Speaker
Description
The Advanced Light Source Upgrade (ALS-U) is an ongoing project at Berkeley Lab to transform the ALS into a fourth-generation synchrotron light source. To minimize the ALS users facility down time, the ALS-U Storage Ring (SR) is composed of 48 unique, highly integrated modules, each split into approximately 11 subsystems. There are over 3000 unique physical interfaces across the system, with 27 interface pairs internal to the module, as well as externally between modules, facilities and beamlines. This contribution presents how the complex interfaces have been managed using interface control documentation and tailored interface verification methods based on a combination of Computer-Aided Design (CAD) assemblies and dedicated prototypes. These tools were adopted to manage both module-level integration and external interfaces with facility infrastructure and beamlines to mitigate integration risks. To validate the design solutions a physical 1:1 mock-up has been developed alongside the CAD models. The combined CAD-mockup validation approach revealed critical issues not detectable through CAD only, including cables’ installation feasibility problems that would have caused redesign work and significant delays. The physical mockup also enabled more accurate analysis of maintenance access, assembly process and electrical safety. The practical experience from SR modules design in facility/beamlines integration context, methodology evolution during the design process, and recommendations for similar accelerator upgrade projects are also presented.
| Paper status | Proceeding files received |
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