4. AL-1636-0722B SR - BE&C Chamber ESD.pdf

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

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Printed hard copies of this document are for reference only.

SR - BE&C Chamber - ESD

Thomas GAUCHER

Release Date: Jan 17 2024 11:54:15 AM PST

Document Number: AL-1636-0722 Revision: B

Document Status: Released

Document Type: SPECIFICATION

Category Code: AL7531

ALS-U - STORAGE RING

VACUUM CHAMBERS

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TABLE OF CONTENTS

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Introduction

4.1 Introduction to ALS-U

4.2 Subject of this Engineering Specification

5 Document Definitions

6 Description of the SR Beam Extraction and crotch chamber

7 NEG Coating (Optional)

8 Final design

9 Environmental requirements

9.1 Codes and Standards

9.2 Cleanliness environment

9.3 Cleaning fluids

9.4 Cutting fluids

9.5 Fasteners

10 Technical requirement

10.1 Vacuum pressure

10.2 NEG Coating (Option)

10.3 Manufacturing process

10.3.1 Material

10.3.2 Fabrication

10.3.2.1 Part fabrication

10.3.2.2 Cleaning after manufacturing

10.3.2.3 Part joining

10.4 Final Cleaning

10.5 Final Assembly

10.6 Final test and NEG coating

10.6.1 CMM Measurement before bakeout

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10.6.2 Bakeout

10.6.3 Residual Gas Analysis

10.6.4 NEG coating Inspection

10.6.5 Final He Leak Test

10.6.6 Final Pressure measurement

10.6.7 HPN2 Backfill

10.6.8 CMM Measurement after Bakeout

10.7 Packing and shipping

11 Aplicable Documents ci al ly R el ea se d to th e

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1 REVISION HISTORY

Rev. CM Number Description of Change A Baseline B

Section 8 Requirement added, “The angular error between the axis of the BPM holes at the top and bottom halves shall be less than 1 degree”

2 APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Ken Chow Chief Engineer and System Engineer Jiani Niu Project QA manager Olusola Omolayo Vacuum CAM Bertrand Nicquevert Mechanical Systems Lead Christoph Steier Accelerator Systems Lead Windchill Approved / Concurred By oomolayo

3 ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade ASTM American Society for Testing and Materials BPM Beam Position Monitor CF Conflate Flange CMM Coordinate Measuring Machine DCC Document Control Center He Helium HPN2 High Pressure Nitrogen EN-ISO European International Organization for Standardization LBNL Lawrence Berkeley National Laboratory PB Pumping Block UHV Ultra High Vacuum VC Vacuum Chamber VCR Vacuum Coupling Radiation WPS Welding Procedure Specification ci al ly R el ea se d to th e

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4 INTRODUCTION

4.1 Introduction to ALS-U

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS is a

1.9 GeV storage ring operating at 500 mA of beam current. It is optimized to produce intense beams of soft x-rays, which offer spectroscopic contrast, nanometer-scale resolution, and broad temporal sensitivity. The ALS facility includes an accelerator complex and photon delivery system that is capable of providing the foundations for an upgrade that will achieve world-leading soft x-ray coherent flux. The existing ALS provides a ready-made foundation, including conventional facilities and also includes extensive beamlines (up to 40 simultaneously operating beamlines) and instrumentation, an experimental hall, computing resources, ancillary laboratories, offices, and related infrastructure that will be heavily utilized in an upgrade scenario.

The ALS will be upgraded with a multibend achromat (MBA) lattice design that will provide a soft x-ray source that is orders of magnitudes brighter — an up to 100-1000 times increase in brightness and will provide a significantly higher fraction of coherent light in the soft x-ray region than is currently available at ALS.

4.2 Subject of this Engineering Specification

The SR Beam Extraction and Crotch (BE&C) vacuum chambers are part of the ALS-U storage ring and are located near the photon source point of all standard bend magnet beamlines. As the name suggests, the BE&C chamber provides a photon beam extraction port for the ALS-U bend magnet beamlines. The downstream section for the chamber hosts a crotch absorber that separates the extracted photon from the stored electron beam. The chamber features ports to host a beam position monitor (BPM) and several vacuum instrumentation including gauges, pumps and valves. The BPM and vacuum instrumentation are not in the scope of this contract. The ports on the BE&C chambers will be blanked off during the vacuum qualification steps of the fabrication process.

All of the 12 sectors of the ALS-U storage ring except sector 1 features BE&C vacuum chambers. Each sector of the SR is sectioned into units consisting 1 x straight section and 1 x arc section that further divide into 4 raft units. Each raft consists of magnets, vacuum chamber assemblies and support structures. The BE&C chamber span a dipole and a quadrupole magnet. The chamber will also be NEG coated. The chamber is also fitted with an integrated bakeout heater (See Figure 4-1).

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Figure 4-1: BE&C Chamber Design and Integration Overview

There are two design variants of the BE&C chambers: Standard Bend chamber and H-

Bend Chamber. The H-Bend BE&C chambers are used in sectors 4, 8 and 12 where the high field bend magnets are located. The standard Bend BE&C chambers are used in the other sectors.

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5 DOCUMENT DEFINITIONS

Shall, will, may, and should are used to define every specification listed in this document. The definitions of these terms are as follows

May – is used to indicate a desire or goal of a specification. This can also be interpreted

‘as nice to have’ and are not contractually binding.

Shall –is a specification that is contractually binding and must be implemented.

Should – is used to indicate a desire or goal of a specification. This can also be interpreted ‘as nice to have’ and are not contractually binding.

Will – is used to inform intent or declaration of purpose. This is not a specification.

Example, the author will use the word ‘shall’ to indicate that a specification is contractually binding and must be implemented.

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6 DESCRIPTION OF THE SR BEAM EXTRACTION AND CROTCH

CHAMBER

The main functions and requirements of the BE&C chamber are:

1. Provide a 13mm electron beam aperture through the associated dipole and quadrupole magnets.

2. Provide an appropriate aperture for the existing photon beam from the storage ring into the photon transport line of the respective beamline.

3. Host a BPM in the gap between the dipole and quadrupole magnets

4. Host a photon absorber at the downstream end of the chamber

5. Provide ports for hosting vacuum instrumentation including pumps in accordance to the vacuum design stipulated to meet vacuum requirements

6. Maximize the vacuum volume within the chamber to minimize conductance restriction

7. Support features to allow stability and positioning requirements to be met.

8. NEG coating of the internal surface in accordance to the vacuum design stipulated to meet vacuum requirements

9. Provide suitable flange interface along the beam path to adjoining chambers

The BE&C chamber has been designed by LBNL to meet these requirements and perform these functions. The chamber has four sections as shown in Figure 4-1:

1. Dipole section

2. BPM section

3. Quadrupole section

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Each section is geometry is unique and optimized to the space constraints of each section. The first three sections are achieved in one clamshell style chamber body. The fourth section is achieved in a monolithic machined body that is then welded to the clamshell.

The material of choice for this chamber is Aluminum (Al 2219-T851). The welding method is TIG welding with no filler. A similar chamber has been successfully prototyped by LBNL.

All ancillary vacuum ports utilize explosion bonded stainless steel CF flanges. The beam entry and exit flanges utilizes Helicoflex vacuum seals. The entry port is closed using a chain clamp, the exit port is bolted.

The clamshell section is machined in two halves and welded together. The welded clamshell is in turn welded to the crotch section (see Figure 6-1)

Figure 6-1: Welding assembly of the vacuum chamber parts

Top half shell

Lower half shell

Upper crotch chamber

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The chamber has bakeout heater grooves on the top and lower shell. The heaters will be press fit into the groove and held in place by local deformation of the chamber material near the grooves.

Figure 6-2: View of Heater groove

7 NEG COATING (OPTIONAL)

ID NUM

(SYY-XX-) Specification

S09-05- 000295

The chamber shall be NEG Coated. The surfaces highlighted in green below show the minimum area who need to be NEG coated. The selected contractor shall try in a best effort to coat as much of the entire internal surface as possible. See section 10.2 for technical requirement on the NEG coating.

Figure 7-1: NEG coating surface

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Figure 7-2: NEG coating surface

8 FINAL DESIGN

ID NUM

(SYY-XX-)

Specification

S09-05- 000296 The final design shall incorporate features to alleviate the risk of trapped volume along the clamshell weld lips.

S09-05- 000297 The mechanical deformation of any part of the chamber under atmospheric loads shall not exceed 0.2mm at any location on the chamber.

S09-05- 000298 There shall be no features that cross within +/- 2mm of the beam plane of the chamber except the external walls.

S09-05- 000299 The center axis through the BPM and crotch absorber section shall be fiducialised.

S09-05- 000300 There shall be no change to the position of the ancillary vacuum ports.

S09-05- 000301 The electron beam channel shall be void on any abrupt geometry change through the chamber.

S09-05-000302 The chamber is in very close proximity to magnets, therefore the overall footprint of the chamber shall be maintained unless otherwise approved by the ALS-U vacuum systems technical lead.

S09-05-000360 A process shall be developed using positioning pins to ensure the BPM button holes axis on the two halves of the main body is aligned to each other to within 50 microns before and after welding of the halves

S09-05-000361 The angular error between the axis of the BPM holes at the top and bottom halves shall be less than 1 degree ci al ly R el ea se d to th e

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9 ENVIRONMENTAL REQUIREMENTS

9.1 Codes and Standards

ID NUM

(SYY-XX-) Specification

S09-05-000303

The following standards shall apply for the fabrication and test of the SR BE&C chamber:

EN ISO 13919-2 or EN ISO 10042

EN ISO 17637

ASTM E498.

EN ISO 17640

ASTM E2734/E2734 M − 10

9.2 Cleanliness environment

ID NUM

(SYY-XX-) Specification

S09-05-000304 The cleaning environment shall comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.2

9.3 Cleaning fluids

ID NUM

(SYY-XX-) Specification

S09-05-000305 The cleaning fluids shall comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.3

9.4 Cutting fluids

ID NUM

(SYY-XX-) Specification

S09-05-000306 The cutting fluids shall comply with UHV Chamber and Component Production Requirements AL-1220-7841, §7.4

9.5 Fasteners

ID NUM

(SYY-XX-) Specification

S09-05- 000307 The fasteners of the of vacuum chambers shall comply with AL-1220- 7841, §7.6 ci al ly R el ea se d to th e

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10 TECHNICAL REQUIREMENT

10.1 Vacuum pressure

ID NUM

(SYY-XX-)

Specification

S09-05-000308 The maximum thermal outgassing rate shall be better than 1.00e-11 Torr.l.s-1.cm-2

S09-05- 000309 Achievable final pressure shall be 5.00e-10 Torr

10.2 NEG Coating (Option)

ID NUM

(SYY-XX-)

Specification

S09-05-000310 The thickness of the NEG coating shall be between 0.5 to 1.5 micron

S09-05-000311 The NEG material shall be 30%,30%,40% atomic weight. TiZrV +/- 10%

S09-05- 000312 The NEG film shall be deposited using PVD process using Krypton gas

S09-05- 000313 The vacuum pressure achieved on the NEG coating station prior to NEG coating shall be better than 1e-8 Torr and a clean RGA scan

S09-05- 000314 The NEG coated chamber shall be free of surface oxides and sufficiently cleaned prior to NEG coating to ensure adhesion

S09-05- 000315 The NEG coating coverage on the internal surface of the chamber along the electron beam path channel shall be greater than 99%

S09-05- 000316 The NEG coating shall be carried out at a chamber temperature of 100oC +40 oC /- 0oC

S09-05- 000317 The coating recipe shall be maintained from the first article to the production chamber coatings ci al ly R el ea se d to th e

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10.3 Manufacturing process

10.3.1 Material

The procurement of the raw material by the Sub-contractor shall comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-05- 000318 All materials shall be new.

S09-05- 000319 All material shall be free from surface cracks and fissures, forge and other tool marks, burns, delamination and other defects that would make it incompatible with a high vacuum environment.

S09-05- 000320 Certification shall be in accordance with EN ISO 10204 3.1.

S09-05- 000321 Magnetic permeability for vacuum chamber base material shall be

1.01 and for welds or braze joints 1.04

S09-05- 000322 The material shall be compatible with synchrotron radiation

10.3.2 Fabrication

10.3.2.1 PART FABRICATION

The fabrication of the SR BE&C chamber shall comply with the following requirements

Cutting fluids

ID NUM

(SYY-XX-) Specification

S09-05- 000323 A water-soluble and non-halogenated cutting fluids shall be used for fabrication

S09-05-000361 An intermediate CMM measurement of all parts along the electron and photon beam path shall be carried out prior to welding including surface roughness measurement.

S09-05- 000324 All others requirements relative to the vacuum components fabrication shall comply with AL-1220-7841, §8.1, §8.2, §8.3 ci al ly R el ea se d to th e

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10.3.2.2 CLEANING AFTER MANUFACTURING

An intermediate cleaning must be done after manufacturing and shall comply with the following requirements

ID NUM

(SYY-XX-) Specification

S09-05-000325 UHV surfaces shall be protected as per best practices during handling operations.

S09-05-000326 Parts shall be stored in a clean area from the workshop (See §9.2).

S09-05-000327 Parts shall be suspended in tanks by wire, hooks or in baskets

S09-05-000328 All others requirements relative to the vacuum components cleaning shall comply with AL-1220-7841, §9

10.3.2.3 PART JOINING

The joining process of the components must comply with the following requirements

General requirement

ID NUM

(SYY-XX-)

Specification

S09-05-000329 Step change in geometrical profile across weld shall be less than 0.2mm

S09-05-000330 All parts shall be cleaned prior to welding (See §10.4)

S09-05-000331 A WPS is not required

S09-05-000332 The weld quality shall be level D according to EN ISO 13919-2 or EN

ISO 10042

S09-05-000333 All welds shall be free from cracks and fissures or other defects that would make it incompatible with a high vacuum environment.

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Inspection of welded joints

ID NUM

(SYY-XX-) Specification

S09-05-000334 100% of the vacuum boundary welded joints shall be visually inspected

S09-05-000335 The visual inspection shall comply with EN ISO 17637

Component leak check

ID NUM

(SYY-XX-) Specification S09-05-000336 100% of the vacuum boundary welded joints shall be leak tested.

S09-05-000337 The leak test of the welded joint shall comply with ASTM E498.

S09-05-000338 The criteria and parameter expected for the He leak check shall comply with AL-1220-7841, §14

10.4 Final Cleaning

The final cleaning of the SR BE&C chamber must comply with the following requirements

General requirement

ID NUM

(SYY-XX-)

Specification

S09-05-000339 Once the final cleaning process has started, it shall not be stopped before the end.

S09-05-000340 After the final cleaning, all subsequent operations shall be performed in a cleanroom.

Cleaning

ID NUM

(SYY-XX-) Specification

S09-05-000341 The cleaning agent used shall be identified and approved by LBNL prior to the Factory acceptance test.

S09-05-000342 All other requirements regarding the final cleaning and intermediate inspection shall comply with AL-1220-7841, §11 and §12.

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10.5 Final Assembly

(SYY-XX-) Specification

S09-05-000343 All requirement with final assembly shall comply AL-1220-7841, §13

10.6 Final test and NEG coating

The final tests to ensure the performance of the SR BE&C chamber must be performed in the sequence shown in Figure 10-1.

Figure 10-1: Final test sequence ci al ly R el ea se d to th e

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General requirement

(SYY-XX-) Specification

S09-05-000344 All test shall take place in a clean room

S09-05-000345 During pumping down of the part, all connection above the turbo pump shall be all-metal

S09-05-000346 The HPN2 port shall be all-metal

S09-05-000347 The HPN2 port shall be a VCR to CF16 adapter that is replaced with a CF16 blank as the last connection to the chamber prior to shipping.

S09-05-000348 LBNL shall have right to visit the contractor during these tests

10.6.1 CMM Measurement before bakeout

ID NUM

(SYY-XX-) Specification

S09-05-000349 A CMM measurement shall be performed, on all SR BE&C chambers

S09-05-000350 The dimensions to be controlled shall be specified by the University technical representative.

10.6.2 Bakeout

ID NUM

(SYY-XX-) Specification

S09-05-000351 Bakeout shall comply with AL-1220-7841, §14.1

10.6.3 Residual Gas Analysis

ID NUM

(SYY-XX-) Specification

S09-05-000352 Residual Gas Analysis shall comply with AL-1220-7841, §14.2

10.6.4 NEG coating Inspection

ID NUM

(SYY-XX-)

Specification

S09-05-000353 NEG coating coverage shall be inspected on the first article by insertion of a camera probe through the chamber

S09-05-000354

A short Aluminum ribbon sample shall be placed in the extension chamber in series with every coated chamber. The thickness of coating on the ribbon sample shall be reported in a least 3 locations around the circumference of the ribbon.

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10.6.5 Final He Leak Test

(SYY-XX-) Specification

S09-05-000355 Final pressure measurement shall comply with AL-1220-7841, §14.4

10.6.6 Final Pressure measurement

ID NUM

(SYY-XX-) Specification

S09-05-000356 Final He leak test shall comply with UHV Chamber and Component Production Requirements AL-1220-7841, §14.5

10.6.7 HPN2 Backfill

ID NUM

(SYY-XX-) Specification

S09-05-000357 HPN2 Back fill shall comply with AL-1220-7841, §14.6

10.6.8 CMM Measurement after Bakeout

ID NUM

(SYY-XX-) Specification

S09-05-000358 A CMM measurement shall be performed on all SR BE&C chamber with the same critical dimension given in §10.6.1 after the bakeout

10.7 Packing and shipping

ID NUM

(SYY-XX-) Specification

S09-05-000359 Packing and shipping shall comply with AL-1220-7841, §15 ci al ly R el ea se d to th e

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11 APLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document shall be valid to the full extent, unless specifically noted within this document. Applicable documents shall be obtained from the LBNL Document Control Center (DCC).

Table 11-1: Applicable documents ID Document

Number Title

1 AL-1220-7841 UHV Chamber & Component Production Requirements

2 AL-1507-6867 BE&C Standard - Chamber -Weldment 3 AL-1585-5778 BE&C H-Bend - Chamber –Weldment VC08 / VC10 4 AL-1633-8530 Blank Flange QF 50 F 5 AL-1633-7073 Blank Flange QF 63 F 6 AL-1665-0271 BPM Blank

7 AL-1663-8349 OBROUND END CAP, H-BEND CHAMBER

8 AL-1664-4944 END COVER PLATE

9 AL-1458-3547 CROTCH CHAMBER SUPPORT BRACKET

10 AL-1637-3398 PUMP MOUNT

11 AL-1433-1932 MOUNT

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