In his new role as ALS Engineering Lead, Ken Chow has taken on a consolidated role that was previously split between mechanical and electrical. As of August, a reorganization of ALS engineering has Chow overseeing all engineering tasks at the ALS, which includes magnetic and vacuum systems, mechanical engineering and technology, and electrical and controls engineering.
Chow has only been in his new role for about a month, but he already has a vision of greater communication. “I’m planning to meet regularly with engineering leads at the ALS,” he says. “I really see an important part of my job as helping to communicate engineering-related matters within ALS, to engineering staff, scientists and management, but also between ALS Division and Engineering Division.”
Chow is anticipating that a new engineering systems program being developed in the Engineering Division by Engineering Systems Lead Daniela Leitner will be rolled out to all engineering staff soon. “Here at the ALS I see us using a version that is tailored to our specific needs,” says Chow. “We’ll be doing the same work but I think an improved structure will add clarity to our engineering practices and also yield greater consistency between different projects.”
Another primary focus in his new role will be ALS-U. “It’s going to be a big challenge to keep current ALS projects going and to also try to get ALS-U off the ground at the same time,” he says. “ALS-U is going to be a really exciting upgrade.”
Prior to his new role, Chow’s work was mainly focused on beamlines and endstations—he was involved in larger beamline projects such as MAESTRO and COSMIC, providing engineering management and support.
“It’s a great time to be here; there are a lot of great projects going on and the prospect of ALS-U is very exciting,” Chow says. “It’s always fun to be involved with something like this.”
The new Safety Manager at the ALS, Scott Taylor, is not so new. Taylor has been working at Berkeley Lab for 30 years now, starting in his early days as a biofuels researcher working with Melvin Calvin. Taylor isn’t new to safety either—he has been on the Lab’s Safety Review Committee since 1992 and the division safety coordinator for Life Sciences for the past six years.
Taylor’s first foray into safety at the Lab was back in 1990, when he was working in research medicine at Donner Lab. DOE safety inspections were announced and Taylor, being the youngest member of the team, was tasked with making sure his building was ready for safety inspections. There weren’t division safety coordinators back in those days, Taylor explains.
Joining the ALS reminds Taylor of his early days at the Lab, when he felt energized by the eclectic mix of coworkers from various disciplines all working toward a common goal.
“I liked those experiences because they make you realize that there are so many things you don’t know and you’re outside of your normal comfort zone,” says Taylor. “And that really defines the ALS—there’s a huge breadth of research interest and so the safety scope is also enormous.”
Taylor sees many safety challenges that are unique to the ALS, and many hazards are so intricately intertwined that the mere level of complexity itself is a challenge. “We have such a huge influx of users from all over the world,” says Taylor. “And the DOE has a safety culture that’s probably different from anywhere else in the world, with a higher degree of compliance and a reduced acceptance of risk.”
He’s been inspired by how welcoming everyone at the ALS has been, and comforted in the knowledge that his friend and previous ALS safety manager, Jim Floyd, is just a phone call away.
Taylor sees a couple of big projects taking main stage in the near future, the first being a new work planning and control system that will modify and streamline the work authorization process. He’s been intimately involved in the creation of the system as project manager for the past four years, which will definitely be an advantage when it comes to implementation, he says.
The second major focus, as Taylor sees it, will be the electrical safety changes coming to the Lab. “We’ll have to learn how to apply those so that we are working safely, but still maintaining our high level of scientific productivity.”
User office guest registration “specialists” Angel Hernandez and Giselle Jiles play a unique role at the ALS—they are often the first line of face-to-face contact new users have when they arrive for their beamtime. As such, the two see themselves as the caregivers of the ALS user experience.
“We are here to do everything in our powers to make sure they get down to that beamline,” says Jiles. “And the best customer service we can offer produces the best results for the scientists,” adds Hernandez.
Hernandez manages guest registration, travel, stipends, and publications, while Jiles manages the reception desk in the mezzanine. When asked what they most enjoy about what they like to call their “meet and greet” role at the ALS, the two agree in their enthusiasm about supporting science. Hernandez has been in his role at the ALS for five years; Jiles for two.
That support starts long before users arrive at the ALS, with making sure that they everything they need to make the check-in process seamless. “They get every detail to make the transition as smooth as possible,” says Jiles. “We give them almost an overload of information!”
Once users arrive, they usually see Jiles first for processing of travel documents, then head over to Hernandez for badging and publications management. They both enjoy building relationships with users and are often rewarded for their customer service role with treats from all around the world, invitations to visit, and birth announcements. “The users know that I have a weakness for chocolate,” jokes Jiles.
Hernandez describes his job as “culturally infusing” because of the range of global visitors he regularly interacts with. “We get to see how each segment of the world reacts to us and, in a sense, we’re also representing the United States,” he says.
“It’s really interesting to hear about what users are researching and how it is going to affect our lives down the line,” says Hernandez. “We almost have a look into the future from that respect.”
“I tell some of the scientists: I want to get you down onto that floor, because I am going to benefit from what you do,” says Giselle. “I don’t think I’ve ever worked in an environment where people are as passionate about what they do,”
The weekend before the ALS was scheduled to start up again after the most recent shutdown, mechanical technician Monroe Thomas kept things running on schedule by coming in on a Saturday to pull a 300-pound capacitor “uphill” out of the new RF power supply. It’s just another “(not so) typical” day at work for him, he says. But it’s his reliability operating cranes and supervising moves of heavy equipment around the ALS that plays an integral role in keeping the facility going.
Monroe has been a part of the ALS “mech tech” team for the past 14 years and is the point person for all critical equipment and endstation moves. Though he’s training another mechanical technician to operate the crane, it’s Monroe who is called upon for critical moves. He plays a key role in shutdowns—whether it’s installing magnets and undulators or taking an endstation on- or off-line. For bigger jobs he coordinates with the riggers from the Facilities division.
“The biggest challenge of this job is simply picking things up, because they’re not engineered to lift,” says Monroe. “So you have to figure out how to pick up each individual piece without damaging other parts.”
Monroe came to the ALS after 20 years in the military and about 10 years in the aftermarket motorcycle business, where he worked assembling and packaging parts for resale. He maintains this interest, riding his motorcycle every day and performing all his own maintenance work.
Though he’s a common sight around the ALS, Monroe surmises it’s his epic homemade cheesecakes that have made him well-known (he once brought in about 24 cheesecakes to share; his recipes are a well-guarded secret).
When asked to recall a particularly memorable moment in his time at the ALS, Monroe harkens back to his first year here, when he and a few other members of his team spent 17 hours straight working with the crane to change out a magnet cooling coil. And yet, he’s stayed on 14 years running after that grueling event.
“It’s the variety of work and the variety of people I get to interact with here that I like the most about this job,” he says.
Procedures Center Manager Karen Nunez has been working somewhat “behind the scenes” at the ALS for the past seven years, ensuring that documentation for the many procedures involved in ALS operations is clear, correct, and up to date. She works with a plethora of ALS engineers, operators, technicians, and scientists, who all lend their technical expertise to her work.
“I maintain the documents that help people maintain the accelerator,” says Nunez. “In my position I get to interact with various individuals at the ALS, and everyone has a specialized understanding of the accelerator based on their knowledge and work they do. I get the benefit of learning a bit about these different perspectives while recording the necessary information for everyone else.” She feels that documentation is the best means for retaining and sharing the knowledge that is needed.
The procedures at ALS include everything from how users safely enter and operate the hutches at the beamlines and how operators start up and shut down the accelerator, to how the electrical maintenance techs test each beamline radiation safety system. The documents she’s charged with fulfill safety, compliance, and basic ALS operational needs, plus a good many others that serve to remind staff of what is needed for jobs that are rarely done, such as removing and installing an insertion device. In her position, document control, technical writing, and project management all come into play.
Nunez regularly coordinates reviews and updates dozens of procedures each year, and there are always additional projects that arise as upgrades occur and safety requirements change. A recent example is the new lock-out-tag-out (LOTO) procedure that’s being implemented Lab-wide; Nunez will have to revise and implement new documentation to go along with it. She stays on top of everything with her favorite software, Smartsheet, which she says is “like Excel-plus.”
When asked about one thing she enjoys about her job, she says: “For everyone who works on procedures, it is like another task on top of their main responsibilities; however, I really appreciate that when it comes time to do so, everyone is ready to lend their support and help out when needed.”
Procedural documentation is necessary for ALS functionality, and although much of it is invisible to users, it is obviously something that contributes greatly towards allowing work to run more smoothly at the ALS.
The recent ALS power supply failure was one of the most challenging projects that Electronics Engineer Technical Superintendent Tim Kuneli has worked on in his 12 years at the ALS. And judging by how quickly ALS engineering and accelerator physics staff resolved the issue and the ingenuity involved in the fix, it may also be one of the most successful projects he's been involved in.
“There were easily 15-20 people involved and we had to really look at what we needed and then configure, test, and reconfigure to make it work,” says Kuneli. “We were up and running again in less than a week.”
Kuneli came to Berkeley Lab as an electronic maintenance tech 15 years ago, after serving 11 years active duty in the Navy and eight years for General Electric, where he worked as an electronics calibration technician. In 2003, Kuneli retired from the Navy Reserves after achieving the rank of Senior Chief Petty Office. After working for the Lab’s central shop and for the Spallation Neutron Source Project (SNS), he was then assigned as the lead in the electronics maintenance shop at the ALS in 2002. In 2003 he became the electronics maintenance supervisor for the ALS. He’s also a member of the Lab’s electrical safety review committee and supervises all the techs on the hill.
The shop runs 24/7 except during shutdowns, when the seven employees’ times are aligned with scheduled shutdown projects. Kuneli and his team take care of all ALS electronics maintenance, making sure machines are running properly, troubleshooting new equipment, and supporting users’ electronics and equipment needs. Preventive maintenance is also a big part of his job, and that will hopefully get easier in the near future with a new database that will automatically schedule regular ALS maintenance tasks.
There are no “typical” days for the electronics maintenance shop, or the installation and fabrication shop that employs a staff of three and runs concurrently downstairs. Their tasks are driven by what’s happening at the ALS and what users need. If there’s new equipment coming in to the ALS, Kuneli’s team does extensive safety testing before it’s installed. If users are having trouble with equipment setup, Kuneli or someone from his team help them troubleshoot the problem.
During this shutdown, Kuneli’s team will be working on installing new power supplies, controls upgrades, the radio frequency upgrade, changing water interlocks, and some smaller safety projects. Kuneli notes that one of the challenges particular to the ALS is finding repair and replacement parts for older equipment.
“This job is unique in that you can be here 20 years and still not know about everything,” Kuneli says. “There’s so much to do and learn that you never get bored.”
Kenneth Goldberg, deputy director of the Center for X-Ray Optics (CXRO), has been a part of the ALS since 1993, when he began setting up one of the first experiments on the floor, a project in coherent EUV optics. After completing his PhD in physics at Cal in 1997, Goldberg joined CXRO as a staff scientist.
These days, Goldberg’s work is funded by SEMATECH, a consortium of semiconductor manufacturing companies that includes IBM, Intel, GlobalFoundries, and Samsung. SEMATECH, through CXRO, funds several research and engineering projects at ALS beamlines, including Goldberg’s beamline, 11.3.2. CXRO has a long history of collaboration with SEMATECH; CXRO scientists and engineers have built many of the advanced experimental tools for photolithography research that are keys to finding new directions in chip-making technology.
“Semiconductor manufacturers are always looking for ways to make chips that are smaller, faster, cheaper,” says Goldberg. “They follow Moore’s Law.”
What’s helping SEMATECH keep up with Moore’s Law these days is the new extreme-ultraviolet-wavelength microscope, SHARP, that Goldberg’s group commissioned in June 2013. Developed in-house by CXRO scientists, engineers, and technicians, SHARP performs unique measurements for semiconductor manufacturing research, focusing on photomask imaging, a diagnostic tool that is critical for the commercialization of EUV lithography. Photomasks, the glass plates that carry the patterns for each single layer of a computer chip’s circuitry, are extraordinarily complex and even a nanoscale defect can ruin a circuit. SHARP can characterize defects with great detail. Unlike conventional microscopes, electron microscopes, and atomic-force microscopes (AFM), SHARP operates with extreme-ultraviolet (EUV) light, near 13.5-nm wavelength, the same color of light used in next-generation chip-making tools. Beyond that, SHARP provides customizable sample-illumination patterns, referred to as coherence control, that lithographers use to push the physical limits of fine-patterning.
“With these photomasks, there are a lot of open questions,” says Goldberg. “It’s a very complex optical system, with dozens of thin layers and five or more different materials all sitting on an atomically smooth surface. A lot of the research we do helps support the development of the masks—to make the mask work, to make it more efficient, to make it more inspectable, and to validate cleaning and pattern-repair work done at other facilities.”
It’s the depth of experience that’s a unique strength in the CXRO, the group that made the development of SHARP possible, along with the funding from SEMATECH. Regarding the new microscope, Goldberg asked, “How many times in your career do you get to start with a clean sheet of paper and say, ‘How would I do this if I had the chance to do everything right?’”
“I’m really proud that the work we do guides a multi-trillion dollar industry,” he says. “Our research has direct, profound effects on the decisions they make, and eventually the gadgets they produce.”
Even though the semiconductor industry is the second biggest in the U.S., the research teams for these companies can be small, says Goldberg. In EUV it can be just a handful of people, and they rely heavily on the ALS tools to inform them of where to take their products, he says. There are a few other facilities with microscopes that offer semiconductor companies some research capabilities, but none today with the capabilities of SHARP. After less than a year of operations, the data from the SHARP tool is already well represented in papers at the main industry conferences, says Goldberg.
“Making a complex system like that work is one of the most fun aspects of the job,” says Goldberg. “We are continually optimizing SHARP and discovering new capabilities; it’s an ongoing, exciting process.”
Peter Nico, recently appointed chair of the UEC, brings a varied user perspective to his new post: like many environmental science users, Nico has worked at a number of different ALS beamlines, from hard x-ray tomography to x-ray diffraction to STXM to infrared. It’s the combination of these multiple capabilities that he sees as one of the greatest assets the ALS has to offer users.
Nico’s research is focused on soil chemistry, specifically looking at carbon and how it’s stored in soil. He and his fellow researchers use the ALS to understand the chemistry of carbon in soil – understanding how it changes, what types of minerals it associates with, and what makes it more or less stable.
Nico has worked in the Earth Sciences division of the Berkeley Lab since 2005 and has served on the UEC for the past two years, which has given him time to develop an understanding of ALS user needs. He sees the near future as an important and interesting time to be representing users, as the ALS grapples with fiscal challenges and continues developing plans for an upgrade project.
“It’s a really interesting time to be chair of UEC,” says Nico. “We’re doing our best to represent users during these changing times at the ALS.”
The budgetary realities that the ALS faces are inevitably going to reduce options available to users, so Nico sees the role of representing their needs during this process as particularly important. Likewise, as the ALS plans and prepare for an upgrade, Nico wants to be sure users’ needs are kept at the forefront of the discussion.
“There’s this balance between being on the cutting edge and providing workhorse capabilities,” he says. “Not every beamline needs to be on the cutting edge; there is great science that can be done with average x-ray techniques and then there’s great science that can only be done with cutting-edge x-ray techniques and I think the ALS needs to serve both of those needs.”
In addition to representing users, Nico is particularly interested in developing new connections and dynamic communication streams between the UEC and the user community. He’s looking at various ways to streamline and encourage greater communication.