The EBS project required the shutdown and dismantling of the existing storage ring, and the design, construction, and installation of a new synchrotron source in a limited period with minimal disruption to the ongoing user program. From 2015 to 2018, in addition to keeping the existing accelerator operational more than 1,000 magnets, 900 m of vacuum chambers, and several thousand other components were designed, procured, and pre-assembled. On December 10, 2018, ESRF stopped the beam of the original accelerator for just 17 months to dismantle the existing accelerator, install and commission the new one, before the start of beamlines program at the end of August 2020. The EBS produced its first stored beam as scheduled, thanks to ESRF staff and international teams who have worked tirelessly to make this possible. One of the major challenges of this upgrade program was to replace these 32 cells, within the existing infrastructure, by new ones whose magnet density made engineering much more complicated. The new ring comprises over 10 000 components, each precision-aligned to within 50 microns over the storage ring length. The timing of different activities and the coordination of teams during all phases was another challenge, but the expertise, team spirit, commitment and responsiveness of teams and management to deal with unforeseen situations or technical problems greatly contributed to the success of the project. After such a project, several lessons are to be learned, first it is necessary to capitalize on all the positive aspects, then technical issues needs to be analyzed, in order to keep the knowledge and expertise. This presentation will cover the different phases of the project by highlighting the difficulties encountered and the lessons to be learned.
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B. List, L. Hagge, M. Hüning, D. Miller, P.-O. Petersen
DESY, Hamburg, Germany
The PETRA-IV next-generation synchrotron radiation source planned at DESY is currently in preparation as successor of PETRA-III, with a completely new accelerator and a new experimental hall, while existing buildings, tunnels and experimental beamlines will be retained where possible. The Technical Design Report is due to be completed by the end of 2022. A CAD integration model has been set up for the complete accelerator and photon science complex. It combines the contributions of all relevant trades, the accelerator components, supply infrastructure, installations, frames, tunnels and buildings, and the design of the campus. The CAD model structure is aligned with the project’s part breakdown structure (PBS) and the Work Breakdown Structure (WBS) to facilitate integration with systems engineering and reflect responsibility within the project organization. Within the model, it is possible to switch between different levels of detail for space allocation (DG1 - "black box"), interface definition (DG2 - "grey box") and detailed design (DG3 - "white box"), separating layout from design, while ensuring their consistency. Placement of accelerator components is directly governed by the lattice through direct access to spreadsheet data, allowing fast design changes after a lattice update and ensuring consistency between mechanical and lattice design. The resulting model will support the complete facility lifecycle, from layout and design to fabrication, installation and operation. The presentation explains the tasks and requirements of the CAD integration process and uses examples to explain the structure and the modeling methodology of the CAD integration model.
Design of Girders on the New Upgrade Lattice at Soleil
218
J.L. Giorgetta, A. Lestrade, A. Mary, K. Tavakoli
SOLEIL, Gif-sur-Yvette, France
The current girder set of SOLEIL features 4 girder types weighing from 1.85 t to 3 t, with a respective mass payload varying from 4.1 t to 8 t and lengths from 2.40 m to 4.80 m. The smaller size of magnets used for the present version of the SOLEIL upgrade allows a dramatic size and weight reduction of the magnet-girder assemblies. On the other hand, the number of magnets and girders has increased by a factor of 3, implying longer alignment and installation operations. Another constraint is due to the high compactness of the new lattice causing some limitations and access restrictions in the area between girders and tunnel wall. Several setups involving a number of girders from 116 to 212, various magnet layouts and binding systems have been studied. Dynamic and thermal performances have been evaluated by FEA analysis. This approach gives to accelerator physicists the performance of each solution, and thus a great versatility in the choice of the best setup in terms of dynamic and thermal stability. Alignment constraints, installation schedule reducing "dark time" period and economic considerations have also been taken into account during all the design phase.
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LINAC Section 3 and 4 Replacement at the Canadian Light Source
266
X. Li, X. Shen, R. Zwarich
CLS, Saskatoon, Saskatchewan, Canada
The Canadian Light Source Inc. (CLSI), opened in 2004 and located in Saskatoon, Saskatchewan, Canada, is a third-generation synchrotron light source facility with a 2.9 GeV storage ring. CLSI was built based on the Saskatchewan Accelerator Laboratory (SAL) with its LINAC. The SAL LINAC was built in 1960s and refurbished to operate at 250 MeV in 2002. It was also de-signed at an average beam power up to 46KW. To be used by CLS, the LINAC was modified for operation at pulse power levels of 25 MW with the current 100 mA. The modified LINAC consists of an electron gun and section 0 to 6, Energy Compression System (ECS) and Section 7. The LINAC has kept a steady performance throughout the years, along with many repairs and replacements ’ most of which are preventative. The original Varian type accelerating Sections are planned to be replaced gradual-ly by SLAC type Sections. Section 3 and 4 are two of the original 3 Varian type sections left in CLS - with over 55 years of service, they were accumulating vacuum leak problems from time to time. The replacement of Section 3 and 4 was completed in 2020. The mechanical consideration of the Section 3 and 4 replacement mainly includes upgrading supporting structures, designing Wave-guides, modifying LCW systems, getting solution to move the sections around in the LINAC tunnel, etc.
Magnet Measurement Systems for the Advanced Photon Source Upgrade
269
S.J. Izzo, C.L. Doose, A.K. Jain, W.G. Jansma
ANL, Lemont, Illinois, USA
Funding:Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility, operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357. The Advanced Photon Source-Upgrade (APS-U) project* is under construction and will incorporate a new Multi-Bend Achromat (MBA) lattice. With this design, the new storage ring will require over 1320 new magnets that are being produced under build-to-print contracts to several vendors across the globe. Magnetic measurements are needed to characterize and fiducialize all these magnets to ensure field quality and alignment requirements are met. Seven specialized test benches were designed and built to meet the measurement requirements. These measurement benches may be classified into two groups. The first group is the field quality measurement that includes the strength of the main field and higher harmonics. The multipole magnets are measured using four rotating coil benches, whereas the longitudinal gradient dipoles are mapped using a Hall probe system. The second group is fiducialization that locates the magnetic center of the magnet using a rotating wire and relates it to magnet fiducials and reference surfaces using a laser tracker. This information accompanies each magnet through the module assembly and final installation in the ring to ensure that the magnet is aligned within the allowable tolerance. To date, about 65% of all magnets needed for the storage ring have been measured and fiducialized. Mechanical design of the measurement benches will be presented. *Advanced Photon Source. (2017). APS Upgrade Project Preliminary Design Review Report (APSU-2.01-RPT-002). Retrieved from https://www.aps.anl.gov/APS-Upgrade/Documents.
Design and Fabrication Challenges of Transition Section for the CWA Module
273
S.H. Lee, W.G. Jansma, S. Sorsher, K.J. Suthar, E. Trakhtenberg, G.J. Waldschmidt, A. Zholents
ANL, Lemont, Illinois, USA
A.E. Siy
UW-Madison/PD, Madison, Wisconsin, USA
Funding:Work support by Laboratory Directed Research and Development funding from Argonne National Lab, by the Director, Office of Science, of the U.S. Department of Energy under contract DE-AC02-06CH11357. An effort to build Argonne’s Sub-THz AcceleRator (A-STAR) for a future multiuser x-ray free-electron laser facility proposed in [1] is underway at Argonne National Laboratory. The A-STAR machine will utilize a compact collinear wakefield accelerator (CWA) assembled in modules. To extract the wakefield and monitor beam position downstream of each module, a 45-mm-long transition section (TS) has been proposed and designed. This paper will discuss the design and fabrication chal-lenges for production of the TS. *A. Zholents et al., "A conceptual design of a Compact Wakefield Accelerator for a high repetition rate multi user Xray Free-Electron Laser Facility," in Proc. IPAC’18, Canada, 2018, pp. 1266-1268.
Mechanical Design of a Compact Collinear Wakefield Accelerator
276
S.H. Lee, D.S. Doran, W.G. Jansma, S. Sorsher, K.J. Suthar, E. Trakhtenberg, G.J. Waldschmidt, A. Zholents
ANL, Lemont, Illinois, USA
A.E. Siy
UW-Madison/PD, Madison, Wisconsin, USA
Funding:Work supported by Laboratory Directed Research and Development from Argonne National Lab, provided by the Director, Office of Science, of the U.S. Department of Energy under contract DE-AC02-06CH11357 Argonne National Laboratory is developing a Sub-THz AcceleRator (A-STAR) for a future multiuser x-ray free electron laser facility. The A-STAR machine will utilize a compact collinear wakefield accelerator (CWA) based on a miniature copper (Cu) corrugated waveguide as proposed*. The accelerator is designed to operate at a 20-kHz bunch repetition rate and will utilize the 180-GHz wakefield of a 10-nC electron drive bunch with a field gradient of 100 MVm’1 to accelerate a 0.3-nC electron witness bunch to 5 GeV. In this paper, we discuss specific challenges in the mechanical design of the CWA vacuum chamber module. The module consists of series of small quadrupole magnets with a high magnetic field gradient that houses a 2-mm diameter and 0.5-m-long corrugated tubing with brazed water-cooling channels and a transition section. The 45-mm-long transition section is used to extract the wakefield and to house a beam position monitor, a bellows assembly and a port to connect a vacuum pump. The CWA vacuum chamber module requires four to five brazing steps with filler metals of successively lower temperatures to maintain the integrity of previously brazed joints. *A. Zholents et al., "A conceptual design of a Compact Wakefield Accelerator for a high repetition rate multi user Xray Free-Electron Laser Facility," in Proc. IPAC’18, Canada, 2018, pp. 1266~1268.
Mechanical Design of the Booster to Storage Ring Transfer (BTS) Line for APS Upgrade
279
J. Liu, M. Borland, T.K. Clute, J.S. Downey, M.S. Jaski, U. Wienands
ANL, Lemont, Illinois, USA
Funding:Work supported by the U.S. Department of Energy, Office of Science, under Contract No. DE-AC02-06CH11357 APS Upgrade selected the horizontal injection scheme which requires exchanging the x and y emittances in the BTS transport line through a series of six skew quadrupoles, as well as matching the beam parameters to the APS Upgrade storage ring through two dipoles and a conventional pulsed septum. This paper presents the layout of this BTS line section in the storage ring tunnel and key components in this section including the mechanical design of dipole magnet, quadrupole and skew quad magnets, the vacuum system, the diagnostics system, and the supports. Finally, detailed mechanical design of this BTS line section in modules and some consideration for fabrication and installation are addressed.
K.J. Volin, R. Bechtold, A.K. Jain, W.G. Jansma, Z. Liu, J. Nudell, C.A. Preissner
ANL, Lemont, Illinois, USA
Funding:Work supported by the U.S. Department of Energy, Office of Science under Control DE-AC02-06CH11357. With APSU well into the procurement phase of the project, the APSU assembly team has completed a "DLMA Practice Assembly", comprising of the support system, and all magnets required to complete a module. The purpose of this test was to verify assembly and documentation procedures, ensure proper fit between mating components, and verify that alignment specifications can be met. The results of this exercise are presented. Though this test was completed on the Argonne site, work continues on building 981, the APSU offsite warehouse, where our first production plinths and girders have been shipped, and where production modules will be assembled. This space has been outfitted by Argonne contractors and APSU Assembly technicians with 1) 5 parallel DLM/FODO module assembly stations, each complete with a 3 tn. overhead crane, retractable cleanroom, staging tables, and tools, and 2) 2 QMQ module assembly stations each complete with a 5 tn. gantry crane, assembly support stands, staging tables, and tools. An overview of this production assembly space is also presented.
