Long Straight Sections WBS U1.03.02.01

Long Straight SectionsWBS U1.03.02.01

Leonard MorrisonLong Straight Sections Technical LeadAPS Engineering Support Division/Mechanical Engineering & Design Group

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

Outline

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

Scope of Work Staff / Org Chart Requirements Design Interfaces Risks Review Recommendations ES&H Cost Schedule

Science Case / Technical Motivation

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Goals for APS-U include higher brightness and capacity Provision of Long Straight Sections (LSS) meets this need

– Very long devices for flux-hungry experiments– Long devices in spite of canting– Optimized superconducting devices requiring space for

cryostat LSS also meets the need for short-pulse x-rays

– Provides room for SPX cavity cryostats– Reduces crowding out of insertion devices

M. BorlandAPS-U Directors ReviewMarch 15, 2011

Long Straight Sections Scope / Cost Summary

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Girder 5(Typical 3-sectors)

Girder 1(Typical 3-sectors)

3-m long SCU-2 Cryomodule

Revolver Undulator

Superconducting Undulator LSS Layout(Sector 1 only) Canting

Magnets

k$Labor Nonlabor TOTAL

U1 03.02 - Storage Ring Technical Components 457 688 146 161 1,452 03.02.01.01 - Long Straight Sections 457 688 146 161 1,452

ESCALATION ($k)

DIV OH + ANL G&A ($k)

WBSDIRECT (k$)

Long Straight Sections - Scope

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Design, Fabricate, Assemble, and Install:– Girders 5 and 1– Tapered transitions– Support structures– Vacuum systems

• Bellows• Valves• Drift Space Chambers• Place Holder Chambers

Insertion devices and SPX systems interface with the long straights in their respective sectors.

Design and testing of bellows, drift space chambers, and place holder chambers by these groups will be used in the long straight sections.

Long Straight Sections Scope – Cont’d


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Deliverables:– Reconfigured girders 5 and 1 assemblies– Long taper transition assemblies– 6.0” flanged all-metal gate valves with storage ring elliptical aperture– 4.63” flanged all-metal gate valves with 52.0 mm diameter aperture– 6.0” flanged bellows assemblies with storage ring elliptical aperture– 4.63” flanged bellows assemblies with 52.0 mm diameter aperture– SCU replacement vacuum chamber– SPX replacement vacuum chamber– Drift space vacuum chambers– SPX taper transitions – 52.0 mm diameter to storage ring ellipse– SCU taper transition – 7.2 mm x 53.0mm slot to storage ring ellipse

Girder 5

Girder 1SPX Cryomodule

Revolver Undulator

User Beam

Stored Beam

Short Pulse X-ray (SPX) LSS Layout(2-sectors)

BellowsLong Taper Transition Gate Valve

Long Straight Sections - Project Team

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Marion White - Associate Project Manager Leonard Morrison – Technical Lead Ralph Bechtold and Edward Theres – Installation (20+ yrs at the APS) Joseph Gagliano – Vacuum Chamber Welding and Storage Ring Vacuum

System (20+ years and over 300 chambers welded and certified) William Turner – Mechanical Designer Mechanical Designers and Technicians (average 15 yrs at the APS) Patric Den Hartog – Group Leader for Mechanical Engineering and Design

Marion White

Ralph Bechtold Edward Theres Joseph GaglianoLeonard Morrison William Turner

Long Straight Sections Requirements

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The existing storage ring Insertion Devices (ID) straight sections are designed for 4.8 m of undulators.

Magnets on adjacent girders will be reconfigured and their respective vacuum chambers and girder weldments modified.

This will create approximately 7.7 m of space for longer undulators or a combination of undulators and superconducting devices.

The technical requirements for the Long Straight Sections (LSS) are derived from the APS-U Long Straight Sections and Lattice Physics Requirements Document, APSU_1429111.

Sectors 1, 5, and 7 will be converted into long straights. Sector 1 will be populated with conventional and Superconducting

Undulators (SCU). Superconducting rf deflecting cavities and conventional undulators will be

installed in sectors 5 and 7.

Long Straight Sections Requirements – Cont’d


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Table 1 Summary of Magnets Lattice – (Z=0 at center of ID Straight)

First installation: Magnets and photon absorbers will be taken from our inventory of spares.

Future installations: Magnets and photon absorbers taken from those removed from previous installations.

Element Type – Name Z (m) Location

Quadrupole – S1B:Q3 -6.170 Girder 5

BPM - S1B:P2 -5.399 Girder 5 Vacuum Chamber

Sextupole – S1B:S1 -5.619 Girder 5

Quadrupole – S1B:Q2 -5.066 Girder 5

Corrector – S1B:H1 -4.489 Girder 5

BPM – S1B:P0 -3.594 Upstream-End ID Chamber

BPM – S2A:P0 3.697 Downstream Cryomodule

Corrector - S2A:H1 4.489 Girder 1

Quadrupole – S2A:Q2 5.066 Girder 1

BPM – S2A:P2 5.404 Girder 1 Vacuum Chamber

Sextupole – S1A:S1 5.619 Girder 1

Quadrupole – S2A:Q3 6.170 Girder 1

Long Straight Sections Requirements – Cont’d


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Transitions Parameter(for 8 mm aperture ID chamber)

Specification Condition

Upstream & Downstream Transitions ≥ 50 cm LSS with ID Chamber onlyAPS Extrusion to ID Chamber ≥ 50 cm LSS with SPX & ID ChamberID Chamber to SPX Chamber Transition ≥ 20 cm LSS with SPX & ID ChamberSPX Chamber to APS Extrusion ≥ 22 cm LSS with SPX & ID ChamberAPS Extrusion to ID Chamber ≥ 50 cm LSS with SCU & ID ChamberID Chamber to SCU Chamber ≥ 20 cm LSS with SCU & ID ChamberSCU Chamber to APS Extrusion ≥ 50 cm LSS with SCU & ID Chamber

Table 2 Summary of Vacuum Transitions Parameters

APS Extrusion ID Chamber

53.2cm taper transition

User Beam

Stored Beam

APS Extrusion to ID Chamber

SCU ChamberID Chamber

51 cm taper transition

SCU Chamber to APS Extrusion

Existing Girder 5 Configuration

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BQ3 BQ1BQ2BS1BH1/BV1BH2/BV2

Stored Beam BQ3/BQ1 – 0.5 m Quadrupoles

BS1 – Sextupole

BQ2 – 0.8 m Quadrupole

BH2/BV2 – Horizontal/Vertical Corrector

BH1/BV1 – Horizontal/Vertical Corrector

BP2 BP1 EA5

User Beam

BP1 & BP2 – Beam Position Monitors

EA5 – Photon Absorber

Existing Girder 5 Vacuum Chamber

Existing Girder 5 Support Weldment

Reconfigured Girder 5


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Magnets Reconfiguration

1.Replace 0.8 m quad with 0.5 m quad (BQ2 w/ BQ1)

2.Eliminate corrector magnet (BH1/BV1).

3.Move corrector magnet BH2/BV2 upstream.

LSS Girder 5 Vacuum Chamber

LSS Girder 5 Support WeldmentBP2 EA5

User Beam Vacuum Chamber Modification

1.Eliminate beam position monitor BP1

2.Move photon absorber EA5, upstream.

3. Change vacuum chamber length from 3.64m to 2.65 m

Girder 5 Modification

1.Change girder length from 3.60 m to 2.62 m.

BQ3 BQ2BS1

BH2/BV2

Stored Beam

Existing Girder 1 Configuration


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Existing Girder 1 Vacuum Chamber

Existing Girder 1 Support Weldment

AQ1 AQ3AQ2 AS1

AH2/AV2AH1/AV1

Stored Beam AH1/AV1 – Horizontal/Vertical

Corrector

AQ1/AQ3 – 0.5 m Quadrupoles

AH2/AV2 – Horizontal/Vertical Corrector

AQ2 – 0.8 m Quadrupole

AS1 – Sextupole

AP1AP2 EA1

AP1 & AP2 – Beam Position Monitors

EA1 – Photon Absorber

Reconfigured Girder 1


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LSS Girder 1 Vacuum Chamber

LSS Girder 1 Support Weldment

AQ3AQ1 AS1AH2/AV2

Magnets Reconfiguration

1.Replace 0.8 m quad with 0.5 m quad (AQ2 w/ AQ1)

2.Eliminate corrector magnet (AH1/AV1).

3.Move remaining corrector magnet AH2/AV2 downstream.

AP2 EA1

Vacuum Chamber Modification

1.Eliminate beam position monitor AP1

2.Change vacuum chamber length from 3.76 m to 2.0 m

Girder1 Modification

1.Change girder length from 3.71 m to 2.40 m

Documents in Process


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LSS ESD Draft – APS-U Long Straight Sections # APSU-1.03.02.01-ESD-000 on APSU SharePoint.

Drawings: – U132010102-101111 – U132010102-101121– U132010102-101100 (2 sheets)– U132010102-101101 (4 sheets)– U132010102-101102– U132010102-101107– U132010102-101108– U132010102-101000– Sector 1 SCU Long Straight Section Layout – Sectors 5 SPX Long Straight Section Layout– Sectors 7 SPX Long Straight Section Layout

Interfaces

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LSS for the SCU will be installed at sector 1. The scope for the SCU and conventional undulators is covered under WBS #U1.03.04, and includes design, fabrication, testing, and installation.

LSS for the SPX will be installed at sectors 5 and 7. The scope for the SPX systems is covered under WBS #U1.03.03, and includes design, fabrication, testing, and installation.

At the preliminary design level of the LSS for both of these systems, the vacuum and mechanical interfaces have been identified.

Weekly integration meetings involving the LSS, SPX, and SCU Groups are ongoing.

The LSS Interface Control Document will describe the mechanical and vacuum interfaces with the SCU and SPX systems.

Interfaces with the existing storage ring vacuum system and other systems such as water, power, diagnostics, and controls will also be included.

Long Straight Sections Risks

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If there is a failure with the SPX cavities or SCU and it becomes necessary for them to be removed them from the ring

– Place holder chambers, purchased by the project, will be available for installation.

– These chambers will already have been tested and proven for operations during the SPX-0 and SCU-0 R&D storage ring tests.

Once the girders are taken out and the space is reconfigured for the new equipment to be installed, it will be difficult to re-install the old devices if components do not come together as designed. Location of existing devices such as girders 4 and 2, that are adjacent to the long straight sections will be mapped and included in the LSS layouts to minimize the risks that components being installed will not fit the space provided.

Review Recommendations

Preliminary design internal review was held on October 30, 2012Some of the recommendations already addressed are:Every reasonable effort should be made to maximize the space available for insertion devices since this is the ultimate driver for the effort.

– Reviewed the vacuum chamber designs and shortened girder 1 vacuum chamber an additional 30 cm. Currently working with welding experts on fabrications methods that might allow us to further shorten girder 5 vacuum chamber.

The referenced AQ1 and BQ1 magnet locations are not be correct due to recent modifications. The LSS designs should reference the latest girder configurations.

– Corrected magnets configuration showing AQ1 and BQ1 in correct locations.

Other recommendations are being addressed.


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Long Straight Sections 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

Identify General Safeguards and Security Requirements– There are no special materials or project specific security requirements– APS-U Project is required to follow Argonne’s Operations Security Program

(OPSEC) Master Plan


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Long Straight Sections ES&H – cont’d

For the installation of the long straight sections, electrical and mechanical hazards have been considered. Personnel working in these areas will have completed the necessary training.

Health Physics will survey all girder assemblies and other devices before they are removed from the tunnel.

Procedures that were used during the APS construction and are used during current shutdown/maintenance periods that are applicable to this installation will be used.

In addition to the application of Integrated Safety Management (ISM), the Laboratory-wide Argonne Procedures, LMS-PROC-64 (Non-Experimental Work Planning and Control), LMS-PROC-65 (Non-Experimental Skill-of-the Worker), and LMS-PROC-152 (Blind Penetration of Floors, Walls, Ceilings, and Exterior Foundations), there will be a written installation procedure that addresses safety concerns.

Long Straight Sections Cost Summary

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Girder 1 Vacuum/Mechanical Components _ Non-labor $442K for 3 sectors– Sector 1 Girder 1 Vacuum/Mechanical Component - $152,578.61– Sector 5 Girder 1 Vacuum/Mechanical Component - $134,799.76– Sector 7 Girder 1 Vacuum/Mechanical Component - $134,799.76 Total: $422,178.13

k$

Labor Nonlabor TOTALU1 03.02 - Storage Ring Technical Components 457 688 146 161 1,452

03.02.01.01 - Long Straight Sections 457 688 146 161 1,452 03.02.01.01 - ACWP 55 - - 14 69 03.02.01.01.01 - Girder 1 Vacuum/Mechanical Components 245 442 77 81 846 03.02.01.01.02 - Girder 5 Vacuum/Mechanical Components 32 227 40 19 317 03.02.01.01.04 - Integration & Installation - LSS 125 19 29 47 220

WBS

ESCALATION ($k)

DIV OH + ANL G&A

($k)

DIRECT (k$)

Long Straight Sections Cost Summary – Cont’d


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Sector 1 – Girder 1 Vacuum Chamber Assembly & Supports Ready for Installation - $56,368.27– Vacuum System (bellows, replacement chambers, taper transitions, valves) - $70,650.34– Locating Cart (one-time purchase for installation at all 3 sectors) - $25,560.00– Total: $152,578.61

Sector 5– Girder 1 Vacuum Chamber Assembly & Supports Ready for Installation - $50,963.68– Vacuum System (bellows, replacement chambers, taper transitions, valves) - $83,836.08– Total: $134,799.76

Sector 7– Girder 1 Vacuum Chamber Assembly & Supports Ready for Installation - $50,963.68– Vacuum System (bellows, replacement chambers, taper transitions, valves) - $83,836.08– Total: $134,799.76

Long Straight Sections Cost Summary Chart by FY

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Long Straight Sections Schedule Summary

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WBS Start Finish

Long Straight Sections (3)06-Feb-12 A 17-May-18

Preliminary Design 06-Feb-12 A 25-Sep-12

Final Design 01-Oct-13 31-Mar-14

Procurement 01-Oct-13 22-Sep-17

Assembly/Test 02-Oct-14 11-Jan-18

Installation/Test 11-Dec-15 17-May-18

FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4FY2012 FY2013 FY2014 FY2015 FY2016 FY2017 FY2018 FY2019 FY2020WBS Start Finish





















FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4 FQ1 FQ2 FQ3 FQ4FY2012 FY2013 FY2014 FY2015 FY2016 FY2017 FY2018 FY2019 FY2020

Long Straight Sections BOE Contingency


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Work between CD-2 and CD-3

Start the final design for the Long Straight Sections Start writing Interface Control Documents for the LSS Continue to review and update Engineering Specifications

Document for the LSS Internal Review for the LSS final design

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Summary

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Magnets reconfiguration on girders 5 and 1 are done according the APS-U Long Straight Sections and Lattice Physics Requirements Document.

Tapered transitions for both SCU and SPX LSS meet the minimum LSS PRD specifications.

Layout drawings for the SCU and SPX sectors are complete to the preliminary design phase.

Modifications to the respective girders vacuum chambers and girder supports are done to suit the magnets lattice reconfiguration.

Preliminary drawings of girder and vacuum chamber components are being processed.

The cost is $1,452k We are ready for CD2
