The Four 50 MW XL4 X-band klystrons installed on the 8-Pack
The Demonstrate an NLC power source Two Phases: 8-Pack Phase-1 (current): Multi-moded SLED II power compression Produce NLC baseline power: 475 MW 400 ns. LC TRC R1 requirement for GLC/NLC: Demonstration of the SLED II pulse compression system RF power and energy handling capability at the design level. 8-Pack Phase-2 (2004): Use the SLED II system for a Linac sub-unit test: A full power demonstration of an RF feed to 4.8 m of high gradient structures on the NLCTA beamline. One of the LC TRC R2 requirement for GLC/NLC: A linac subunit test
The Phase 1&2 baseline goals NLC Baseline Phase 1 Phase 2 Klystrons @ power 2 @ 75 MW 4 @ 50 MW 4 @ 50 MW Pulse length 1.6 µs 1.6 µs 1.6 µs Klys. - SLED power transfer efficiency 95% 90% (1) 90% (1) SLED power multiplier 3.3 3.0-3.2 (2) 3.0-3.2 (2) Power at SLED output 475 MW 540-576 MW 540-576 MW Pulse length 400 ns 400 ns 400 ns SLED - structure power transfer efficiency 95% n/a 90% (1) Power at structures - total 450 MW 486-518 MW Structure gradient 65 MV/m 66-68 MV/m (3) Notes: 1) Phase 1 power handling inefficiency is due to liberal use of WR90 2) Phase 1 SLED power multiplier low due to potential mode conversion inefficiency 3) Eight 60 cm. S17 structures
Phase 1 Summer 03 m-sled Straight-up layout Four 50 MW XL4 klystrons allows SLED commissioning and full power operation. Milestone: 475 MW, 400ns at the load tree September 2003 Test capability: 540 MW, 400ns
8-Pack Phase 1 Status In End Station B. SLED line tubes are placed in position.
Current klystron layout for Modulator & LLRF commissioning Four 50 MW klystrons on modulator; HV checkout, RF checkout, ongoing. The modulator and LLRF systems are being exercised while the high power loads are being conditioned. 7 of 10 loads have been conditioned 2 more are on now.
8-Pack Phase 1 Status LLRF: The system for LLRF control is in and being used. The system for LLRF monitoring is being commissioned. Power from 2 klystrons combined and sent to alternate loads on the hybrid. ~80-100 MW combined 50 ns/div. System now in use for conditioning loads to 80 MW, 500 ns. See Steve Smith s talk
8-Pack Phase 1 Status Modulator: IGBT heating problems solved, modified di/dt protection circuit. The voltage pulse is made flat by delaying the turn-on of 19 driver cards. Flatness for 4 XL4s, 1.6 µs, at 400 kv, ± 0.7% 4/7/03 Now, energy recovery diodes are not fast enough to catch the extremely fast IGBT core reset transients, particularly on the delayed boards. LLNL designed and built an array of fast diodes that works best of all devices tried. Currently building enough arrays for all boards in the system, available this week. Also adding Metal Oxide Varistor (MOV) across diodes to protect them. Have successfully tested at 30 Hz with arrays, but currently running RF tests at 10 Hz to minimize failures until the new arrays are installed. With all boards equipped with arrays, hope to achieve 60 Hz operation. See Dick Cassel s talk
Klystrons: 8-Pack Phase 1 Status: Next Linear Collider Four XL4 klystrons are installed and connected to the modulator, each delivering ~50MW at 400 kv. These are sufficient to perform all high power tests, for 8-Pack phases 1 & 2. Klystron arcs (~10) have been observed, no harm to the klystron. KEK/Toshiba klystron PPM2, which achieved 70 MW @ 1.5 µs at KEK, is being tested at SLAC. Progress is slow, have had 75 MW @ 100 ns., 60MW @ 1.0 µs. KEK/Toshiba klystron PPM4 is being tested at KEK (@ 50 hz). It will be shipped to SLAC in July for further testing (@ 120 hz). See John Cornuelle s talk One of the LC TRC R2 requirement for GLC/NLC: A full test of a PPM klystron at 120 or 150 Hz. KEK PPM2 under test at SLAC
Klystrons: 8-Pack Phase 1 Status: SLAC PPM klystron, XP3-3, is being tested. Eliminate transverse magnetic fields. Re-defeat 11.7 GHz oscillation. Achieved saturation, 80MW, at 200 ns. >60% eff. Examining beam break-up at longer pulse lengths. The second unit, XP3-4, is in fabrication. Convert to an integral pole piece design. Re-optimize cavity tuning for max. RF power. XP3-4 on test 10/03 PPM klystron XP4 is finishing design. More robust design. Larger gun ceramic for lower gradients. Integral pole piece design as XP3-4. XP4-1 on test 2/04 XP4-2 on test 5/04 See John Cornuelle s talk XP3-3 under test at SLAC
8-Pack Phase 1 Status: High power RF system: All Straight-up configuration components are in fabrication (or ready). Critical Items: The Combiner, the Cross Potent*, Splitter all parts have been fabricated, the sub-assemblies brazed and cold tested, and are in the final brazing cycle. The couplers are completed. The SLED pump Tees are nearing completion. The load trees are being assembled *see later slide
8-Pack Phase 1 Status High power RF system: Combiner now complete, in cold test braze prep photo See Sami Tantawi s talk
8-Pack Phase 1 Status Multimoded couplers (3), complete, in cold test.
8-Pack Phase 1 Status Cross Potent body Power out SLED SLED Power in The cover to this port was dented (~.3 mm) when the Cross Potent slipped (~1 ) during QC. Repair is underway. Then ready for final braze.
8-Pack Phase 1 Status SLED Pump Tees, in final prep. & installation Installed for cold testing
8-Pack Phase 1 Status Splitter, being prepared for final braze
8-Pack Phase 1 Status Load tree under assembly
Project schedule overview Phase 1 Finish conditioning loads 7/15 (current configuration) SLED lines in cold testing now Cross potent ready 7/14 Cold testing / assembly in July & August Pump down system 8/8 Bake-out finished 9/4 475 MW 400 ns milestone 9/03
Phase 1 Project schedule Begin System Commissioning: 9/4 copy of schedule attached
The Phase 2 One of the LC TRC R2 requirement for GLC/NLC: A Linac subunit test 8-Pack Phase-2 goal: Use the SLED II system for a full power demonstration of an RF feed to 4.8 m of high gradient structures on the NLCTA beamline. Install eight 60 cm long high gradient RF structures Transmit the high power from the SLED II system to the beamline. Split the high power to the high gradient RF structures Gain experience with a GLC/NLC RF feed at full power and full rep. rate
Phase 2 8-Pack Layout Schematic of the power handling to the beamline From SLED Mechanical/vacuum system in design 6 db 4.8 db Overmoded 3 db WR90 3 db 3 db 3 db 3 db
Phase 2 8-Pack Layout System design underway Layout of power splitters TBD. Structure install copied from present scheme
Phase 2 8-Pack Layout System design, to be reviewed in July
Phase 2 8-Pack Layout Phase 2 RF parts list (not finalized) High power parts designed at SLAC, ready for fab. Power splitters in design at KEK WR90 parts on order with SLAC klystron dept. Build for complete system Design by Des Status Fab by Fab status 1.6 pump tee SLAC Complete SLAC First 6 started in June Pump Varian To be purchased 1.6 coupler SLAC Complete SLAC Complete, recycle from Phase 1 Mode stripper SLAC Complete SLAC Not started Quadrupus SLAC Complete SLAC Complete, recycle from Phase 1 Med power load SLAC Complete SLAC Kly Not started 1.6-2.93 taper SLAC Complete SLAC Not started 2.93 spool SLAC Lengths TBD SLAC Not started H-plane bend SLAC Complete SLAC 4 in Fab, bodies complete 6 db Splitter KEK Started tbd Not started 4.8 db Splitter KEK Started tbd Not started 3 db Splitter KEK Started KEK Not started WR90 45dB coupler SLAC Complete SLAC Kly Not started WR90 E-plane bend SLAC Complete SLAC Kly Not started WR90 spool SLAC Complete SLAC Kly Not started WR90 3dB splitter SLAC Complete SLAC Kly Started in May Magic tee SLAC Complete SLAC Kly Not started WR90 Input arm SLAC Complete SLAC Kly Not started WR90 H-plane bend SLAC Complete SLAC Kly Not started WR90 output arm SLAC Complete SLAC Kly Not started WR90 pump tee SLAC Complete SLAC Kly Not started Component total
Phase 2 8-Pack Layout Schematic of the power handling to the beamline From SLED 6 db 4.8 db Overmoded 3 db WR90 3 db 3 db 3 db 3 db
Phase 2 8-Pack Layout Simplified configuration for initial running. From SLED Motivation: get 8 structures powered as soon as possible. Upgrade as structures and power splitters become available. Overmoded From NLCTA station 1 From NLCTA station 2 300MW, 400 ns 3 db 3 db 3 db 3 db 3 db These structures could be located in stations 1 & 2.
Phase 2 schedule overview, from ISG-X 1 2 Commission Phase 1 3 4 Machine Backup Phase 1 components KEK 5 Braze Backup Phase 1 components SLAC 6 7 Phase 2 design complete ALL 8 Structure - RF system interface defined ALL 9 10 Fabricate 'Mode Stripper' SLAC 11 Fabricate High Power components SLAC 12 Fabricate before-structure WR90 components SLAC 13 Fabricate on-structure WR90 components SLAC 14 15 Install Hardware on roof 16 Install Hardware in tunnel 17 Install Structures 18 Goal: 4+2+2 structures powered 19 20 RF design of 6 db and 4.8 db splitters complete KEK 21 Mech. design of 6 db and 4.8 db splitters complete tbd 22 Machine 6 db and 4.8 db splitters tbd 23 Braze 6 db and 4.8 db splitters tbd FY04 24 Fab. distribution for 6 db and 4.8 db splitter install SLAC 25 8-Pack Phase 2 Fabrication and Installation Plan 2003 2004 July Aug Sept Oct Nov Dec Jan Feb Mar Coordinate with structure test schedule
ID Task Name Duration Start Finish Predecessors 1 8-Pack Parts Schedule 0 days 6/20/03 6/20/03 2 Cross Potent 66 days 4/4/03 7/14/03 3 fab 28 days 4/4/03 5/13/03 9 cold test 20 days 4/21/03 5/16/03 12 final assy. 42 days 5/7/03 7/14/03 13 rcv. jog converters (2) 0 days 5/7/03 5/7/03 79 14 rcv. c/r converters (4) 0 days 5/23/03 5/23/03 86 15 Determine how to braze 0 days 5/20/03 5/20/03 33 16 prepare fixturing 7 days 6/11/03 6/19/03 15 17 QC 2 days 6/9/03 6/10/03 18 repair 5 days 6/11/03 6/17/03 17 19 braze prep 5 days 6/18/03 6/24/03 18 20 braze 1 3 days 6/25/03 6/27/03 13,14,11,16,19 21 braze 2 3 days 7/7/03 7/9/03 20 22 cold test assy. 3 days 7/10/03 7/14/03 21 23 vacuum process 0 days 7/14/03 7/14/03 22 24 Splitter 54 days 4/11/03 6/26/03 25 fab parts 21 days 4/11/03 5/9/03 31 final assy. 40 days 5/1/03 6/26/03 32 rcv. c/r converters (3) (16989) 0 days 5/13/03 5/13/03 86FS-3 days 33 Determine how to braze 14 days 5/1/03 5/20/03 34 prepare fixturing 5 days 5/21/03 5/28/03 33 35 braze 1 3 days 6/16/03 6/18/03 32,30,27,34 36 braze 2 3 days 6/19/03 6/23/03 35 37 Cold test assy. 3 days 6/24/03 6/26/03 36 38 vacuum process 0 days 6/26/03 6/26/03 37 39 Combiner 60 days 4/3/03 6/26/03 40 fab. Body 39 days 4/11/03 6/5/03 47 final assy. 60 days 4/3/03 6/26/03 48 Shims -94 (17199) 1 day 4/3/03 4/3/03 49 rcv. c/r converters (1) 0 days 5/27/03 5/27/03 86 50 braze 3 days 6/17/03 6/19/03 48,46,49,33 51 Cold test assy. 5 days 6/20/03 6/26/03 50 52 vacuum process 0 days 6/26/03 6/26/03 51 53 1.6" MM couplers 55 days 4/3/03 6/19/03 54 Cold Test Part 12 days 4/3/03 4/18/03 57 Production Parts 47 days 4/3/03 6/9/03 66 final assy. 55 days 4/3/03 6/19/03 67 pins (17193) 1 day 4/3/03 4/3/03 68 braze coupler #1 5 days 6/2/03 6/6/03 61,67,63 69 braze coupler #2 3 days 6/10/03 6/12/03 62,67,65 70 Cold test assys. 5 days 6/13/03 6/19/03 69 71 vacuum process 0 days 6/19/03 6/19/03 70 72 Jog converters 25 days 4/3/03 5/7/03 80 Circ - Rect converters 38 days 4/3/03 5/27/03 87 6.725" SLED tubes 54 days 3/31/03 6/13/03 94 Large pump T 58 days 4/4/03 6/25/03 95 Redesign 1 day 4/4/03 4/4/03 96 Machine parts 26 days 4/22/03 5/28/03 97 Weld SS subassy 1 2 days 6/3/03 6/4/03 96 98 Weld SS subassy 2 2 days 6/3/03 6/4/03 96 99 Final weld 2 days 6/17/03 6/18/03 97,98 100 Final machine 5 days 6/19/03 6/25/03 99 101 vacuum process 0 days 6/25/03 6/25/03 100 102 SLED tuner drive 51 days 4/10/03 6/20/03 103 machine parts 32 days 4/10/03 5/23/03 104 assm. System 10 days 6/2/03 6/13/03 103 105 commission controls 5 days 6/16/03 6/20/03 104 June July August September 5/25 6/1 6/8 6/15 6/22 6/29 7/6 7/13 7/20 7/27 8/3 8/10 8/17 8/24 8/31 9/7 6/20/03 Phase 1 schedule 04-03 Page 1 THIS SCHEDULE CHANGES FREQUENTLY. CHECK THE DATE ON LINE #1 - DCS 6/20/03
ID Task Name Duration Start Finish Predecessors 106 Installation 81 days 5/7/03 9/4/03 107 splitter done 0 days 6/26/03 6/26/03 24 108 pump T done 0 days 6/25/03 6/25/03 94 109 cross potent done 0 days 7/14/03 7/14/03 2 110 couplers done 0 days 6/19/03 6/19/03 53 111 combiner done 0 days 6/26/03 6/26/03 39 112 SLED tuner drive done 0 days 6/20/03 6/20/03 102 113 load processing 44 days 5/7/03 7/15/03 114 process 4 loads 8 days 5/7/03 5/16/03 115 swap and bake 6 days 5/19/03 5/27/03 114 116 process 3 loads 6 days 6/2/03 6/9/03 115 117 swap 2 and bake 4 days 6/11/03 6/16/03 116 118 process 3 loads 4 days 6/17/03 6/20/03 117 119 swap and bake 6 days 6/23/03 7/7/03 118 120 process 2 loads and hybrids 6 days 7/8/03 7/15/03 119 121 SLED 48 days 5/12/03 7/24/03 122 install SLED tubes 17 days 5/12/03 6/16/03 90FS-3 days,93ff+1 123 cold test SLED tubes 7 days 6/17/03 6/25/03 122 124 Assemble full SLED (pump T's) 5 days 6/26/03 7/9/03 123,108,112 125 cold test SLED lines 3 days 7/10/03 7/14/03 124 126 cold test SLED with XP 3 days 7/22/03 7/24/03 125,128 127 combiner - cross potent 16 days 7/15/03 8/5/03 128 cold test cross potent - irises 5 days 7/15/03 7/21/03 109 129 mount combiner - cross potent 3 days 7/25/03 7/29/03 111,110,126 130 cold test 5 days 7/30/03 8/5/03 129,121 131 splitter - loads 22 days 6/11/03 7/17/03 132 mount 4 loads to a quadrupus 5 days 6/11/03 6/17/03 114 133 cold test 3 days 6/18/03 6/20/03 132 134 mount 4 loads to a quadrupus 5 days 6/23/03 6/27/03 118 135 cold test 3 days 7/7/03 7/9/03 134 136 mount splitter - loads 3 days 7/10/03 7/14/03 107,133,135 137 cold test 3 days 7/15/03 7/17/03 136 138 attach system together 3 days 8/6/03 8/8/03 121,127,131,110,137 139 cold test 5 days 8/11/03 8/15/03 138 140 bake system 14 days 8/18/03 9/4/03 141 wrap 5 days 8/18/03 8/22/03 139 142 ramp up (2 shifts) 1 day 8/25/03 8/25/03 141 143 bake (inc. 1 weekend) 5 days 8/26/03 9/1/03 142 144 ramp down (2 shifts) 1 day 9/2/03 9/2/03 143 145 unwrap/connect 2 days 9/3/03 9/4/03 144 146 Begin System Commissioning 0 days 9/4/03 9/4/03 106 June July August September 5/25 6/1 6/8 6/15 6/22 6/29 7/6 7/13 7/20 7/27 8/3 8/10 8/17 8/24 8/31 9/7 6/20/03 Phase 1 schedule 04-03 Page 2 THIS SCHEDULE CHANGES FREQUENTLY. CHECK THE DATE ON LINE #1 - DCS 6/20/03