MEMORANDUM

To: J. Albertine, D. Helms, W. Skinner

cc: Division (M7), FEL Coordination Group

From: F. Dylla

Subject: IRFEL Weekly Report, July 28 - August 1, 1997

Date: August 1, 1997

Management

Highlights for this week include the completion of vacuum testing, delivery and installation of the FEL cryomodule in the FEL facility, and a test of the optical transport system from the optical cavity outcoupler (downstairs) to the optical control room (upstairs).

Considerable progress was made with internal and external reviewing of the pre-proposals that have been submitted for initial use of the IR Demo. We have received 15 of 18 proposals that are in process. Many of the 15 have been returned to the principle investigators with comments for revision.

Last Friday (7/15), the Navy signed the FY97/98 MOA for the commissioning/upgrade activities. On Monday (7/28), the MOA was signed by DOE. The Navy expects to release the $3.7M of FY97 funding to DOE for use by the FEL project by next week.

At the SPIE Conference in San Diego, CA this week, Rui Li presented a paper entitled "Shielded Transient Self-Interaction of a Bunch Entering a Circle from a Straight Path", and Michelle Shinn presented a paper entitled, "Optical Design Issues for this Jefferson Lab IR Demo Project".

Accelerator Systems

Regarding the beam-transport system:

The modified structure for magnet measurement apparatus for high resolution amongst a family is running. The pick-up coils/loops have to be mounted. Details of the apparatus to measure the 180 Degree Dipoles are being drawn with the main support ring being signed off today. The magnet measurement stand has one more full time worker on loan from the Cryo group.

Everson Electric delivered six Optical Chicane Dipoles (DWs), fully assembled. Everson is now working on the assembly of injection/extraction dipoles (DUs & DVs) with delivery of the first article DU expected next week. Assembly tooling for the Reverse Bends (DXs & DQs) is in process.

Process Equipment Co. shipped all reverse bend cores to Everson Electric for assembly. The back legs for the 180 degree dipoles are still being ground to their exact size by another vendor with all other parts complete. Winding started on the second of the four 180 degree dipole coils at Magnet Enterprises International (MEI).

The Panofsky trim quad manufacture continued at MEI. The three quads for the recirculation dump line (QIs) again slipped schedule at New England Technicoil. Cores are being plated. Coils are at 50%. They now plan to ship around Aug. 13.

In the corrector area, the bids for phasing dipoles were received and the order is being placed. The vendor to make cores for all mu metal correctors declined to bid and we will give this developmental type task to the Jefferson Lab Shop. Details of the coils for the two, 8 inch mu metal correctors were sign-off and put in the procurement cycle. The magnetic design of the constant perimeter, air core correctors was completed by Robin Wines using TOSCA. There will be two shells, titled the DH and the DB coils (for the corresponding vertical and horizontal correction) that nest to form a corrector set on the BPMs. At the positions in the back leg, where only one corrector is needed, only the BH coil will be used in either horizontal or vertical configuration. A third, larger diameter shell will nest over a DB coil to create the nested pair that can straddle the 2 by 4.5 inch chambers in the optical chicane. Details are signed for the DB and the other two sets are being detailed for signature next week. A prototype DB horizontal corrector is wound and will be potted today. Tests for cross talk to the nearby quadrupole are planned for the following weeks before placement of the orders for the coils.

Reverse bend chambers are now the focus of the shop chamber welding effort. The final configuration of the recirculation dump line, reusing stands from the injector test stand is being detailed. The design of the interconnecting parts of the quad telescope after the second arc remains un consolidated, though the stands and girders are in site. The stands for the insertable dump are in checking. Contrary to the report last week, delivery of the arc dipole stands is expected September 1 rather than August 15. The layout drawing for these stands was signed off, so the alignment crews can spot the stand positions and drilling for the anchor holes can proceed. The Sextupole/Trim quad girder design is still in process. We plan to place these elements and these girders at the low end of our priority list in both magnet measurement and installation so we may concentrate on the dipole and beam tube installation.

Installation of the beam line is progressing, with the connection from the gun/light box to the quarter cryomodule through the solenoid nearing completion. At the other end of the injection line, a mismatch in the height of the injection dump was resolved. A mounting detail of the small cartridges required by the design forced the use of higher cartridges. In addition a wrong model of vacuum pump supplied by the vendor with a large interfering flange on its bottom side caused interference with the floor. Both conditions were accommodated using a shorter mounting nipple on the pump.

Regarding cryomodule fabrication:

The cryomodule was installed in the FEL Facility on Friday (1 Aug. 97). Plans for commissioning the cryounit and cryomodule are under development and will be coordinated with the performance integration effort (which is summarized in the Commissioning/Operations section below). FEL superconducting radiofrequency commissioning activities will be adapted from those of the nuclear-physics machine.

Regarding electron-beam instrumentation and controls (I&C):

A clean area was setup in lab 1 for installation of 1.5 micron Al foil on OTR beam viewers prior to installation into the accelerator. The camera mounting frames will also be assembled in the clean area. Soleniod assemblies are being finished up for the pneumatic devices.

The control room patch panel are being installed on each of the table tops.

Design work continues on the Analog Monitoring System (AMS). Parts are being ordered.

Connections for reading the temperature instrumentation diodes in the cryomodule are in progress. The hardware and software should be in place by next week. The cooldown will be in 10 days or so.

The final file configuration for the new servers is nearing completion. The cooldown diode readout will use the new servers.

Regarding rf systems:

Good progress has been made toward the installation of RF systems in the FEL building. The second 50 kW klystron and HVPS will be moved into the FEL building on 8/6/97. The RF system for the quarter cryomodule is about 30 % complete. The first 225 kW Variable Power Supply was received this week from Hipotronics. It will be moved into the FEL building on 8/6/97. The second unit is nearly ready to ship and should be here shortly. We are waiting for direction from the vendor on what they want us to do with the second failed spare 50 kW klystron. The Buncher cavity was installed and aligned this week. Its water skid is to be installed next week. The RF system for the Buncher is about 40 % complete. The cryomodule was installed this week. The RF system for this unit is about 40 % complete. The Master Oscillator and its components are installed in the FEL building. Installation of the M.O. distribution cables are in progress. The effort is about 40 % complete.

FEL Systems

Wiggler

The completed wiggler girder assembly was installed but found to be one inch too high due to a designer error. It was then pulled out so that the plates could be repositioned and regrouted.

Optics

The optical transport cans and pipeline was leveled and aligned this week and a surrogate HeNe beam was transported to the optical control room for the first time. The intervening piping will be cut to the proper length and the vacuum flanges welded on next week. Assembly of the optical cavity vacuum continued with a little delay when measurements indicated a higher than desired dust particle count in the valves. We will re-clean them. A review of the LVDT performance indicated that they were acceptably reproducible (<2 microns) when attached to the gimbal mounts. They will be used as a secondary backup to the stepper motor positioning readout which is based on step counting.

Commissioning/Operations

The on-line Accelerator Readiness Review (ARR) tracking system is now about 90% complete. Plans continue to be such that only one ARR review meeting will be held, in the January-February 1998 time frame, to complete the sign-off of the FEL ARR.

Performance integration plans are under development for the major systems of the machine. The RF Performance Integration Plan and the Magnet Performance Integration Plan are completely outlined, and the writing of their drafts is well underway. Basically, these plans identify the appropriate subsystem owners and principal investigators and integrate their efforts toward achieving related specifications. The process helps ensure test plans required for commissioning are completely identified and written.

We thoroughly scrutinized plans for measuring magnets prior to their installation in the FEL beamline. The status of procurements, as well as resource and space limitations for magnet measurements, are such that some magnets will have to be measured after 1 Oct 97. We organized the entire process to be compatible with the commissioning schedule, i.e., with priority on completion of the injection line, followed by completion of the straight path for first light, and then completion of the recirculation arcs. We are anticipating that, on 1 Oct 97, the machine will resemble its top-level drawing but may be missing some magnets and possibly the vacuum chamber for the second recirculation arc, depending on the actual delivery dates. At that time, we will begin commissioning the gun on swing and owl shifts, leaving day shifts open for final installation/checkout activities until they are all complete. Our plan to be pulling electrons off the photocathode in mid-October, as well as the timing of the rest of our commissioning activities, remains unchanged.

Facility

The punch list work continues. Grading and topsoil placement is going on outside the building. Lockers were placed in the bathrooms. Office cubicles were placed in each lab for use by the optical technicians and grad students. The elevator issues are in the process of getting resolved and the elevator is running for freight only three times a week on a schedule to permit equipment installation. It is still about two weeks from being turned over to full time use as we are awaiting certification of the fire system. The wiggler table was placed in position but could not be set to the correct elevation. The mountings will be redone next week. The buncher and solenoid were mounted and aligned in the injector. Piping for LCW, N2, and instrument air is nearly complete both upstairs and down. A HeNe beam was successfully sent through the optical transport system to the optical control room. The optical cans are correctly mounted and next week the vacuum pipe will be cut to length and installed. The injector dump girder and the magnet girder upstream of the was placed. The high power DC supply for the cryomodule RF was brought into the building. Last but not least, the cryomodule was successfully installed in the FEL building.

The drive laser hookup continued. The transport line for that system is in fab. The telescope was hung on the ceiling downstairs. Hilties were drilled and placed for the other transport stands. The final stand drawing for that system is in signify, other stands are in fad.

Design is complete for all the drive laser optical transport stands. Good progress was made in the electrical installation of the high voltage power supply. The bunter was aligned and the solenoid before the cryounit was installed.