Vacuum System (Synchrotron Light Source) J. R. Chen Synchrotron Radiation Research Center Hsinchu 30076, Taiwan The Fourth OCPA Accelerator School, Aug. 2, 2006 Vacuum System I. II. Introduction (Vacuum and Pressure Units) Considerations on Accelerator Vacuum System III. Vacuum System Design Considerations IV. Outgas, Pumping and Pressure Distribution V. Vacuum Components and Reliability VI. Case Study Introduction A. Vacuum B. Pressure Units Vacuum Vacuum: an environment with a pressure < 1 atm Low Vacuum : Medium Vacuum: High Vacuum (HV): Very High Vacuum: Ultra High Vacuum (UHV): Extreme High Vacuum (XHV): 760 – 25 torr 25 – 10-3 torr 10-3 – 10-6 torr 10-6 – 10-9 torr 10-9 – 10-12 torr < 10-12 torr Pressure units Pressure: force per unit of area Pa: Newton/m2 (SI unit), 1 Newton = 1 kg-m-sec-2 bar: (kg/cm2), 106 dyne/cm2, 1 dyne =1 g-cm-sec-2 mbar: milli-bar, 10-3 bar, 103 dyne/cm2 Torr: mm-Hg (at 0℃) 1 torr = 1.333 mbar = 133.3 Pa ≒ 1.316 × 10-3 atm 1 Pa = 10-2 mbar ≒7.5 × 10-3 torr ≒ 9.869 × 10-6 atm 1 atm ≒ 760 torr ≒1013 mbar ≒ 1.013 × 105 Pa Pressure PV= nRT “Pressure” is equivalent to “number density”. Number density (at room temperature): at 1 Torr, N ~ 3.2 x 1016 molec./cm3 at 10-10Torr, N ~ 3,200,000 molec./cm3 !! Considerations on Accelerator Vacuum System A. Accelerator Vacuum System B. Vacuum Related Beam Considerations Accelerator Vacuum System --- to provide a comfortable path for the particle beam (to increase the beam lifetime and also the beam quality) --- to provide a clean environment for the critical components (to keep their high performance) --- a vacuum system contains vacuum chamber, pumps, gauges, valves, mechanical and electrical feedthroughs, the related control units, and many other subsidiary components. Vacuum Related Beam Considerations A. Beam Lifetime Issues Pressure: Ion/Dust Trapping: scattering scattering B. Beam Stability Issues Mechanical Stability: Beam Orbit Beam Duct Cross section: Impedance Chamber Material: Frequency Response Ion Effects: Beam Lifetime, Beam Size and Emittance (Electron Clouds: Beam Size and Emittance) Beam Lifetime and Beam Size Issues The The less less the the gas gas molecules molecules density density ▼ ▼ the the less less the the interactions interactions between between the the particle particle beams beams and and the the gas gas molecules molecules ▼ ▼ the the less less the the blow blow up up of of the the beam beam bunch bunch and and also also the the less less the the beam beam loss. loss. Beam lifetime (electron rings) τ-1 = τT-1 + τRGS-1 +τion-1 τ: Beam lifetime (in general,τT <τRGS<τion) τT : Touschek Lifetime τRGS : Residual gas lifetime τion : Ion-trapping lifetime τRGS-1 = τBS-1 + τNS-1 +τee-1 τBS : Bremsstrahlung-scattering lifetime τNS : Nuclear-scattering lifetime τee : Electron-electron-scattering lifetime (in general, τNS < τBS <<τee) Bremsstrahlung-scattering lifetime τBS-1 = c σBS N = c(ρ/X0)W where X0: radiation length of the residual gas (g - cm-2) ρ : density of the residual gas (g - cm-3), c : velocity of light (3x1010cm-sec-1) W = 4/3 ln(γ /△ γ)–(5/6), probability to loss energy > △γ, γ = Ee /mec2 ρ = MP/24500× 760 at room temperature M: mass of the residual gas (a.m.u.) P: pressure (torr) Ref: J. Kouptsidis and A. G. Mathewson, DESY report, DESY 76/49, 1976. Bremsstrahlung-scattering lifetime Assume △ γ / γ =1% τBS-1 = 8539 MP/ X0 sec-1 = 3.1× 107 MP/ X0 hr –1 M/X0 = Σi (M/ X0)i C 12 O 16 CH4 H2O CO Ar 16 18 28 40 CO2 44 M H 1 X0 58 42.5 34.2 45.5 35.9 37.3 19.4 36.1 Nuclear-scattering lifetime τNS-1 = [c1(E2A02/Pβ0)(1/<β>)]x-1 + [c1(E2A02/Pβ0)(1/<β>)]y-1 where C1 : 1.0× 10-7 hr- GeV -2- nTorr-1 E : electron energy P : pressure (nTorr) A0: limiting aperture (min.[vacuum chamber, dynamic aperture]) β0 : Betatron function at the limiting aperture <β> = ∫ring β ds/L, average betatron function Ref: H. Wiedemann, “Coulumb scattering and vacuum chamber aperture,” SSRLACD-NOTE, Dec.13,1983. τEN-1 = c σEN N σEN = 4πr2Z2/ γ2 θmax2 θmax = (d/2)/< β> where, r : classical electron radius = 2.8 x 10-13 cm Z: atomic number γ = Ee/meC2 d: diameter of vacuum chamber < β>: average betatron function Assume: d= 5 cm, < β> = 10m τEN-1 = c σEN N = 3x 1010 × 4π × [(2.8 x 10-13)2Z2/ γ2 θmax2] × (6× 1023/24500) × (P/760) = 1.4 × 105 (Z2/E2)P hr-1 Electron-electron-scattering lifetime τee-1 = c σee N where σee : electron-electron scattering cross section = 5.0 × 10-25 (Z/ γ)( γ/ △ γ) (cm2) Z: atomic number of the residual gas N = 3.2 × 1016 P (# of molecules/cm3), at RT P : pressure (Torr) Beam Stability Issues Mechanical stability: as stable as possible vibration or thermal expansion of vacuum chambersÎ movement of Magnets or BPMs Î Beam Orbit Change Beam duct cross section: as smooth as possible abrupt change of cross sectionÎ wake field ÎInduce Beam Instability (and the lost energy could also heat up vacuum components) Chamber material and thickness: Frequency Response AC or pulse magnetic fieldÎ Eddy current ÎShielding or Changing the Original Magnetic Field and Heating the vacuum Chamber Vacuum System Design Considerations A. B. Basic Vacuum Issues System Operation Issues Vacuum System Design Considerations A. Basic Vacuum Issues 1. How to reduce pressure 2. How to overcome thermal problems B. System Operation Issues 1. How to keep a precise mechanical structure even after baking 2. How to reduce the impact from the stringent environment (radiation, humidity, dust, etc.) 3. How to protect the vacuum system in case of an accident Basic Vacuum Issues --- How to reduce pressure reduce outgassing rate (material, sealing, treatment) effective pumping configuration --- How to reduce thermal problems increase thermal conductivity (material, direct cooling) absorbers, grazing incident, differential heat removal (low Z material), cooling system System Operation Issues --- How to protect the vacuum system in case of an accident device self protection (IP, IG), electrical or pneumatic actuated valves, reliable vacuum interlock system (e.g. PLC), redundant sensors, reliable utility systems (e.g. compressed air and cooling water systems) --- How to reduce the impact from the stringent environment high radiation resistance material, installation under clean room conditions, to avoid the condense of water vapor, and to prevent the contact with humid air (e.g. with isolation coatings, to avoid corrosion) --- How to keep a precise mechanical structure even after baking careful dimension control during machining and welding, rigid fixed points (at BPMs, heavy components, critical positions), bellows and flexible supports, pre-displacement so as to have an optimized-force condition for some critical components during baking, to use springs to reduce the load of heavy components Outgas, Pumping and Pressure Distribution A. Outgas 1. Thermal outgas 2. Photon-induced desorption B. Pumping and Pressure Distribution 1. Throughput, Conductance and Effective Pumping Speed 2. Pumping Configurations 3. Pressure Distribution 4. Pumps In order to get a lower pressure in the UHV range, it is much more effective to reduce outgassing rate than to increase pumping speeds. P=Q/S where P: pressure Q: outgassing rate S: pumping speeds Thermal desorption 1. Qth ~ exp(-Ed/kT) Ed--- surface binding energy of the desorbed gas k --- Boltzmann constant (8.6x10-5eVK-1) T --- temperature (°K) 2. Qth : a) mechanism: surface desorption and diffusion b) can be effectively reduced by the treatments of chemical cleaning and in-situ baking c) water vapor is the major outgas before baking, hydrogen is the major outgas after baking d) Elastomers and the materials with high vapor pressure are not recommended for an UHV system. Photon-stimulated desorption, PSD e—beam ÎSynchrotron Radiation ÎPhoto-electron Î Gas molecules I Î d/dt (d2N(ε)/dIdε) Î Y(hv)F(θ) Î 2η Qpsd = I ×∫d/dt (d2N(ε)/dIdε)Y(ε)F(θ) dε × 2η Y↓, F(θ)↓, η↓ Î Qpsd ↓(normal incident, θ =90ºÎF(θ) minimum) where, I: beam current (mA) Y(ε): photoelectron yield (# of electrons/ # of photons) 10eV< ε ≦ 1560eV for aluminum, Y(ε) ≒ 2.61 ε-0.94 ≒ 441.9 ε–1.13 1560eV< ε < 10keV η: desorption coefficient (# of molecules /# of electrons) F(θ) ≒ sin-1/2 θ Ref: A.G. Mathewson et al., KEK report, KEK-78-9, (1978). Qpsd = I ×∫d/dt (d2N(ε)/dIdε)Y(ε)F(θ) dε × 2η ≒ 8.6 ×1017 I E εc-1/3 Y(εc ) F(θ) 2 η where d/dt (d2N(ε)/dIdε)≒1.51 × 1014 ρ/E2 (ε/εc )-2/3, for ε≦ ε c ≒0 for ε > ε c I: beam current (mA) E: electron beam energy (GeV) ε c : critical photon energy = 2.21 ×103 I E3/ρ F(θ) ≒ sin-1/2 θ ρ: bending radius (m) for aluminum, Y(εc ) = (0.41 - 1.66 εc-0.6) hv ≦ 1560eV = (1 - 216.2 εc-0.6) hv > 1560eV Throughput, Conductance and Effective Pumping Speed Throughput is the volume of gas at a known pressure and temperature that pass a plane in a known time. Throughput = Outgassing rate (if no absorption in the path) Q = P’(ch)S’(ch) = P(pump) S(pump) = C (P’(ch) – P(pump)) C : conductance of the tube (unit: l/s) = function of geometry, independent of pressure for the molecular flow regime 1/S’(ch) = 1/S(pump) + 1/C S’(ch) : effective pumping speed at the chamber C : conductance of the tube It is useless to use a large pump with a narrow tube! Pumping Pumping Configurations The conductance of the beam duct in an accelerator is always very small so that special pumping configurations are necessary to meet the stringent low pressure requirements. a) Distributed Pumping b) Localized Pumping Heavy HeavyGas GasLoad Load Î ÎAnte-chamber Ante-chamber++Localized LocalizedPumping Pumping IP NEG DIP NEG IP DIP NEG IP DIP Conductance ConductanceLimited LimitedArea Area Î ÎDiscrete DiscreteAbsorber Absorber++Localized LocalizedPumping Pumping NEG IP IP Insertion InsertionDevice DeviceChamber Chamber(extremely (extremelyconductance conductancelimited) limited) Î Î(Distributed (Distributedpumping) pumping)(NEG (NEGStrip Strip/ /NEG NEGcoating) coating) TMP TMP(commissioning) (commissioning) Î Î IP+NEG IP+NEG(normal (normaloperation) operation) TMP IP NEG Distributed Ion Pump Pressure Distribution Si Pi = Qi + Ci(Pi-1 – Pi ) + Ci+1(Pi+1 – Pi ) Ref: D.C. Chen et al., J. of Vac. Soc. of ROC 1(1), 24(1987). Pump considerations a) pumping speeds b) preferred gases c) ultimate pressure d) oil free e) vibration free f) micro-dust free g) failure safe (or interlocked) h) long lifetime and maintenance free Pumps a) Mechanical Pumps b) Sputter ion pumps c) Getters (NEG, TSP) (NEG: Non-evaporable getter, TSP : Ti-sublimation pump) d) Adsorption pump e) Cryo-pump Î Î Î Î Î NEG Turbomolecular Pump (TMP) Titanium Sublimation Pump (TSP) Non-Evaporable Getter (NEG) gas molecule N Sputter Ion Pump S Ti cathode electron anode (cell) Magnet field magnet ion N Ti cathode S Sputtered-Ti magnet Sputtered-Ti gas molecule (trapped) Vacuum Components and Reliability A. B. C. D. E. F. G. Vacuum Chamber Material and Treatment Sealing Technique Valves Bellows Mechanical feedthrough Electrical feedthrough Special components Vacuum Chamber Material (& thermal absorber) UHV Considerations --- low defect (to avoid virtual or real leak) --- low outgassing rate, low vapor pressure --- easy machining, easy welding (increase reliability) --- bakable High Thermal Load Considerations --- high thermal conductivity --- grazing incident (to reduce thermal density) --- differential heat removal, the first layer with low Z material Surface Treatments 1. 2. 3. 4. 5. chemical cleaning in-situ baking glow discharge cleaning surface coating high temperature degas Sealing Technique • Welding, Tungsten Inert Gas (TIG), metal-to-metal • Brazing, between two different materials, metal-toceramics, different metals, • E-beam welding • Flange sealing, Con-Flat Flange, O-ring, Helicoflex, metal wires (e.g. indium wire, aluminum wire, etc.) • leak check, He-gas mass spectrometer Leak rate unit: Torr-L-sec-1, Pa-m3-sec-1, atm-cc-sec-1 Valves • Gate Valves, Angle Valves, Variable Leak Valves, Fast Closing Valves • All metal valves and O-ring valves • Considerations: leak tight, tunability, response time, baking temperature, type of actuation, mechanical reliability and lifetime Bellows • • • • Flexibility, expansion/suppression dimension Rf sliding fingers (touch force, flexibility) Thermal conductivity Mechanical reliability (strength and lifetime) • How to fix ? or free suspended (vacuum force!!) Mechanical Feedthrough Applications: scrapers, screen monitors, rf tunners, front-end and beam line components, etc. Considerations: Stroke, Precision, Heat removal (thermal contact and cooling), Mechanical Reliability (wearing and lifetime) Electrical Feedthrough Applications: beam position monitors, stripline monitors, excitation electrodes, gauges, pumps, etc. Considerations: Frequency response, HV range, Current range Radiation induced damage (corrosion, degrade of contact or insulation) Special Components • • • • RF bridge Be-window Ceramic chambers Glass- and ceramic-windows Case Study A. B. TLS Vacuum System 1. Vacuum Chamber Fabrication and Treatments 2. System Installation and Operation TPS Vacuum System Design (Lessons learned from the TLS vacuum system) TLS Vacuum System Vacuum Chamber Fabrication and Treatments 1. Aluminum vacuum chambers 2. Oil-less Fabrication Process 3. Low Impedance Structure System Installation, Operation, and Commissioning 4. Oil-less and Effective Pumping System 5. Low-Dust Treatments 6. Vacuum Safety Interlock System The TLS Vacuum System A. Vacuum Chamber Fabrication 1. Aluminum vacuum chambers 2. Oil-less Fabrication Process 3. Low Impedance Structure B.System Installation and Operation 4. Oil-less and Effective Pumping System 5. Low-Dust Treatments 6. Vacuum Safety Interlock System Aluminum vacuum chambers Aluminum Components (B-chamber, S- chamber, flanges, gaskets, bellows, BPMs, etc.) Aluminum TIG Welding Al-Al and Al-S.S. Seals with Al Gaskets (between two chambers or components) (no transition material was used) Co-extruded or Co-machined Cooling Channels Oil-less Fabrication Process A. Bending Chambers Oil-less numerical control machining in an ethyl-alcohol environment Degreased cleaning B. Straight Chambers Extrusion Detergent + Acid + DI water ultrasonic cleaning Low Impedance Structure 1. Smooth Cross Section (main chamber: 38mm-H x 80mm-W) 2. Gate Valves, Bellows, Flange Gaps shielded with rf bridges 3. Smooth Transitions in Cross Sections 4. Port with small holes or slots 5. Long Slots with a Large Width to Height Ratio (in B-chamber for extraction SR to beamlines) Oil-less and Effective Pumping System 1. 2. 3. 4. Oil-less pumps were adopted sorption pump, dry pump (membrane pump + molecular drag pump), magnetic bearing turbo-molecule pump, sputter ion pump, and non-evaporable getters The pump locations and pumping speeds determined by computer simulations “Localized” pumping + distributed ion pump in the bending chamber Heavy dynamic gas loads mainly evacuated out of the vacuum system (by the TMPs) in the beginning of commissioning Low-Dust Treatments 1. 2. 3. 4. 5. Welding and pre-assembly in clean rooms. Clean booths were used during installation Ion pumps turned on after baking (at ~10-8 torr) Slow venting (if necessary) Low IP voltage (HV ~ 3kV) TLS Vacuum System (Fabrication) 4) DIP Installation 3) Surface Cleaning 2) Dimension Check After Machining 1) NC Machining with Ethyl Alcohol 5) Welding in Clean Room 9) Installation in the Tunnel 8) Pre-assembly In Lab 7) Leak Test 6) Deformation Check After Welding TLS Vacuum System (Fabrication) 88 80 Standard S-Chamber 38 44 80 B-Chamber 60 4.16 m ID-Chamber for EPU5.6, U5, U9 Undulators 174 13 17 171 ID-Chamber for Wiggler (W20) 17 21.5 10 mm TLS Vacuum System (Cold Chamber) ID-Chambers for Superconducting Wiggler SWLS (2002), SW6 (2003), IASW x3 (2005-6) (1) Al Beam duct (Extruded) (2) TIG welding on one side (3) Leakage Check (4) Flatness Check 11 mm inner height Al/SS Bimetal adaptor S.S. Taper (5) TIG Welding on the other side (with Al beam duct installed in SW6) Temperature of beam duct ~ 100 K SW6 TLS Operation Results (Beam Dose) 1). Accumulated Beam Dose : ~ 8622 Ah 1993.07 ~ 2005.11 (12 years) Yearly operation hour: ~5000-5500 hours 8622 Ah TLS Operation Results (Reliability) 2). High Reliability: Vacuum Failure < 2 hr/ year 600 PS Booster RF 400 Hour Control Magnet Vacuum 200 Utility Safety 0 Other 1996 1997 1998 1999 2000 2001 Total Year Machine Failure Hours -- About 100 hour (~2%) of the users’ time was lost in a year. -- Less than 2% of the failures (< 2 hours in a year) was attributed to the vacuum failure. -- The most popular items of the vacuum failures are utility related components. TLS Operation Results (Beam Cleaning) Installation of New Devices a) P/I vs. Beam Dose EPU,U5 SWLS W20 U9 SW 6 SRF cavity 1×10-10 Pa/mA b) I τ vs. Beam Dose 27 hours at 200 mA Lesson Learned from TLS -1 1) Beam Cleaning Interrupted by New ID Installations The data of P/I and I ·τ scattered due to frequent installation of new devices. Busy with Installation Work Replace new Kicker Chambers W20 EPU5.6 U5 SRF Cavity U9 P/I vs. time SWLS SW6 Top-up 300 mA Homework to Design the TPS (Lesson-1) Q1: Beam Cleaning Interrupted by New ID Installations, How to Avoid? A1: 1) -- Most of the ID-chambers are to be fabricated and installed before the TPS is commissioned, to prevent the vacuum from being frequently broken and to allow the beam dose on the ID-chamber to be accumulated effectively. -- Some ID-chambers will be unavailable at the commissioning of the TPS, they will be cleaned in a photon beam line before installation. 2) Effective pumping system is necessary for the ID-Chamber. -- NEG strip is to be installed in a side-channel of the beam duct as a distributed pumping. The arrangement is effective to reduce the potential effects caused by the drop off of the NEG powders in the beam channel. -- Some other pumps (e.g. Ion Pump) are required to remove the inert gases and methane, which the NEG cannot do. Lesson Learned from TLS -2 2) Effect of the Movements of Vacuum Chambers mA 200 100 0 Temp (C) The expanded vacuum chamber moves the components touched or connected to it. The force transferred to the girder, to the magnets and then to the beam orbit. 28 27 26 25 24 B eam C urrent 0 um mm -0.02 -0.04 -0.06 -0.08 400 600 800 1000 1200 1400 V ac-cham ber T em p 0 2.0 1.5 1.0 0.5 200 200 400 600 800 1000 1200 1400 B P M D isplacem ent 0 200 400 600 800 1000 1200 1400 B eam P osition 0 200 400 600 800 1000 1200 1400 m in Movement of the vacuum chamber, sensitivity to water temp.: ~10 μm / ℃ Movement of the girder (~0.3μm/℃) and BPM (~1μm/℃) Induced beam orbit drift: ~10-30 μm / ℃ Homework to Design the TPS (Lesson-2) Q2: Effects of the Movements of Vacuum Chambers, How to Reduce? A2: For vacuum chambers: 1) Independent supports fixed directly to the ground. 2) A 3mm gap between the magnet and vacuum chamber. 3) The vibration caused by water flow must be suppressed. A heavy chambers is helpful to reduce the vibration amplitude. Lesson Learned from TLS -3 3) Vacuum Pressure and RF Impedance Need be Better Vacuum Related Beam Instabilities 1) Pumping slotsÆ RF impedance 2) Gas molecules & ions > 1,000,000/cm3 !! (@0.1nTorr) SGV完全開啟與不完全開啟影像 SGV完全開啟(機構撐開) RF fingers撐開 SGV不完全開啟(機構未撐開) RF fingers未撐開 RF Fingers 撐開機構 RF Fingers 撐開影像 RF Fingers 撐開機構 故障! RF Fingers 撐開影像 RF Fingers 略彎曲影像 Al Bellows (R6S6) 影像 Heater RF contact Cu sheet PT100 Thermal sensor RF Fingers Homework to Design the TPS (Lesson-3) Q3: Vacuum Pressure and RF Impedance Need be Better, How to Improve? A3: A large B-chamber with ante-chamber structure. 5m 1) A large B-chamber can confine more PSDs locally. 2) It is easier to design with more pumps and also with a differential pumping structure in a large B-chamber to benefit the ante-chamber design, which is good in reducing the number of gas molecules (and ions) in the beam channel. Homework to Design the TPS (Lesson-3) 4) In addition to the chambers and pumping ports, the bellows, flange gap, gate valve, tapers, BPMs, and other monitors will be carefully designed to reduce the impedance. Movable end of RF fingers Movable end of RF fingers Fixed end of RF fingers (BPM-chamber: 70mm*13mm,Left side: SGV, Right side: ID ) TPS Vacuum Parameter TLS TPS Remark Beam energy (GeV) 1.5 3.0 Beam current (mA) 200 400 QTot atη= 1x10-5 molec./e (Torr*l/s) ~5.9x10-6 ~2.4x10-5 4x Q (for one cell) ~1x10-6 ~1x10-6 1x Beam Duct Material Aluminum Aluminum Bending Angle of Dipole Magnet (deg.) 20 7.5 Percentage of the synchrotron light inside the B- chamber 77% 92.8% more Nominal Pumping Speed (per cell) ~ 4000 L/s ~ 4000 L/s same Pump ports per cell 13 (on axis) 10 (off axis) less Pressure increase (design value) atη= 1x10-5 molec./ e ~1.3nTorr ~ 0.3nTorr 1/4 |Z/n| (Chamber/Total) 0.012/0.0163 0.003/0.0085 1/4 (1/2) Homework to Design the TPS (Lesson-4) 3 GeV, 400 mA, ~ 22 W/mm2 at L = 3.3 m (from BM source) ~196 °C Stepped surfaces fins in the cooling channel ~109 °C Saw tooth (0.4 mm / 2 mm-step) Crotch-1 Crotch-2 1) The thermal problem is reduced by designing a larger B-chamber, so that the crotch absorber in the Bchamber is farer away from the source point. The criteria are met by a B-chamber with ~ 5 m long. 2) By using stepped surfaces (to keep a smaller photo electric yield) and fins in the cooling channel enables the maximum temperature of the aluminum chamber surface to be reduced from ~196°C to ~109°C. Vacuum Safety Interlock System • • • • • device self protection or alarm (IP, IG, TMP) electrical or pneumatic actuated valves reliable vacuum interlock system (e.g. PLC) redundant sensors reliable utility systems (e.g. compressed air and cooling water systems) • Thermal problem protections
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