October 30, 2007Undulator Breakout

1 Dean R. Walters

drw@aps.anl.gov

Undulator Vacuum System Vacuum System

Geoff Pile, Dean R. Walters, Soon-Hong Lee, James Bailey, James Morgan, Dana Capatina, Scott Doran, ANL

October 30, 2007Undulator Breakout

2 Dean R. Walters

drw@aps.anl.gov

Undulator Vacuum Chamber SupportStatusProduction Schedule

Bellows ModuleTesting: Combined Offset test and Surface MeasurementProduction Plan

Quadrupole SpoolDesignProduction Schedule

Long Break SpoolsStandard Spool DesignSpools with Sector ValveProduction Plan

Beam Finder WireStatus of ProductionModification to ChamberProduction Schedule

All Metal Chain Clamp Vacuum SealTesting Results

Undulator Vacuum System Vacuum System

October 30, 2007Undulator Breakout

3 Dean R. Walters

drw@aps.anl.gov

Undulator System LatticeL14-200000

SA-381-003-01

Undulator CELLL14-501000

SA-381-003-03

Girder AssemblyL143-010000

SA-381-003-04

Support Mover SystemL14-401000

SA-381-006-24

Girder WeldmentL1430401-100396

SA-381-002-76

Pedestal AssemblyL1430802-200000

SA-381-010-50

Girder WeldmentL1430401-100396

SA-381-002-76

UndulatorL143-112000

SA-381-001-35

BFW AssemblyL14506-110000SA-381-007-96

Quad AssemblyL1430501-100394

SA-381-012-74

RFBPM AssemblyL1450503-100000

SA-381-008-70

Vacuum ChamberL1440202-200000

SA-381-0XX-XX

WPM-WLSL-

MO-381-901-13

Control AssemblyL142-100060

SA-381-011-28

BFW SupportL14506-112000SA-381-013-25

Quad SpoolL14405-117000SA-381-013-97

RFBPM SupportL14505-104000SA-381-014-39

RFBPM ReceiverL1450501-310000

SA-381-011-80

Bellows ModuleL14403-110000SA-381-0XX-XX

Ion PumpL14405-104000SA-381-013-40

Long BreakVacuum Spool

L14406-111000SA-381-014-70

Long Break IsoVacuum Spool

L14406-112000SA-381-014-81

Long Break Diag.Vacuum Spool

L14406-116000SA-381-0XX-XX

October 30, 2007Undulator Breakout

4 Dean R. Walters

drw@aps.anl.gov

Sub-Assemblies in the Undulator Vacuum System

Beam Finder Wire

Ion Pump

RF Beam Position Monitor

Quadrupole Magnet

RF BPM Waveguide

Vacuum Chamber and Support

Wire Position Monitor

RF BPM Electronics

Bellows Module

Girder

Undulator Magnet

October 30, 2007Undulator Breakout

5 Dean R. Walters

drw@aps.anl.gov

Tubing Support Structure Production Status

Awarded to Walco Tool & Engineering (July, 2007).Tubing material was changed to Aluminum 6061-T6 from Steel due to a magnetic material risk. (August, 2007)Raw material was ordered in Sept. 2007 and was arrived at the vendor. (Oct. 18, 2007)A first article is being fabricated to reduce the risk. After rough machining, the tubing will be vibration stress relieved.Two weeks lead-time from the painter.One week for final machining and assembly.

October 30, 2007Undulator Breakout

6 Dean R. Walters

drw@aps.anl.gov

Production ScheduleFirst Article Inspection

Support tubing will be inspected before starting the machining of remaining 36 assemblies.Expect in the week of November 19th, 2007.Within 2 weeks after inspection, APS will allow the vendor to cut the remaining materials.

Production completionLead time: 8 weeks after the first article inspection.First Unit complete 12/10/2007Completion of remaining 36 assemblies: Week of Feb 4th, ’08.Will be directly sent to SLAC from the vendor.

Shipping CarriersCo-worked with Pak-Rite Ltd. to design

the “Sure-Lok” shipping carrier.10 carriers were delivered to Walco (Sept. 07)

October 30, 2007Undulator Breakout

7 Dean R. Walters

drw@aps.anl.gov

Bellows Module Design

Travel length Lateral offset Bellows length Angular

Extended +6.5 mm 5.08 mm 1.69 inch

Installed 0 mm 3.56 mm 1.43 inch

Compressed - 6.5 mm 2.03 mm 1.17 inch 35 without flange ends

Outer bellows assemblyEVAC flange with copper gasket and chain clampsRemovable tie rods for restraints to prevent damagesTravel Distance of a welded bellows (200-125-3-EE)

Internal pipe assembly Inner pipe assembly with ID 10 mm x OD 12 mm x ~ 68 mm long pipe/tubeNo finger assembly for electric conductivityGap in the Bellows will be of 7.8 mm +/- 6.5 mmPipe axis in the Bellows will be aligned to the Undulator within +/-100 m.

October 30, 2007Undulator Breakout

8 Dean R. Walters

drw@aps.anl.gov

Surface finish measurement - Internal pipe ID 10 mm pipes were honed for 2, 4, and 8 -inch Ra finish.Roughness data after 2nd degree LMS fitting (polynomial data fitting line to line) show that either 2 -inch Ra or 4 -inch Ra honing process works fine. RMS slope analysis shows that 2 -inch Ra is preferred and that 4 -inch Ra is marginal.

Sample 2Ra Sample 4Ra Sample 8Ra

Samples

October 30, 2007Undulator Breakout

9 Dean R. Walters

drw@aps.anl.gov

Bellows Tests and Results Original Tests (DCN 14403-0001).

Focused on internal sliding parts (RF and Spring Fingers).±2 mm X-Y offset with 0.5°angular offset x 2000 cycles.Tests were completed. Internal parts met specification.

Sliding internal parts no longer used. New tests focused on maximum possible rotational and X-Y offset.

Flange rotation of ±~ 0.8° is possible with < 75 in-lb of torque. 2000 cycles were run. Leak check showed no leaks.X-Y offset of ±10 mm is possible with ~ 10 lb of force. 2000 cycles were run. Leak check showed no leaks.

Further motion analysis showed rotational and X-Y offset may be simultaneously possible, but very unlikely.

Flange rotation of ~ 0.8° plus X-Y offset of ±9 mm is possible without permanently deforming the bellows. 50 cycles were run. Leak check showed no leaks.

October 30, 2007Undulator Breakout

10 Dean R. Walters

drw@aps.anl.gov

Production StatusOuter bellows assembly

Edge-welded Bellows were received from Standard Bellows Company.Welded flange (flange + adapter)

EVAC flange and its hardware were received from EVAC Inc.Weld shrinkage of the flange sealing diameter must be compensated.Drawings and SOW for production are complete.Lead time 6 weeks for the 1st articles (2 ea), 8 weeks for the remaining balance.

Flange with weld-neckExpect less shrinkage, but flange delivery for production will take 7 weeks ARO.4 custom-flanges with weld-neck will be weld tested.

Internal pipe assembly Drawings and SOW for production are complete.Internal surface finishing process is being tested.

Honing process was done. (honing oil - Perkins 284) Vacuum cleaning-baking-RGA process is on progress.

Lead time 3 weeks for the 1st articles (2 ea), then 3 weeks for the remaining balance.Production Schedule

First Articles complete on 1/31/200835 completed units on 3/25/2008

Weld Bead

October 30, 2007Undulator Breakout

11 Dean R. Walters

drw@aps.anl.gov

Short Break Sub-Assembly

BFWUndulator

Undulator

Beam

GirderGirder

RF BPMQuadrupole

Magnet

October 30, 2007Undulator Breakout

12 Dean R. Walters

drw@aps.anl.gov

Quadrupole Spool Design

October 30, 2007Undulator Breakout

13 Dean R. Walters

drw@aps.anl.gov

Quad Spool Redesign and Production Schedule

New Requirements from Short Break Test“Driveshaft” design with a small bellows on each end.±0.15° angular offset possible at each end.0.03” compression possible at both ends.“Driveshaft” design allows X-Y offset > allowable from Quad.

Production ScheduleDesign complete. All parts and fabrication on order. Small bellows delivery is driving the schedule. Bellows delivery scheduled for 11/7.Ship bellows and flanges for first three units on 11/10 to AES for laser welding and post welding electro-polish.Ship bellows to Alumiplate for interior aluminum plating.First three units are scheduled for completion on 12/1.If no design/QA problems are encountered, two additional production runs of 17 pieces each should be completed by 1/31.

October 30, 2007Undulator Breakout

14 Dean R. Walters

drw@aps.anl.gov

Long Break Subassembly

October 30, 2007Undulator Breakout

15 Dean R. Walters

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Long Break

October 30, 2007Undulator Breakout

16 Dean R. Walters

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Long Break SpoolWith Pump Down Valve

and Sector Valve

October 30, 2007Undulator Breakout

17 Dean R. Walters

drw@aps.anl.gov

BFW Assembly Mounted on Adjustable Support

Adjustable Mounting Support

Vacuum Pump Connector (2.75” Conflat Flange)

Card Position Monitor (Limit switches)

Air Supply Shut Off Valve

Pneumatic Solenoid Valve

Precision Screw

Electrical Connectors for Wire Signals

Vacuum Chamber Connection Flange

(NW-50 CeFix w/Clamp)

Beam Port

Pneumatic Cylinder

Alignment Fiducials

Frame

Compression Spring Positioner

Potentiometer

Housing

October 30, 2007Undulator Breakout

18 Dean R. Walters

drw@aps.anl.gov

StatusCatalog Items– Delivery CompleteMachined Parts– Delivery CompleteShaft Frame Weldment– First Article Delivered and Approved by ANLBFW Vacuum Chamber– Contract Awarded. Delivery of 1st Lot within 5 weeksStarted Assembly of First Article at ANLAssembly and Alignment Procedures— Completed DraftVacuum Test and Bake-out Procedures– Completed DraftIn Field Alignment Procedure– Conceptually PlannedDeliverables Drawing– Completed Draft

October 30, 2007Undulator Breakout

19 Dean R. Walters

drw@aps.anl.gov

Significant IssuesCurrently developing electrical interfaces with control groupNeed to develop pneumatic interfaceNeed to develop wire signal interfaceNeed to develop protection cover strategyComplete Assembly and Testing of the First ArticleModified beam tube to accommodate new BLM designModifed Ion Pump connection to allow space for BLM Wire Card Installation

Schedule for Completed BFW Assemblies w/ Supports to SLAC

Deliver 1st Lot (3) --- 12/12/07Deliver 2nd Lot (10) --- 1/14/08Deliver 3rd Lot (10) --- 2/11/08Deliver 4th Lot (14) --- 3/20/08

October 30, 2007Undulator Breakout

20 Dean R. Walters

drw@aps.anl.gov

All Metal Chain Clamp Vacuum Seal

October 30, 2007Undulator Breakout

21 Dean R. Walters

drw@aps.anl.gov

Short Break Test System System

1

2 3 4 5O-ring seal on hose to

leak detector

October 30, 2007Undulator Breakout

22 Dean R. Walters

drw@aps.anl.gov

Test ProcedureInitial tests (number #1-14) were conducted on individual seals to work out assembly technique.

Copper seals were used in tests #1-5Aluminum seals were used in tests #6-10

Step #1 installed gasket at 60 in-lbStep #2 Leak checkStep #3 increase torque 75 in-lbStep #4 Leak checkStep #5 If it still leaks replace gasket and repeat steps #1-4

Second round tests (number #15-27)In this set of test all five gaskets were replaced using 75 in-lb of torqueIn reporting the results only the leaks were noted.Background of the leak detector was equal or lower that 1 X 10-10 mbar-lit/sec of heliumLeaks were defined as any reproducible meter deflection on any scale.On test #18 the entire assembly was helium bagged for 10 minutes without any leak detector response. The results of the bagging of test #27 are shown in a later slide.

October 30, 2007Undulator Breakout

23 Dean R. Walters

drw@aps.anl.gov

Test ResultsTest Log Bood

Seal Mat'l No. No. Seal #1 Seal #2 Seal #3 Seal #4 Seal #5Friday Copper 1 Ok Ok Ok Leak OkFriday Copper 2 OK Cu - not rplc OK Cu - not rplc OK Cu - not rplc Leak new chain OK Cu - not rplcFriday Copper 3 OK Cu - not rplc Leak Leak OK OK Cu - not rplc Initial Failure RateFriday Copper 4 NA Leak Leak NA NA 46.2%Friday Copper 5 NA NA OK OK OK Cu - not rplc

Saturday Aluminum 6 1 NA NA Leak Leak OK Cu - not rplcSaturday Aluminum 7 2 NA NA Leak Leak OK Cu - not rplcSaturday Aluminum 8 3 NA NA Leak Leak OK Cu - not rplcSaturday Aluminum 9 4 NA NA Leak Leak OK Cu - not rplc

Monday Aluminum 10 NA NA Leak Leak OK Cu - not rplcMonday Aluminum 11 NA NA Leak Leak OK Cu - not rplcMonday Copper 12 NA NA OK OK OK Cu - not rplcMonday Aluminum 13 NA NA Leak OK - Cu OK Cu - not rplcMonday Copper 14 OK Cu - not rplc OK OK Lk OK Cu - not rplc

Tuesday Copper 15 1 B1 OK - New chainTuesday Copper 16 2 Lk - bellows B1 flgTuesday Copper 17 3 Lk - bellows B1 flgTuesday Copper 18 4 replc w/ B2Tuesday Copper 19 5 B2Tuesday Copper 20 6 B2Tuesday Copper 21 7 B2

Wednesday Copper 22 8 B2Wednesday Copper 23 9 B1Wednesday Copper 24 10 B1Wednesday Copper 25 11 Leak Leak B1 LeakWednesday Copper 26 12 Ok - new chain Ok - new chain B1 Ok - new chainWednesday Copper 27 13 B1

15 15 24 1 142 2 12

112

Failure rate in the formal test65 5

7.7%

No. of Times the Chains are used:

October 30, 2007Undulator Breakout

24 Dean R. Walters

drw@aps.anl.gov

Transportation TestMoved assembly onto hard wheel roller cartRolled around APS ringProbe leak check

No leaks at 5 X 10-11Bagged the assembly

After 7 minutes a rise was notedAt 10 minutes leak rate rose to 5 X 10-10Loose tape seal around bag could be evidence of permeability of vacuum hose o-ring.

October 30, 2007Undulator Breakout

25 Dean R. Walters

drw@aps.anl.gov

Induced Deflection Test & Aluminum GasketsSet-up

This is a test where a known leak tight assembly has a single component shifted 2 mm (.08”) and then re-leak checked.

Three test were performedEach with a new gaskets to the component which in this case is the RFBPMThe assembly was leak testedThe component was moved 2 mm

Test #1 it was moved 2 mm in X directionTest #2 it was moved 2 mm in Y directionTest #3 it was moved -2 mm in Y direction

The assembly was leak checked again after movingIn all cases the assembly was leak free.

Transportation TestAt the end of Test #1 the assembly was rolled around the APS ring, greater than 1 km, and then leak checked one more time, no leaks.

ALUMINUM GASKETSEVAC supplied replacement gaskets to replace the initial setTested 15 standard thickness gaskets, 2.17 mm, torqued to 39 in-lbs finding no leaksTested 5 extra thick gaskets, 2.36 mm, and were successful in 4 of 5.These tests were conducted with Dicronite dry lubricant on the chains.In further testing Armoloy XADC lubricated chains will be tried.