**MEMORANDUM**

**To:** Distribution

**From:** F. Dylla

**Subject:** FEL Upgrade Project Weekly Brief -- March 3-7, 2003

**Date:** March 7, 2003

**Highlights:**

We had an important and successful project review with ONR, NAVSEA and
DOE this past Monday. Our contract monitors were able to see the FEL
Upgrade in its completed first light configuration prior to the start of
the review. We are cleaning up punch list items on our commissioning
list as noted below as the gun components are being prepared for
re-assembly later in the month. The last remaining magnets for the high
power configuration (in the 2nd recirculation Arc) were mounted on the
qualification stand this week.

***Commissioning Activities:***

[Beam Transport:]{.underline}

The first of two remaining GQ dipole magnets for the 2nd recirculation
ARC went on the magnet test stand yesterday. The Purcell gap glue down
for the 2nd ARC 180 bend dipole (GY) was successfully completed this
week and the magnet is being reassembled today for start of
qualification measurements next week.

[Controls and Diagnostics:]{.underline}

The switched electrode Beam Position Monitors are ready for control room
checks.

[Optics:]{.underline}

The insertable optical dump assembly is being installed today. This
assembly will allow the cavity length measurements and adjustments to
begin next week.

[Photoelectron Gun:]{.underline}

The gun ceramic stack assembly (without the electrode structure) is
cleaning up nicely with a 250C bake all week while the electrodes are
being prepared. Repolish of the ball electrode continues. In parallel,
all other gun parts are being cleaned and pre-baked so that all parts
can be staged for re-assembly.

**Special Meeting Notices:**

[FEL Users and Laser Processing Consortium Workshop: March 19-20,
2003]{.underline}

Our annual users meeting will be held on March 19-20 at the CEBAF Center
Auditorium at Jefferson Lab. This meeting is open to anyone interested
in past and planned future use of the FEL User Facility for basic,
applied and mission related R&D. The preliminary agenda for this meeting
is posted on the JLab WEB site.

[FEL Upgrade Cost and Schedule Teleconference: March 24,
2003]{.underline}

[FEL IR/UV Upgrade Semiannual Review: April 9-10, 2003]{.underline}

At Jefferson Lab (ONR/AFRL/DOE invitees only)

**Management:**

On Monday, March 3rd we held a project status review on the FEL Upgrade
project for our ONR and NAVSEA project managers. Topics of discussion
included the status of the FEL Upgrade hardware qualification and
commissioning activities, negotiation of the revised ONR/Navy MOA for
the second half of FY03 FEL Upgrade activities, technical discussions on
the gun, magnet, optical systems commissioning, technical discussion on
the cryomodule design and fabrication, and initial discussion on JLab\'s
plans for FY04 activities including support the Navy\'s high power FEL
development program. A draft MOA was agreed upon, signed by our DOE
contract monitor and forwarded to ONR HQ for signature. On Thursday a
draft agenda was forwarded to the ONR/AFRL and DOE program offices for
the upcoming April 9-10 semiannual project review which will include
many of the topics discussed in the March 3rd meeting.

On Friday March 7th G. Neil attended (at NAVSEA\'s request) a review of
Northrop Grumman\'s studies on FEL development for naval applications.

**WBS 4 (Injector):**

The hot nitrogen purge for the gun chamber was turned off on Monday. The
assembly has been kept at 250 C all week while the electrode structure
is being prepared. The gun chamber pressure at 250C peaked at 3.5 10E-6
torr and has since fallen to 4.3 x 10E-7 at the same temperature. The
residual gas spectrum is now dominantly (\>99%) hydrogen) and we have
been monitoring the clean up of residual hydrocarbons all week. After
checking the partial pressures early next week, this bakeout process may
be terminated.

The steps remaining to complete re-assembly and high voltage
conditioning of the gun were scheduled at the daily task level so that
we could add extra labor where needed. The cathode support electrode has
been re-polished; the ball polishing started late last week and should
finish up next week. In parallel all the other gun parts are being
re-cleaned and rebaked.

In the process of requalifying all cleaning procedures, we found that DI
water from the R&D Chem Room no longer meets specifications. All DI
water in use anywhere in the project is now coming from the Production
Chem Room until the R&D Chem Room source is requalified. We are also
checking the integrity of the dry nitrogen purge lines that are in the
FEL Vault using on of our clean RGA systems.

**WBS 6 (RF):**

The RF systems are complete and need only maintenance to keep them
operational. All systems were operated last night except zone 2 that had
a Phase Imbalance fault. This will be repaired today. Maintenance
testing will be run again this afternoon if machine time is made
available.

**WBS 8 (Instrumentation):**

Effort continued on the commissioning of the transport system from racks
FL05B10 thru B13. Commissioning effort has begun on the DY, DW string
and the 5 kW extraction power supply for the temporary dump.
Installation of the 896 power supplies has been completed in Zone 1 and
5.

SEE BPM installation was completed except for the GY in the 2nd Arc
String. Testing can begin next week. Commissioning of Beamviewers,
Ultraviewers and the insertable mirrors continued from the 3F region to
the Output Coupler. 15 additional Beamviewer cameras are available for
installation as assemblies become available.

Layout of the optical cavity process flow and analog signals continue.
The three chassis fabrication will begin next week. The two Machine
protection - Machine Mode interface chassis are completed and are
waiting on return of the interface PCBs. The cables are being installed
for these from zone 1 and 5 to zone 2.

Drawings completed this week:

F0190 - High Voltage Interlock Analog I/O Board

F0191 - High Voltage Interlock Comparator Isolation Module

F0192 - User Lab Patch Panel Front

The check-prints for both schematics and board layouts on a number of
projects have been reviewed and marked-up for final prints.

F0117 - VME Interface Module

F0118 - 4 Channel Fiber Driver Module

F0119 - 16 Channel Relay Module

F0079 - General Purpose VME Carrier Board

F0151 - VME BLM front board

Patty Hunt and Deborah looked at the fire block installation. She is
satisfied that the requirements of the ODH assessment and fire safety
have been met. These will be added to the start-up check list to ensure
that if they are removed during a \"down\" they are replaced prior to
start-up.

**WBS 9 (Transport):**

***Work Arounds***

Substitution of IR Demo 180° Bend (DY) for the Upgrade 180° Bend (GY) in
the First Arc and installation of a GW beyond the Optical Klystron as a
diverter-to-the-dump magnet.

• The first arc 180 degree magnet (DY) (and the temporary linac
spectrometer magnet on the same circuit) passed hi pot check and were
powered to 84 A (anticipated maximum of 220 A). The power supply folks
are checking out a DC overload and leakage to ground problem that
appeared at that current value.

• The temporary diversion dipole at the end of the optical cavity, used
for pulsed operation was hi potted, and then connected to its power
supply. An attempted turn-on revealed a false water supply fault to the
power supply. The power supply folks are fixing it.

***Dipoles***

[Optical Chicane Dipoles (GW)]{.underline}

• No progress.

[Injector Dipoles (DU/DV)]{.underline}

• No progress.

[Arc 180 Degree Dipoles (GY)]{.underline}

• The Purcell Gap Shims for the upper core were glued in place passed
inspection and the magnet is being put together today.

• Wang NMR postponed potting on this magnet to concentrate on the
replacement coil for the GX below.

[Arc Bend & Reverse Bend Dipoles (GQ, GX)]{.underline}

• The first of the GQ magnets was placed on the test stand. A
temperature switch short to the main coil delayed further testing until
Monday.

• Wang NMR finished making the replacement GX coil for the #2 GX Dipole.
We will attempt to air freight it today.

***Quadrupoles***

[Trim Quad (QT)]{.underline}

• The additional coils to modify the remaining two quadrupoles for the
second arc to add the vertical corrector function were received from
Milhous Co.

***Sextupole (SF)***

• No news.

***Octupole (OT)***

• The order is ready to be placed anticipating the availability of
funding.

***Correctors***

• The parts for the horizontal optical chicane corrector (GZ) are being
made in the shop.

• Robin Wines found a 0.5% solution for a saddle shaped, air core
vertical corrector in the optical chicane. Specification is 1 %. She is
sketching the magnet and its holder for the shop to fabricate and they
are ordering the tooling material. We have the #14 square conductor.

***Beam Line and Vacuum***

• Hiroyuki checked polarity on a number of the quadrupoles and
correctors after the cryomodule and in the return leg.

**WBS 11 (Optics):**

We continued to address some contamination issues that were discussed in
last week\'s WBS 4 report. We saw evidence of contamination in the
electron beamline we installed, and in the pump cart we were using, so
we initiated a hot nitrogen purge on the former and a bake of the
latter. Both activities were successful in removing the contamination,
so we intend to pump the beamline down so we can make progress with
optics system commissioning. It will have to be let back up to install
\"paddle viewers\" in the optical chicane, but that will not be a
lengthy activity. The HR pump down continues, sampling with the RGA
shows water vapor as the primary residual gas. We will continue to let
the ion pumps work. Meanwhile, the OC vacuum vessel has been hot
nitrogen purging for the entire week. As we are installing the
insertable mirror assembly in a first light configuration today, we plan
to let it up to 760 Torr, connect it to the insertable mirror assembly,
then begin re-pumping the entire system down.

One OCMMS optical assembly is being aligned and should be ready for
installation next week. We determined the lens parameters to mode match
the ultrafast laser into the optical cavity, and have begun to assemble
the optical hardware. We plan to begin alignment next week.

Both ultraviewer assemblies have been upgraded with central apertures,
motion control on the mirrors, and remote controlled attenuators. They
will be installed next week. Work continues to clean and paint the grout
for the optical cavity vacuum vessels and the diagnostics platforms to
minimize dust. Working with the I&C group, we resolved some hardware
connections and a software problem to get the ultraviewers operating
under remote control. They are making progress on getting the laser
safety shutter and diagnostic viewer connected as well. Both the
enclosure and the optical hardware for the THz diagnostic for the
injector are assembled and ready for integration.

The impeller on our facility chiller was replaced and we once again have
chilled water for the user labs. We plan to have the service engineer
back to complete the installation the week of the 24th.