variants

Arcs 360 40 61

DS 64 20 34

MS 50 27 41

Total 474 87 136

LHC, the push for energy: a gigantic magnet system

1500 tonnes of top quality SC cables

Bdip 8.3 T Rdip 3 kmLdip 15 m 1232Ltunnel = 27 km

15’000 MJ of magnetic energy

Type Number Function

MB 1232 Main dipolesMQ 392 Arc quadrupolesMBX/MBR 16 Separation & recombination dipolesMSCB 376 Combined chromaticity & closed orbit correctorsMCS 2464 Sextupole correctors for persistent currents at injectionMCDO 1232 Octupole/decapole correctors for persistent currents at

injectionMO 336 Landau damping octupolesMQT/MQTL 248 Tuning quadrupolesMCB 190 Orbit correction dipolesMQM 86 Dispersion suppressor & matching section quadrupolesMQY 24 Enlarged-aperture quadrupoles in insertionsMQX 32 Low-beta insertion quadrupoles

Domains of Expertise Vacuum Controls and Interlocks

• Vacuum Controls and Interlocks for Accelerators– Design and implementation of PLC based front-end electronics for pressure

and temperature acquisition and machine protection interlocks– Design and implementation of database (ORACLE) driven PVSS vacuum

supervision interfaces for accelerators– Validation of the vacuum electronic equipment installed in the accelerator

tunnel, which will be subjected to neutron, fast-particle and gamma radiation

Multiple beam shots

Hydrogen oscillation