FEL Monthly Highlights
September 2001

By September 30, 2001, which is the official end date of Phase 1 of the FEL Upgrade Project, we have met all
the major deliverables per the Phase 1 Statement of Work.  These items will be reviewed in detail at the
November 8-9, 2001 semiannual project review:

1. Sub system designs complete.
2. RF powers systems for upgraded injector and Cryomodule 2 and 3 complete (except for final testing into
    cryounit/cryomodule loads).
3. Gun improvements specified, tested, and incorporated into upgrade gun fabrication (implanted electrodes,
    shielded cesiator, improved vacuum)
4. Design, construction and measurement of the wiggler (optical klystron) complete.
5. Design of 10 kW optical cavity complete; mirror test stand benchmarked.
6. Design of the electron transport complete system complete (through Release of Version 1.1which is
    compatible with 1 kW UV FEL add-on); magnetic models for magnets benchmarked and procurements
    released for the two largest dipoles DY and DW, and for the quadrupoles).
7. Design of the Upgrade cryomodule complete (shared project with DOE-NP); electropolished cavity tests
    show >20 MV/m performance.

Despite having our RF engineers stranded across the country by the shutdown of the airlines on September 11,
CPI in Palo Alto proceeded with the scheduled test of 100 kW klystrons for the upgrade injector on September
12.  CPI is pleased to report to us that the tube meets all specifications and has delivered 112 kW.  On
September 29, we received delivery of two of these tubes completing a major milestone for the FEL Upgrade

We held a successful preliminary design review on the optical cavity design for the FEL upgrade on
September 14.

During September we received funding ($2.84M) from the Air Force for the start up of the 1 kW UV FEL
program.  The funding is valid until September 30, 2002.

In addition, we have received information that additional funding for the UV FEL project is included in both the
SASC and HASC FY02 authorization bills for the Dept. of Defense.

We devoted the last two weeks in September to FEL operations for the second run for laser material damage
studies funded by the Joint Technology Office (JTO).  This completes the full exposure matrix that was
presented in the JTO proposal. For details see the operations section.

The science and technology involved in the Jefferson Lab FEL program was reviewed on September 24-26,
during the annual DOE Review of Jefferson Lab’s programs.  The FEL program received high marks for
meeting and exceeding technical goals, project planning, and the high quality science that has been
demonstrated by the FEL users over the past year.  The reviewer’s also took note of the important synergy
among the lab’s advanced accelerator R&D efforts and the lab’s Navy funded FEL upgrade program and
DOE-funded linac contract for the Spallation Neutron Source.

A CRADA with STI Optronics for the design and analysis of compact, permanent magnet recirculation
magnets for energy recovered linacs was sent through the lab management chain for sign-off this month.
Preliminary discussions were opened up with AES, Inc. for negotiation of a CRADA to support an SBIR grant
that AES recently secured to begin the development of a 100 mA injector based on the IR Demo dc photogun.

A draft budget request was prepared for the Commonwealth of Virginia to support the upcoming request (Oct.
12th) for input for the state 2002-2003 budget.  The Virginia budget allocation over the last 4 years has
supported the FEL operations budget and we look forward to and appreciate continued state support of the
FEL program at Jefferson Lab.

Four proposals were completed and submitted to the DoD JTO on September 17.  These proposals are
concerned with technology development that can help push the power of the FEL upgrade or improve the
cost/reliability of the control and power systems.  Proposals were submitted on the topics:  (1) development of
cryogenic mirrors for high power loading; (2) development of drive laser components for increased
performance/reliability; and development of control/power components for (3) diagnostics and (4) magnet trim
power supplies based on the commercially available CAN bus technology (used in the auto industry).

We reviewed the technical proposal that we received from the Aerospace Corporation concerning our request
for the design and construction of UV laser processing tools to be used with the UV FEL.  Aerospace Corp.
was very responsive to our request and we look forward to working with our colleagues at Aerospace Corp. in
the execution of the planned subcontract. The “Work for Others” contract for the Aerospace portion of the
UV FEL effort has been submitted to our DOE Contracting Officer for approval

A proposal to the state of Virginia's Commonwealth Technology Research Fund was completed and submitted
through the primary sponsoring institution, the College of William and Mary for support of the installation and
re-commissioning of the Helios x-ray source in a planned addition to the FEL Facility.

Project Cost Performance:
The project (Phase 1) budget for the period June 1, 2000 to September 30, 2001 is $9,029k.  The Phase 2
project was approved for $4,500k for a performance period of February 1, 2001 to September 30, 2002.  The
project through the month of September has a total of $9,031k of performance scheduled (assuming the project
started at the originally planned start date of April 1, 2000).

The work performed through the end of September was $6,562, which is 73% complete vs. 100% scheduled.
The actual cost accrued through September totals $7,856.  This results in a schedule variance of -$2,469k and
a cost variance of -$1,294k.  The first phase of the project is fully obligated as of the end of September.  The
total project cost to date-actual costs plus commitments is $9,029k as planned for Phase 1 completion.  When
the open commitments are fully costed on or before December 30, 2001, we predict that the remaining cost
and schedule variances will be approximately equal. We expect to recover remaining Phase 1 cost and
schedule variances by the completion of the Phase 2 barring unforeseen difficulties.

Actual charges of $524k were accrued on Phase 2 (see individual WBS charges below):
No significant earned value is planned for the first quarter of FY02.

WBS 10
WBS 11


WBS 3 (Beam Physics):
Field analysis and certification of the GY performance was completed and documented (JLAB-TN-01-042, at

A preliminary energy recovery dump design was developed and sent into engineering.  See:
http://www.jlab.org/~tennant/TN-01-038.doc; interferences are being resolved and diagnostic layout worked

The recent beam transport experiment to test 3-pass operation with the Demo was documented:

Vacuum system designs were discussed.  Most effort went toward refinement and documentation of the
CEBAF-ER design, a proposed high energy test of the energy recovery concept.

Beam physics activities and opportunities were reported at the CASA staff retreat.  Compaction  management
in FEL drivers was investigated and it was determined that simultaneous bunch length compression during
acceleration and energy compression during energy recovery was possible during recirculation/recovery of
multiple beams, and that for a "magic phase" (value available from your correspondent for a fee) the injected
bunch is imaged at the dump.  Provided you're not lasing, of course.

WBS 4 (Injector):
Initial design of the gun stand and ceramic stack removal cart is complete.  Machining on the gun chamber
main body is underway.  Port tubes for the gun chamber were electro-polished.  Design/detail work continued
on the rear portion of the gun.  Finished assembly of the cathode shield test assembly and put it under vacuum.
It was found that under vacuum it would still operate but the design tolerances allowed the mechanism to shift
and run stainless against stainless.  We are modifying the design for better operation. The cathode ball was
roughed out inside and is having the interior electro-polished prior to final machining. Parts for the cathode stalk
were completed by the machine shop and checked.  We will wait to weld the assembly so we can match
machine the stalk seat with the interior cut in the ball when the ball is completed.  A schedule was set with
W&M for implanting the cathode ball and support tube.  Assisted the implantation efforts by cleaning their
modified chamber.

Gun HVPS - The specifications for the HVPS Tank have been firmed and the actual design is starting.
Design of the tank and holders for the stacks in Upgrade gun HVPS continues.

WBS 5 (SRF):
The first production 7-cell cavity was completed this month.  (Helium vessel and end groups welded).  This
assembly will allow us to determine if HOM coupling will be adequate for the FEL upgrade cryomodule and
will also conclude the development of the assembly procedures.

The space frame and vacuum vessel for the FEL cryomodule was completed this month.

WBS 6 (RF):
Zone 3 - The Filament and Mod Anode board tests were successfully completed.  Testing of interlocks is
progressing.  The 5 watt pre-amplifiers and their power supply are being installed.

Zone 4 - Progress was made this week in getting RF Control Modules calibrated and then returned to the zone.

Injector Klystrons - As noted in the highlights, we received notification from CPI that the 100 kW klystron has
met or exceeded all JLab specifications during the scheduled September 12 acceptance tests.  The two
klystrons for the Upgrade injector were received by the end of the month.  Thus, meeting a major project

Injector HPA - Low power S parameter tests were made and plotted for the 100 kW circulators.  This report
is being forwarded to the vendor for suggestions of how to tune the circulators for optimal performance.

Injector HVPS - Design work continues on the upgrade of the HVPS's.

The Main Circuit Breakers, Contactors, SCR Controllers, 12 Pulse Transformers, Rectifier Assemblies, and
Inductors have been specified, ordered, and many have already been received.  Modeling of the power circuit,
crowbar, and klystron continues for best noise and stability performance.  The 50kW RF Loads will be
returned to the vendor in December to upgrade them to 100 kW.

WBS 8 (Instrumentation):
A new combination amplifier/driver board is in the prototype stages.  The testing on the timing/delay board is
complete.  It is installed and working as expected.

The SF6 chassis has been upgraded and the readout is now available in EPICS.  Documentation on this chassis
is being updated as well.

User Lab upgrades continue: cables were pulled to four of the five labs for installation of the intercom system.
More cable is on order and the task should be completed soon.  More tools are available to assist users in
experimental set-ups.  A video distribution amplifier for  each user lab is also in fabrication and is being
installed. The video system, on channel 16, is available in various formats at http://laser.jlab.org/video.  Multiple
cables are now available for all users in the user labs.  These include various lengths of CAT 5 cable and BNC

The new dump current monitor was tested successfully month.  It resolves 1 microsecond pulsed beam, this is
important for operation of 5 microsecond / 60Hz alignment mode operation.  The design is now being finalized
and documented.

Drawings completed this month:  F0032 - Solenoid box assembly and fabrication Rev. B; F0033 - Beamviewer
Interlock Box-Version A, assembly details; F0101 Beamviewer Interlock Box-Version B, Fabrication Details;
and F0102 - Beamviewer Interlock Box Mounting Plate, Fabrication Details. :  OBPM Molectron Quad Buffer
Schematic, Fabrication, Assembly and Artwork; OBPM, Molectron Quad Daughter Board Schematic,
Fabrication, Assembly and Artwork; Beamviewer Interlock and Lamp/Camera, Interface Box Fabrication and
Assembly; OBPM Circuit Board Test Box Wiring Diagram and Fabrication Details; and the 32 Channel
Sample & Hold Buffer Board Schematic, Assembly, Fabrication and Artwork.

The drawing index on the Laser website has been updated to include many new and updated designs. Material
and test equipment control data bases are being developed to enable us to easily tell our users what we have

WBS 9 (Transport):
Optical Chicane Dipoles (GW)
•  Manufacturing proposals were received and evaluated.  After some feedback on the cost of some
    tolerances, the award was made to Magnet Enterprises International.  The award (to the company who is
    making our QX quadrupole coils) was all three phases of the task, coils, cores and assembly.
•  We started receiving the steel for the dipoles from Bethlehem Lukens Steel
Injector Dipoles (DU/DV)
•  DULY Research completed the Small Magnet's (GV) Assembly Drawing and the Large Magnet’s (GU)
    details and is nearly complete with the latter’s assembly drawing.
Arc Dipoles (GY, GX, GQ)
•  David Douglas analyzed and approved the magnetic model data for the 180 Dipole (GY) from Advanced
    Energy Systems (AES). They completed the detail drawings to mimic the magnetic model and they are
    working at finishing the Assembly Drawings.
•  AES completed their manipulation of the magnetic model of the Reverse Bend (GQ), adding a .001 inch
    step to the edge of the pole near the faces and adjusting the gap height.
•  Design continued on backchecking the detail drawings of the Bend (GX) and Reverse Bend Dipoles (GQ)
    with the comments, corrections and adjustments for the changes in the magnetic model.
3 inch quad (QX)
• We signed off the specification for assembly and the assembly drawing and placed them in a procurement
• Manufacturing continues on cores and coils at the respective vendors.
Trim Quad (QT)
• We signed off the drawings and statement of work and started a procurement cycle.
Sextupole (SF)
•  3D magnetic modeling and drafting layout continued at a slow pace because of vacations, work on the
    Statement of Work and requirements that the engineer service Physics commitments and Accelerator
    maintenance problems.
•  We determined that additional steel made by Bethlehem Lukens Steel on the dipole order and offered to us
    for purchase is an ideal candidate for the core material for this magnet style.
Octupole (OT)
•  DULY Research had excellent results from their 3D magnetic modeling, finding that a mushroom cap pole
    tip of the right shape, placed on the recycled corrector coils obtains less than 1% error fields when a non
    rational number is used for the exponent in the pole face generation equation.  They went on to get the
    same levels of field quality with a design using field clamps.
•  DULY has now been tasked to produce a preliminary mechanical design using the magnetic model above.
•  Analysis of the new design’s powering needs shows that we will have to use the power supplies used for the
    Trim Quads (20 A, 50 V) rather than the standard 10 A, 20 V supplies.
Corrector Dipoles (DB, DJ)
•  We received feedback from the plastic molding company on our concept design of the new mounting bracket
    for the DB/DJ correctors onto the beam positions monitors.  We judged that an aluminum bracket is probably
    the better choice.
Beam Line and Vacuum
•  Work continued on the definition of the Optical Chicane Chambers and continued to the mounting stand for
    the GW magnets.
•  The bid package drawing set for the girders and stands in the return leg was signed off.
•  We continued engineering work on the LCW distribution.  LCW flow rates and manifold locations for the
    dipole have been defined and put on a layout.
•  The recirculation dump concept was finalized by Dave Douglas to the satisfaction of George Neil.  It will
    utilize two Trim Quads (QTs)
•  Work started on the injector line stands and vacuum chambers.  There was extensive discussion and finally
    definition of the aperture in the injector line and the vacuum chamber in the beam combining area.

WBS 10 (Wiggler):
The final probe calibrations were completed for the wiggler magnet test stand.  The probe is extremely linear
with no evidence of transverse Hall effect at the 1 Gauss level.  The measurement apparatus was installed on
the wiggler and test scans carried out.

Initial wiggler measurements indicate that the DC field has been overcompensated.  When a 5.3 G DC field is
added to the measured field the attached trajectory is found.  The trajectory is straight to better than 50
microns with a peak to peak wiggler amplitude of 1.3 mm.  As expected for an electromagnetic wiggler, the
field quality is exceptional.  The end correction also appears to be quite good with no end pole kick in evidence.
Finally, the trajectory offset from the initial position is less than one wiggler amplitude, which is what was
expected.  The vertical field indicates a probe angle of 1.2 degrees.   We will attempt to fix this and the DC
fields before taking final scans.  So far, no problems with the wiggler field have been seen.

The vacuum chambers for the wiggler sections are essentially complete except for some final welding on the
upstream wiggler chamber. The downstream chamber and dispersion section chamber are complete.

WBS 11 (Optics):
The designers for the optical cavity chambers produced the first set of prints to support the procurement of
components, and  purchase orders for some of these components were placed this month..  We have sent a
number of spare mirrors, procured for the IR Demo, to Veeco (Wyko Div) to determine their surface

As the cost of the new drive laser is far over our budgeted amount, we are revisiting our planning and
developing alternate plans for the use of in-house labor and purchased components.

The design of the cooling loop and electrical connections is in the conceptual stage, detailing continues in other

A preliminary design  review of the optical cavity was successfully held on September 14.  Some good
comments came out of this review, and will be incorporated into the design.  Everyone agreed it was a good
design, and that we should proceed with component procurements.  This has been occurring, for example, with
orders signed for the critical vacuum rotary feedthroughs.

This month, we received the first article of our new, near-Brewster windows that also serve as the vacuum/air
interface in the user labs.  These windows incorporate a larger window that permits us to image the entire
beam for profiling, position monitoring, or power.  It is being checked for correct angle, and will then be
cleaned for vacuum use and installed on the optical transport. We received new IR cameras from Raytheon;
they are a much-improved version of the cameras we use now to monitor beam position in the optical transport
(at one point in the accelerator vault, in the optics control room, and at the end-of-line).

The schedule for the FEL Fall 2001 run (October 8-November 16) was completed and is being sent to all of
the Users and placed on the Web.

This month we completed the second phase of experiments for the JTO-funded materials studies, and
irradiating more than 300 target sample.  The measurements involved collaboration with scientists from NRL,
who are using their diagnostics to observe the targets during irradiation.  We also hosted Dr. Dennis Burianek
from Lincoln Labs, and irradiated targets of interest to his organization.