Accelerator/RF systems Anders Sunesson RF group leader www.europeanspallationsource.se April 22, 2015 RF Overview • RF provides the power to accelerate • 2 WPs are covered, WP 8 and WP 17 • There are 155 cavities to be powered, each by one amplifier station • Start at the wall power plug end at the cavity coupler • New development: SML modulator topology • New development: MB-IOT amplifier • Costbook value 166 M€, ≈118 WP8, ≈48 WP 17 • A large part of the RF systems is provided in kind 2 RF In Kind discussions • NC RF systems and Spoke LLRF provided by ESS-Bilbao • Spoke RF transmitters provided by Elettra • Spoke, medium/high beta interlock systems provided by Hungary • 704 MHz LLRF provided by Poland • Phase reference line provided by Warsaw Technical University • Distribution systems spoke, medium and high beta provided by Huddersfield University • Installation services provided by IFJ PAN Krakow • Ongoing discussions on design of dry HV HF transformers with Technical University Tallinn, Estonia • Covers all of WP 8 except Master oscillator, medium/high beta amplifiers • Covers WP 17 except medium/high beta High voltage supplies 3 Master Schedule – RF Systems MILESTONES REVIEWs MASTER SCHEDULE - RF SYSTEMS Q3 2015 Q4 Q1 Q2 Q3 Q1 Q2 2017 Q3 Q4 Q1 Q2 UPPSALA TEST STAND 1st KLYSTRON PROTOTYPE READY FOR TESTS MASTER OSCILLATOR PROTOTYPE READY PHASE REFERENCE 352 & 704 MHz DISTRIB. READY RF LAYOUT PLAN READY Q3 2018 Q4 Q1 FULL ACCESS TO TUNNEL 2-MAY-2017 EARLY ACCESS TO GALLERY 7-OCT-2016 MS PROTOTYPING 2016 Q4 Q2 2019 Q3 Q4 Q1 Q2 FULL ACCESS TO GALLERY 31-MAY-2018 Q3 2020 Q4 Q1 Q2 Q3 2021 Q4 2022 Q3 FIRST PROTON ON TARGET 28-JUNE-2019 Q4 Q1 Q2 Q3 Q4 CAPABILITY for 2 GeV 23-SEPT-2022 LLRF PROTOTYPE & CONTROLS READY 330 kVA MODULATOR PROTOTYPE CDR LOW LEVEL RF & CONTROLS Q2 DECISION IOT or KLYSTRON for HIGH BETA LINAC 1st IOT PROTOTYPE READY FOR TESTS SML 130 kVA MODULATOR PROTOTYPE Q1 TECHNICAL STOP Q2 TECHNICAL STOP 2014 Q1 SYSTEM DESIGN AND INDUSTRY PREPARATION PROCUREMENT AND MANUFACTURE INSTALLATION AND COMMISSIONING TRR LAST DELIVERY INSTALLATION PHASE 1 INSTALLATION PHASE 2 CDR HB LAST DELIVERY MODULATORS MB LAST DELIVERY TRR INSTALLATION PHASE 1 MB SPEC INSTALLATION PHASE 2 MB CDR HIGH POWER AMPLIFIER MB LAST DELIVERY INSTALLATION PHASE 1 HB LAST DELIVERY INSTALLATION PHASE 2 RF DISTRIBUTION CDR ] DATA EXTRACTED BY P6 PLANNING - MARCH 2015 TRR PHASE 1 LAST DELIVERY INSTALLATION PHASE 1 PHASE 2 LAST DELIVERY INSTALLATION PHASE 2 PREPARED BY A. SUNESSON, L. LARI & L. GUNNARSSON CHECKED BY J. WEISEND APPROVED BY M. LINDROOS RF Technical performances 352.21 MHz 2.4 m Source LEBT 75 keV 4.5 m RFQ 3.6 m MEBT 704.42 MHz 40 m DTL 3.6 MeV 54 m 75 m Spokes Medium β 90 MeV Energy (MeV) Frequency /MHz 220 MeV 174 m High β HEBT & Contingency Target 570 MeV 2000 MeV No. of Cavities βg Temp / K RF power /kW Source 0.075 - 0 – ~300 – LEBT 0.075 - 0 – ~300 – RFQ 3.6 352.21 1 – ~300 1600 MEBT 3.6 352.21 3 – ~300 20 DTL 90 352.21 5 – ~300 2200 Spoke 220 352.21 26 (2/CM) 0.5 βopt ~2 330 Medium β 570 704.42 36 (4/CM) 0.67 ~2 870 High β 2000 704.42 84 (4/CM) 0.86 ~2 1100 HEBT 2000 – 0 – ~300 – RF Selected technologies • Two new technology developments are presented • SML – stacked mutli-level modulator topology • This gives scalable, compact, and cost effective solutions • Multi-beam IOT • This gives higher efficiency, and a more compact system compared to klystrons • The following slides detail technology choices and strategies throughout RF systems 6 Modulators Strategy A • ESS internal development of a new topology (SML – Stacked Multi-Level) • Construction and validation of a Reduced Scale prototype rated for 120 kVA (115kV / 20A, 3.5ms / 14Hz) in collaboration with Lund University (LTH). Can power one 704MHz 1.2MWpk klystron • Project has started in June 2013. Completion and demonstration of technology are foreseen for fall 2015 • Upgrade to the full scale system 660kVA (115kV / 100A, 3.5ms / 14Hz) is a matter of thermal re-design and selection of higher current components. The full scale modulator is able to power 4x 704MHz 1.2MWpk klystrons in parallel. Straightforward approach with low risks 7 Modulators Strategy B • ESS has launched an Invitation To Tender for the design and construction of one 330kVA modulator • • • • Contract awarded to Ampegon on June 2014 Technical Design Report under review Delivery foreseen for Feb 2016 Soak testing in Uppsala RF test stand, from March to May(?) 2016 • CEA / Saclay has launched an Invitation To Tender for the design and construction of another 330kVA modulator for their RFQ test stand. It can also serve as a technology demonstrator for ESS • Contract awarded to DTI on Oct 2014 • Delivery foreseen for Jan 2016 • Soak testing at CEA/Saclay RFQ test stand from January to April(?) 2016 8 The Stacked Multi-Level (SML) to modulator: From a conceptual design reality… – Development roadmap Sept ’13 – May ’14 Apr ’14 Modulators for ESS Klystron CAP. BANK 6 DC- LEM 1+ LEM 1- LEM 2+ HF Transformer 2 Lf LEM 3+ LEM 2- Cf HF Transformer 3 KLYSTRON OIL TANK (NOT PART OF THE SUPPLY) Lf KLYSTRON HEAD HF Transformer 4 HV CABLE LEM 4+ LEM 3- Cf KLYSTRON BODY Construction and testing of High Voltage Oil tank assembly Feb’15 to Sept’15 Lf LEM 5+ LEM 4- Cf HF Transformer 5 Lf Cf LEM 5- DRIVER Lf Cf LEM 6+ DRIVER Kds ON OFF DRIVER DC/AC #6 Ldc C HF Transformer 1 HF Transformer 6 Lf Cf LEM 6- DRIVER GSw Rds CAP. BANK 5 DRIVER DC+ LEM DC-C DRIVER CC Rcb LEM T-C Rp DRIVER DRIVER KAC C LEM CB-C DRIVER Lf T-C DC/DC #C AC/DC #C Tcb 24 V dc LEM R-C Lf S-C LEM S-C MCB DRIVER DC/AC #5 Lf R-C No Volt Coil Jun ’13 DB- 14 24 24 V dc A2 A1 13 23 SD DRIVER Kds CAP. BANK 4 SDE OF DRIVER GSw DC/AC #4 Ldc B LEM T-B KAC B Rds CAP. BANK 3 DRIVER DB+ LEM DC-B DRIVER CB DRIVER DRIVER Lf T-B DRIVER Lf S-B LEM S-B EMC FILTER LEM CB-B Rcb LEM R-B DC/DC #B AC/DC #B Rp Lf R-B T DRIVER Kds DC/AC #3 Tcb 24 V dc R S DA- 14 24 A2 R PreCh (3x) A1 24 13 23 DRIVER DC/AC #2 CAP. BANK 2 KPreCh 23 DRIVER GSw CAP. BANK 1 Ldc A LEM T-A KAC A 14 24 DC/AC #1 Rds 13 23 LEM DC-A CA Rcb DRIVER Lf T-A LEM CB-A DRIVER Th PreCh DC/DC #A AC/DC #A Rp LEM R-A Lf S-A LEM S-A DRIVER A2 Lf R-A OIL TANK (NOT PART OF THE SUPPLY) (PART OF THE SUPPLY) DA+ Tcb A1 24 V dc 14 24 24 V dc CABINET #2 (INVERTERS) 14 24 DRIVER A1 13 23 AUX POWER SUPPLY (PART OF THE SUPPLY) 13 23 - A2 CABINET #1 (CAPACITOR CHARGERS) + Experimental results, low voltage stage May ’14 Carlos A. Martins – ESS AB, Accelerator Division, RF Group Jan ’15 9 Aug ’14 9 Modulator decision chart (to medium b) Strategy A - SML B:1Ampegon Ready/Delivery Validated Fall 2015 Q1 2016 Decision point End 2015 Mid 2016 If A: SML fully validated, Q1 2016 If B: July 2016 B:2 - DTI Q1 2016 Mid 2016 Outcome Strategy A: Launch call for tender for 660 kVA units medium beta. ESS Bilbao similar action for NC linac Strategy B: Launch call for tender for 330 kVA units for medium beta. ESS Bilbao similar action for NC linac Note: higher cost (≈6 M€ Mb), schedule challenges 10 ESS LLRF prototype and efforts – – – – – – – mTCA 4 standard Regulation 352 and function 704 tested Adaptive feedforward learning Lorentz force detuning compensation Tests (352 @ FREIA, 704 @ Saclay) Klystron linearisation Requirements on precision • • • • • Control/cavity system modeling Beam physics (loss) modeling Regulation system set-up Handling beam current variations Handling modulator ripple • Note all LLRF provided in kind 11 Phase ref line • First design prepared • Prototyping 2015-2016, scaled down version to test Temperature controlled within ±0.1°C MO 20dBm,352.21MHz ~40dBm, 352.21MHz • Phase reference signal delivery system • Air pressure system • Temperature control system • Data acquisition, drift calibration, EPICS interface • Phase reference line provided in-kind 20dBm, 704.42MHz ~50dBm, 704.42MHz Temperature controlled within ±0.1°C 352.21MHz, 1 5/8’’ rigid line 704.42MHz, 1 5/8’’ rigid line … … 12 High power amplifiers Section Power /kW Baseline Status Normal conducting RFQ and DTL 2800 Klystron In kind Normal conducting bunchers 30 Solid State In kind Spoke linac 400 Tetrode In kind Medium beta linac 1500 Klystron Prototyping 1500/1200 Klystron/IOT MB-IOT (decision end 2017) Prototyping High beta linac 13 Spoke power sources • 400 kW tetrode-based solution • Two complete stations to Uppsala University FREIA facility (Proof of concept) • FAT of tube recently (Thonon) Results Peak power 200 kW Efficiency 66% Gain 15 dB Duty 4.6% 14 Medium and high beta (klystron option) Three klystron prototypes are being procured, from three different manufacturers (Thales, Toshiba and CPI) Status of the contract Expected delivery date Thales Contract started in January 2015 (Kickoff meeting held at the end of January) Klystron design based on the TH2182 for Cern with minor modifications Design review in one month March 2016 Toshiba Contract started at the beginning of March 2015 (Kickoff meeting held on March 17th) Design review next May May 2016 Contract in place July 2016 CPI Toshiba E37504 CPI Thales TH 2180 15 Multi-Beam IOT for ESS (High beta baseline) 10 Beam Multi-Beam IOT 1.2 MW 704 MHz 16 Output Power [MW] 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 Multi-Beam IOT, courtesy L3, CPI, Thales MAGIC-3D simulation of one beam with MB-IOT offaxis B-field 45kV Body Current Per Beam [A] Output Power [MW] 6 8 10 Input Power [kW] 12 14 16 36kV 40kV 45kV 50kV 0 0 4 36kV 40kV 45kV 50kV 0 2 2 4 0.80 1.2 0.75 1 0.70 0.8 0.65 0.60 0.6 0.55 0.4 0.50 0.45 0.2 0.40 0 0.35 0.30 0 0 6 8 10 [kW] 6 Input Power 8 10 Input Power [kW] 4 1.4 Efficiency Body Current Per Beam [A] Vk = 48 kV Class-C 2 2 1.8 1.4 1.6 1.2 1.4 1.2 1 1 0.8 0.8 0.6 0.6 0.4 0.4 0.2 0.2 0 12 12 14 14 16 16 36kV 40kV 45kV 50kV 2 2 4 6 8 10 [kW] 6 Input Power 8 10 Input Power [kW] 4 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0.45 0.40 0.35 0.30 12 12 36kV 40kV 45kV 50kV 14 14 16 16 Power and Efficiency Impact of HV Efficiency 1.2 MW 40kV 50kV 0 Power Transfer Curve 36kV 36kV 40kV 45kV 50kV 17 0 2 4 6 8 10 12 14 16 IOTs and power supplies for high beta • 2 prototypes will be delivered end 2016 • Testing at CERN complete mid 2017 • IOT/Klystron decision for high beta end 2017 – If IOT looks successful PSU development needed • Proof of concept start 2017 • Start of series contract 2018 • Delivery first unit 2020 – If Klystron is the choice • Start of series contract 2018 • Delivery first unit 2020 18 IOT/Klystron selection criteria • Technical performance • Project risk • Financial considerations • Manufacturing capability compatible with timescales • Power output minimum 90% of rated power • Reliability (time to repair/replace, MTBF trip & fault) • (ESS document ESS-0008307) 19 RF Distribution systems Section Type Status Partner Normal conducting RFQ and DTL Waveguide In kind ESS Bilbao Normal conducting bunchers Transmission line In kind ESS Bilbao Spoke linac Waveguide In kind +Prototype UU Huddersfield University Medium beta linac Waveguide In kind +Prototype Lund Huddersfield University High beta linac Waveguide In kind +Prototype Lund Huddersfield University • Issues: high temperature cooling water in loads – new external development needed • Several km of waveguides needed 20 Interlock: Prototype design – PLC module plus fast module. – PLC monitors slowly varying signals (temperatures etc) – Two FIM (Fast Interlock Module) are being designed in parallel (arc detectors, pin diodes, etc) • Siemens FM352-5 Fast Boolean Processor (FPGA based) – 12 Inputs / 8 outputs per module. Only 24VDC digital inputs/outputs are available. • Fast Interlock Module NI cRIO connected via Fieldbus to the main controller PLC CPU. Different signal types I/O are available. 21 RF Integration and Verification • RF systems will be prototype level tested at CERN (IOT), FREIA (330 kVA modulator, 704 klystron), Lund (Reduced scale SML modulator, 704 klystron) • In kind contributions will be tested at our partner sites prior to delivery • RF systems will be installed directly in the gallery and tested on site (by our partners and as part of Polish contribution from Krakow) • A detailed plan for these activities is needed 22 RF Organization • Until EOC there will be – 13 technicians added to WP 8 – 5 technicians added to WP 17 23 RF Major Procurements I • 330 kVA modulator prototype • Awarded t o Ampegon Jan 2014 • Cost 1100 k€ • Delivery schedule Jan 2016 • 2nd 330 kVA modulator • For Cryomodule test stand Lund • Estimated cost 1440 k€ • Call for tender Q4 2015, delivery Q4 2017 • Medium beta linac modulators • • • • 9 x 660 kVA modulators baseline 10300 k€ total Possible suppliers Jema, DTI, Ampegon,… Call for tender Q1 2016, delivery Q4 2017-Q1 2019 24 RF Major Procurements II • 704 MHz 1.2 MW Multi-beam IOT prototypes • 2 contracts awarded to L3 and CPI/Thales consortium • Cost 5000 k€ together • Delivery scheduled Oct 2016 • 704 MHz 1.5 MW klystron prototypes • 3 contracts awarded to Toshiba, Thales, and CPI • Cost 1400 k€ together • Delivery scheduled March 2016 (Thales), May 2016 (Toshiba), and July 2016 (CPI) • Medium beta 704 MHz klystrons • • • • 36 x 1.5 MW klystrons Cost 11200 k€ total Possible suppliers Thales, Toshiba, CPI,… Call for tender Q3 2016, delivery Q2 2018-Q2 2019 25 RF Major Procurements III • High beta linac modulators • • • • 21 x 660 kVA modulators baseline 21000 k€ total Possible suppliers Jema, DTI, Ampegon,… Call for tender Q4 2017, delivery Q1 2020-Q2 2022 • High beta 704 MHz IOTs • • • • 84 x 1.5 MW IOTs baseline Cost 26000 k€ total Possible suppliers Thales, L3, CPI,… Call for tender Q2 2018, delivery Q3 2019-Q2 2022 26 RF Top risks Issue Risk Solution A large fraction of the RF systems is designated as inkind In kind partners might redesign already designed systems like LLRF, LPS, and Spoke RF transmitters When milestone slippage is detected, procure from industry In kind partner personnel not capable of delivering the desired functionality When milestone slippage is detected, procure from industry Gallery space is very tight and not all is designed RF systems might not fit into the gallery Add space The klystrons are cooled at high temperature (50 -80 C) 1)Reduced lifetime 2)Not stable performance 3)Unsafe Cool klystrons at 30 C 27 Next Six Months • HoAs and in kind contracts signatures, and finalisation of the SoWs (mid summer) • Continued follow-up of IOT, klystron, and modulator contracts • Finalization of the SML modulator prototype • First HV tests of SML prototype • Hiring of four positions to the RF group • Finalization of interlock system design • Phase reference line prototype 28 RF Summary • • • • Power to all accelerating cavities provided Very demanding schedule Challenging in kind portion Exciting new developments • SML modulator topology • MB-IOT concept 29 Thank you 30 • SPARE SLIDES 31 High Voltage oil tank assembly: - Design in view of construction . Collaboration with LU HV module HV oil tank assembly (Collaboration between ESS and LTH) - Design of the whole system undergoing; HV module (HV transformer + HV rectifier) Construction and validation of one HV module prototype is undergoing: - HV transformer assembled (first test results obtained two weeks ago); - HV rectifier is under construction (PCB’s delivered last Tuesday) control signal primary voltage secondary voltage secondary current 32 330 kVA modulator, strategy B1 AMPEGON AG H-bridge inverters (x36) based on MOSFET’s (x720) Electrolythic capacitors (x108) HVHF transformers (x36 units) 33 330 kVA modulator, strategy B2 Diversified Technologies Incorporated, DTI Pulse Transformer (7.4tons; 1’850 liters of oil) 34 Primary pulse generator (weigth = 5 tons) LLRF system NC Power Grid Klystron modulator 9 U 10 I Pz Ctrl fine grain tuning Circulator Pz PreAmp Klystron 3 LLRF system: Motion control Cavity 4 5 6 7 M Motor Ctrl coarse grain tuning Load 2 1 LLRF system: PI-controller 1 … 10 Phase Reference Clk 352.21 MHz 8 Master Oscillator LLRF system: Monitoring & Storing Warning/Errors 35 Prototype Block Diagram Temperature controlled within ±0.1°C Data Acquisition and EPICS interface MO 20dBm,352.21MHz ~40dBm, 352.21MHz 20dBm, 704.42MHz ~50dBm, 704.42MHz CPU Data Communication Bus Data Acquisition Board Input from temperature sensors, air pressures, amplifier protection signals 7/8’’ Coaxial cable Temperature controlled within ±0.1°C 352.21MHz, 1 5/8’’ rigid line Drift Calibration 704.42MHz, 1 5/8’’ rigid line Digital Domain … … • 16dBm at each tap point for LLRF, BPMs, and BSMs • Total 12 taps in prototyping • SNR at each output shall be >70dB in single side bandwidth1MHz • Integral phase noise 1Hz~100kHz shall be >70dB AD C AD C AD C AD C AD C AD C AD C AD C AD C 3/8’’ coaxial cable Input from 6 taps and 2 MO outputs 36 Medium and high beta (klystron option) 36 Medium beta elliptical cavities: 704.42 MHz, input power from 207 kW to 866 kW (plus 30% for losses compensation and overhead) saturated power from klystrons up to 1.15 MW 84 High beta elliptical cavities: 704.42 MHz, input power from 835 kW to 1.1 MW (plus 30% with klystrons); 1.2 MW MB IOTs (or klystrons as backup) Racks Klystron specs Nominal output power 1.5 MW Frequency 704.42 MHz BW ≥ +/- 1 MHz Pulse width 3.5 ms Repetition rate 14 Hz Perveance 0.6*10-6 Efficiency >60% VSWR Up to 1.2 Power Gain ≥ 40 dB Group Delay ≤ 250 ns Harmonic Spectral content ≤ -30 dBc Spurious Spectral content ≤ -60 dBc Klystrons Modulators 4.5 Cells of 8 klystrons for Medium Beta 10.5 Cells of 8 klystrons (IOTs) for High Beta 37 Output Power [MW Operational Optimisations Courtesy of L3 Communications 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 36kV 40kV 45kV 50kV 0 Power and Efficiency Impact of HV Efficiency Body Current Per Beam [A] Increased beam voltage provides for better performance • Increases gain • Increases efficiency • Decreases body current Simulations are for 10 beams 00 1.4 0.80 1.2 0.75 0.70 1 0.65 0.8 0.60 0.55 0.6 0.50 0.4 0.45 0.40 0.2 0.35 0 0.30 78 0 0 4 6 8 10 Input Power [kW] 0.80 0.75 74 0.70 72 0.65 0.60 70 0.55 0.50 68 0.45 0.40 66 0.3535 0.30 0 12 14 16 36kV 40kV 45kV 50kV 36kV 40kV 45kV 50kV 22 44 66 88 1010 Input Power [kW] Input Power [kW] 1212 1414 1616 36kV 40kV 45kV 50kV 36kV 40kV 45kV 50kV 2 2 4 4 76 Efficiency Efficiency [%] Plot shows maximum achievable efficiency for various operating points Body Current Per Beam [A] Output Power [MW] 1.3 MW 70% eff 2 1.4 1.8 1.2 1.6 1.4 1 1.2 0.8 1 0.8 0.6 0.6 0.4 0.4 0.2 0.2 00 2 40 2 4 6 8 10 6 8 10 Input Power [kW] Input Power [kW] 45 50 Voltage [kV] 6 8 10 Input Power [kW] 12 12 55 12 14 14 16 16 36kV 40kV 45kV 50kV 60 38 14 16 MAGIC Prediction of MB-IOT Performance Courtesy of Thales and CPI Power Transfer Curve Efficiency & Gain vs Output Power 1.2 MW Efficiency Gain Vk = 48 kV Class-C MAGIC-3D simulation of one beam with MB-IOT offaxis B-field • • At 1.2 MW, h = 72% with Vk = 48 kV At 600 kW • h = 59% with Vk = 48 kV • h = 68% with Vk = 34 kV 39 Some results from the TH2182 klystron testing at CERN The klystron TH2182 has also been tested at ESS parameters Nominal output power 1.5 MW Frequency 704.42 MHz Beam Voltage 111.4 kV Beam current 22.2 Repetition rate 2 Hz Pulse length 1.8 ms Efficiency 66% Saturated Gain 45.15 dB Group Delay 130 ns 40 Courtesy of Thales ED and CERN Distribution system layout example MB ESS needs waveguides in Huge quantity 41