spx high level rf and rf interlock systems wbs u1.03.03.01 doug horan rf systems engineer...

SPX High Level RF

and

RF Interlock SystemsWBS U1.03.03.01

Doug HoranRF Systems EngineerAccelerator Systems Division/RF 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

The HLRF Team HLRF System WBS Scope Requirements Design Interfaces Risks Considered R&D ES&H Cost Schedule

HLRF Scope / Cost SummaryWBS U1.03.03.01

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Design, construction, installation, and commissioning of eight 2.815GHz/10kW cw high-level klystron rf amplifier systems, including waveguide transmission systems, interlock systems, and two high voltage power supplies

Interlock systems include: → SPX rf equipment protection → Personnel safety → Interface to Access Control Interlock System (ACIS) → Interface to Machine Protection System (MPS)

HLRF System Requirements – WBS U1.03.03.01

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Produce and deliver approximately 8kW cw rf power to each cavity input waveguide flange

Provide rf interlock functions, including rf hardware protection and personnel protection

Maintain minimum contribution to rf system integrated noise

HLRF Org Chart

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High-Power RFD. Horan

Amplifier SystemsD. HoranA.Grelick

M. MiddendorfR. AgnerTech 3

HLRF Engineer

RF InterlocksD. HoranR. Agner

Interlock Engineer

RF Systems Installation

D. BromberekT. Smith

D. JeffersonTech 4

RF Test StandsM. Middendorf

T. SmithM. Douell

T. Jonasson

Electrical SystemG. Doktorczyk

Electronics D&D

New Hire

HLRF System Scope – WBS U1.03.03.01

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Design, construction, installation, and commissioning of eight 2.815GHz/10kW cw high-level klystron rf amplifier systems, including the following subsystems:

→ Eight waveguide transmission systems → Interlock systems → Two high voltage power supplies

Interlock systems include:

→ SPX rf equipment protection → Personnel safety → Interface to Access Control Interlock System (ACIS) → Interface to Machine Protection System (MPS)

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HLRF System Design -- WBS U1.03.03.01

10kW klystron amplifiers, one per cavity

Common HVPS at each sector

HVPS units fed from common 480V source for correlated noise

Master HVPS switching clock to interleave and reduce HVPS ripple


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HLRF Waveguide System Design -- WBS U1.03.03.01.02

Waveguide is WR284 aluminum – pressurized with nitrogen to 5 psi

10kW amplifiers are positioned on equipment mezzanine in Building 400A1 (Sector 5) and Building 400A4 (Sector 7)

Waveguide system losses estimated at ≈ 1dB

→ Approximately 8kW available at each cavity input flange PRELIMINARY DESIGN OF HLRF INSTALLATION IN BUILDING 400A1

AND STORAGE RING SECTOR 5

10kW AMPLIFIERS

WAVEGUIDES AND PENETRATION INTO SR TUNNEL


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HLRF System Design – RF Interlocks WBS U1.03.03.01.04 → Fast RF IL WBS U1.03.03.01.07 → ACIS/RF InterfaceWBS U1.03.03.01.04 → Slow RF IL

Master slow and fast interlock systems in amplifier systems

Slave slow and fast interlock systems at cryomodule location

Slave fault outputs drive external inputs of respective master

Slow interlock is PLC-based → ≈ 20ms response time

Fast interlock is electronic → ≈ 10μsec response time

Interlocks can trigger fast cavity detuning or beam dump to protect hardware

ACIS/RF Interface disables rf systems for tunnel access


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HLRF System Design – Personnel SafetyWBS U1.03.03.01.06SPX waveguide nitrogen pressure is monitored to detect the potential for rf radiation leakage – Low pressure indicates the potential for rf leakage

→ Affected SPX rf systems are shut down

→ All Storage Ring and Booster rf systems are shut down

High voltage behind bolted panels with interlock switches

STORAGE RING AND BOOSTER RF

SHUTDOWN

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HLRF Interfaces WBS U1.03.03.01

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HLRF System Risks WBS U1.03.03.01

Availability of a reliable and stable klystron → The klystrons will be a new design that will require testing and evaluation

On-time klystron delivery

Mitigation:

-- Plan Advanced Procurement for first-article 10kW klystron

-- Extensive testing and evaluation of first article


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HLRF R&D – SPX0 -- WBS U1.02.01.03.01

Design, construction, installation, and commissioning of two 2.815GHz/5kW cw high-level klystron rf amplifier systems, including waveguide transmission systems, high-voltage power supplies, and interlock systems

Interlock systems include:

→ SPX0 rf equipment protection

→ Personnel safety

→ Interface to storage ring tunnel Access Control Interlock System (ACIS)

→ Interface to storage ring Machine Protection System (MPS)

SPX0 HLRF INSTALLATION IN BUILDING 400A1 AND STORAGE RING SECTOR 5

FIRST SPX0 5kW KLYSTRON AMPLIFIER


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HLRF R&D – Test Stands -- WBS U1.02.01.03.10 Vertical cavity tests at ATLAS

Building 400A RF Test Stand

→ RF power tests on dampers, loads, and windows

5kW Horizontal Cavity and Tuner Test at ATLAS → Utilizes first 5kW SPX0 amplifier → Scheduled for December 2012

5kW cryomodule tests at JLab → Utilizes first 5kW SPX0 amplifier

FIRST SPX0 5kW KLYSTRON AMPLIFIER INSTALLED AT ATLAS

HOM DAMPER RF POWER TEST IN 400A 2.815GHz/4kW CW AMPLIFIER IN 400A


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HLRF System ES&H WBS U1.03.03.01 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– Note special materials or project specific security requirements– APS-U Project required to follow Argonne’s Operations Security Program (OPSEC) Master

Plan

Identify General Safety Requirements to Specific WBS Level– Electrical safety → high voltage– Ionizing radiation → X-ray emission from klystron and rf cavities– RF radiation safety → rf leakage from waveguide transmission system– All equipment not rated by a nationally-recognized testing laboratory (NRTL) will be

inspected by qualified electrical equipment inspectors

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SPX High Level Radio Frequency Scope and WBSU1.02.01.03 & U1.03.03

Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 2,303 4,084 649 786 7,823 U1 02.01.03 - SPX R&D 899 681 23 253 1,857

02.01.03.01 - High Level RF (HLRF) R&D 394 434 14 118 960 02.01.03.10 - SRF Test Stands R&D 379 162 5 101 648 02.01.03.12 - Safety Interlock System - SI/ACIS R&D 126 85 4 34 249

U1 03.03 - SPX Production 1,404 3,403 625 533 5,966 03.03.01 - High Level RF (HLRF) 1,265 3,297 601 494 5,657 03.03.11 - Safety Interlock System - SI/ACIS 139 106 25 39 308

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)

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SPX High Level Radio Frequency Scope and WBSU1.02.01.03 & U1.03.03 Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 2,303 4,084 649 786 7,823 U1 02.01.03 - SPX R&D 899 681 23 253 1,857

02.01.03.01 - High Level RF (HLRF) R&D 394 434 14 118 960 02.01.03.01 - ACWP 176 33 - 46 255 02.01.03.01.02 - Waveguide 80 96 6 25 206 02.01.03.01.03 - Amplifier System 42 204 4 18 268 02.01.03.01.04 - Fast RF Interlock System 30 82 3 11 127 02.01.03.01.05 - Slow RF Interlock System 54 14 0 16 84 02.01.03.01.06 - Personnel Safety System 11 4 1 3 18 02.01.03.01.07 - ACIS RF Interface 1 - - 0 1

02.01.03.10 - SRF Test Stands R&D 379 162 5 101 648 02.01.03.10 - ACWP 196 78 - 51 325 02.01.03.10.01 - 400A Test Stand 68 15 0 17 101 02.01.03.10.02 - 275W TWT Mobile RF System - ATLAS 12 - - 3 14 02.01.03.10.03 - 5kW KLY Amplifier Test at ATLAS 10 44 0 4 58 02.01.03.10.04 - 400A-1 Complex RF Systems for SPX0 94 25 5 27 150

02.01.03.12 - Safety Interlock System - SI/ACIS R&D 126 85 4 34 249 02.01.03.12 - Safety Interlock System - SI/ACIS R&D 126 85 4 34 249

U1 03.03 - SPX Production 1,404 3,403 625 533 5,966 03.03.01 - High Level RF (HLRF) 1,265 3,297 601 494 5,657 03.03.01 - ACWP 12 - - 3 15 03.03.01.01 - Klystron 12 752 92 29 884 03.03.01.02 - Waveguide 135 384 70 58 647 03.03.01.03 - Amplifier System 454 1,320 258 205 2,236 03.03.01.04 - Fast RF Interlock System 143 218 45 43 449 03.03.01.05 - Slow RF Interlock System 141 29 19 36 224 03.03.01.06 - Personnel Safety System 60 13 9 19 102 03.03.01.07 - ACIS RF Interface 138 8 18 38 203 03.03.01.08 - High Voltage Power Supply (HVPS) 16 575 69 25 684 03.03.01.09 - General HLRF System Design 78 - 1 17 95 03.03.01.10 - Support In-Ring Testing 77 - 20 22 119

03.03.11 - Safety Interlock System - SI/ACIS 139 106 25 39 308 03.03.11 - Safety Interlock System - SI/ACIS 139 106 25 39 308

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)

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SPX High Level Radio Frequency Obligation Profile U1.02.01.03 & U1.03.03

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SPX High Level Radio Frequency BOE Contingency U1.02.01.03 & U1.03.03


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HLRF Cost Drivers

SPX0 R&D → 5kW klystrons¹ (2) → 30kW High voltage power supplies¹ (2) → 50kW isolators¹ (2) → Waveguide systems

¹ Internal component of 5kW amplifier

SPX → Klystrons² (8) → 150kW high voltage power supplies (2) → 50kW isolators² (8) → Waveguide, including HOM filters (8)

² Internal component of 10kW amplifier

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SPX R&D and Production MilestonesU1.02.01.03 & U1.03.03

u START: Preliminary Design - SPX0 4/10

u START: Preliminary Design - SPX 2/12

u COMP: PDR - SPX0 7/12

u COMP: PDR - SPX 1/13

u SHIP: SPX0 Cryomodule to ANL 4/14

u COMP: SPX0 Cryomodule Test 6/14

u START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)

u COMP: SPX0 Installation 10/14

u AVAIL: SPX0 Ready for Operation 1/15

u START: Final Design - SPX 6/14

u COMP: Final Design 9/15

u START: Major Procurement 10/15

u AWARD: Cryoplant Contract 10/15

u START: Cryoplant Installation 9/17

u COMP: Cryoplant 3/18

SHIP: Cryomodule #1 to ANL 10/17 uSTART: Cryom #1 Installation 5/18 u

COMP: Cryom #1 Installation 6/18 uAVAIL: Cryomodule #1 Ready for Operation 8/18 u

SHIP: Cryomodule #2 to ANL 8/18 uSTART: Cryom #2 Installation 12/18 u

COMP: Cryom #2 Installation 1/19 uAVAIL: Cryomodule #2 Ready for Operation 3/19 u

SPX SYSTEM

FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17

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SPX High Level Radio Frequency Milestones U1.02.01.03 & U1.03.03

q NEED: Jlab Cryomodule Final Design Review - SPX0 8/12

q AVAIL: Amplifier #2 for Use 8/12

q COMP: Fast Interlock Design - SPX0 1/13

q AVAIL: Amplifier #1 Retrofit - SPX0 1/13

q AVAIL: Slow RF Interlock #1 and #2 - SPX0 8/13

q AVAIL: PSS #1 and #2 - SPX0 2/14

q COMP: Waveguide - SPX0 4/14

q AVAIL: Fast RF Interlock #1 and #2 - SPX0 4/14

q START: HLRF Final Design 6/14

q AVAIL: Amplifier #2 and #1 Retrofit - SPX0 9/14

q COMP: HLRF Final Design 9/15

q AVAIL: HVPS Ready for Amplifier Test 4/16

q AVAIL: ACIS System Ready for Use 10/16

AVAIL: Slave Fast/Slow Interlock Ready for Cryom 12/16 qAVAIL: Master Fast Interlock Ready for Amp 2/17 q

q AVAIL: Waveguide Ready for Use 5/17

AVAIL: Amplifiers Ready for Use 6/18 qCOMP: HLRF 12/18 q

HLRF

FY16 FY17 FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15

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SPX High Level Radio Frequency Summary Schedule U1.02.01.03 & U1.03.03

HLRF Work After CD-2

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1.02 R&D: Complete design of 10kW amplifier systems, waveguide transmission systems, and rf interlock systems

Hold design reviews for each subsystem

1.03: Begin procurement of hardware for amplifiers and sub-systems

Begin procurement of high voltage power supplies

Select and procure klystrons

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HLRF Summary WBS U1.03.03.01▪ Design, construction, installation, and commissioning of: → Eight 2.815GHz/10kW cw klystron rf amplifiers → Waveguide transmission systems → Personnel safety and equipment interlock systems → Two high voltage power supplies

▪ The system traces back to the higher level requirement of: → Providing the rf power necessary for the SPX cavities to develop full deflecting field → Protect SPX rf system hardware from damage due to overpower or arcing → Provide personnel protection against rf radiation, x-ray, and high-voltage hazards

▪ The conceptual design fulfills basic system topology requirements

▪ The total cost is $7,823k

▪ We are ready to proceed with final design of the system

▪ HLRF installation and checkout: → SPX0 R&D HLRF System – Completed in September 2014 → SPX HLRF System – Completed in December 2018


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HLRF Backup Slides Follow


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SPX0 R&D HLRF Installation and Checkout


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SPX HLRF Installation and Checkout


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SPX HLRF Installation and Checkout

▪ 10kW Amplifiers and Klystrons → Preliminary electrical checkout of amplifiers → Klystrons acceptance-tested at manufacturer → Amplifiers and klystrons tested together

▪ Waveguide System → Preliminary VSWR check terminated with precision load → Test to full power into load prior to connection to cryomodule

▪ Interlock Systems → End-to-end electrical check of interlock system and related signal cables → Interlock functionality check prior to application of rf power to cryomodule

▪ HVPS → Factory test at full-load voltage and power

HLRF System Design -- MPS/RF Interface WBS#.....


LLRFCRYOGENICS

INTERLOCK SYSTEM

PIEZO TUNER

RETURN TEMP & FLOW

RETURN TEMP & FLOW

RETURN TEMP & FLOW

RETURN TEMP & FLOW

TEMP

ARC DET

ARC DET

ARC DET

ARC DET

VACUUM FAULT

VACUUM FAULT

VACUUM FAULT

CAVITY QUENCH

REFRIGERATOR FAULT

LOM DAMPER

HOM 1 DAMPER

HOM 2 DAMPER

FPC AND LOM WINDOWS (4)

CAVITY

LOM DAMPER

FPC

CAVITY WINDOW

KLYSTRON ISOLATOR

LOM DAMPER

FPC

CAVITY

FAST CAVITY

DETUNING

BEAM DUMP COMMAND TO STORAGE RING MPS

SYSTEM

(OPTICAL FIBER)

KLYSTRON ISOLATOR

50kW LOAD

POWER FLOW FROM CAVITY

FIELD PROBEREFLECTED

POWER

Protects SPX rf hardware from damage caused by SR beam- generated rf power:

→ Overpower of cavities, HOM dampers, klystron isolator/load → Cavity vacuum fault → Arcs at cavity window, HOM damper, or klystron isolator → Cavity quench → Refrigeration fault

Generates a fast cavity detune command in response to fault conditions Beam dump command sent to storage ring MPS system if fast cavity detuning does not clear fault

SPX-0 MPS/RF

INTERFACE

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HLRF System Design – ACIS/RF InterfaceWBS U1.03.03.01.07

Storage Ring ACIS provides permits for SPX rf drive and high voltage power supplies

Both permits removed when personnel have access to storage ring tunnel

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spx high level rf and rf interlock systems wbs u1.03.03.01 doug horan rf systems engineer...

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