Key SCRF cryomodule R

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• Key SCRF cryomodule RD issues and infrastructure

Sergei Nagaitsev
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Key cryomodule RD issues

• ILC
• S1 Design, develop, construct and test ILC
  Cryomodules with average cavity gradient gt 31.5
  MV/m
• ILC CM (T4CM) is an international collaboration
  effort led by Fermilab
• Evolve Type-3 (XFEL) to T4CM (ILC) (95 complete)
• Effort will benefit PrX CM design
• S2 test one or more ILC RF unit with ILC beam
  parameters
• demonstrate bunch-to-bunch beam energy uniformity
  and pulse-to-pulse beam energy stability with
  long pulses at full beam loading (ILC like
  beam)
• characterise issues which limit operation at high
  gradients, to quantify the klystron rf power
  overhead required for low level radiofrequency
  (LLRF) control and to measure cryogenic loads.

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Key cryomodule RD issues

• Project X
• Design, develop, construct and test Project X
  (1.3 GHz) cryomodules. Develop one cryomodule
  per month capability.
• one-per-month needed for ILC also
• International collaboration on PrX CM design
  (Fermilab-MSU-India)
• gradient goals 25 MV/m
• Systems test, HLRF and LLRF tests
• operational experience

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Cryomodule infrastructure

• International cryomodule design team
• Cryomodule assembly facilities
• MP9 and ICB buildings
• Clean rooms, assembly fixtures, etc
• Cavity string and cryomodule transport

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Cryomodule infrastructure

• RF unit test facility
• New Muon Lab (NML) building and its extension
• Beam injector, rf systems, controls, cryo, beam
  dumps, safety, instrumentation
• The only 1.3 GHz beam facility in the US.
  Similar in scope to TTF (FLASH).
• Will also be used for Advanced Accelerator RD
• Cryomodule test stand (CTS)
• Will use NML as a CTS first (until FY11)
• Later will need a CTS for cryomodule tests (such
  as PrX beta0.81)
• Both require a new cryoplant and buildings

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Cryomodule design

• Cryomodule design starts with a specification
• For ILC it starts from the RDR. Uses XFEL as a
  starting point.
• The PrX cryomodule design is an evolution of the
  ILC T4CM.

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International CM design team

• Founded in May 2006
• FNAL
• INFN
• KEK
• DESY
• RRCAT
• JINR
• International partners with their software, EDMS
  (DESY)
• see Dons talk
• US focus development of parts suppliers, value
  engineering with ARRA funds

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Cryomodule Assembly Facility

• Goal Assemble RD Cryomodules
• Where MP9 and ICB buildings
• MP9 2500 ft2 clean room, Class 10/100
• Cavity dressing and string assembly
• ICB final cryomodule assembly
• Infrastructure
• Clean Rooms, Assembly Fixtures
• Clean Vacuum, gas, water Leak Check
• DESY Cryomodule kit assembled

ICB clean Final Assembly fixtures installed
MP9 Clean Room
String Assembly
Cavity string for 1st CM
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Assembly Workflow _at_ CAF-MP9
Receive dressed Cavities
Receive peripheral parts
Assemble dressed Cavities to form a String in the
Cavity String Assembly Area (Clean Room)
Install String Assembly to Cold Mass in the Cold
Mass Assembly Area
Transport the Cold Mass to CAF-ICB
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Assembly Workflow _at_ CAF-ICB
Install the Cold Mass back to the Cold Mass
Assembly Fixture in Cold Mass Assembly Area
Align Cavity String to the Cold Mass Support
Install the String assembly with the cold mass
into the Vacuum vessel in the Vacuum Vessel
Assembly area
Ship Completed Cryomodule to ILCTA-NML for testing
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1st FNAL-built Cryomodules
Cryomodule 1 From DESY kit
3.9 GHz Cryomodule Designed/built at FNAL for DESY
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CM2 Components

• Vacuum Vessel Cold Mass procured
• Blade Tuners (8) will be provided by INFN

Delivery December 2008
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CM2 Components (FNAL)

• 8 Qualified Dressed Cavities
• Bare Cavities Procured by FNAL from Accel AES
  (received)
• Processing Vertical Test FNAL U.S.
  collaborators
• As of September 2008, the 5 Cavities out of 8
  needed for CM2 are A6, A8, A11, A12, AES2. The
  average gradient based on last measurement is 34
  MV/m.
• Dressing of Cavities at CAF-MP9 in FNAL
• Horizontal Test at HTS in FNAL
• Helium Vessels
• Cavity Interconnecting Bellows
• Gate valves
• Tuner motors, harmonic drives
• Magnetic Shielding
• Dipole Corrector Package, BPM
• Couplers (provided by SLAC, funded by ILC)

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One CM per month

• The current infrastructure installed at CAF-MP9
  and at CAF-ICB has a throughput of RD quantities
  cryomodule fabrication.
• The ultimate throughput is to assemble 1
  cryomodule per month at CAF facilities.
• Currently at DESY Hall 3 (45 work days)
• String Assembly (Clean Room) 10 work days
• Cold Mass Assembly 13 work days
• Final Vacuum Vessel Assembly 10 work days
• Warm Part Coupler Assembly 5 days
• Coupler Pump Lines Assembly 2 days
• Cables/Wires Termination 5 days
• CM1 was assembled at FNAL with the assistance of
  DESY colleagues in 60 days

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One CM per month (contd)

• In order to achieve a throughput of 1 cryomodule
  per month
• Work two shifts in the Cavity String Assembly
  Clean Room to assemble cavity string (one
  assembly rail in the clean room)
• This will assure 1 assembled string every 5 work
  days
• Transport the assembled string from CAF-MP9 to
  CAF-ICB. (preferably right after the string is
  rolled out of the clean room)
• Have two parallel Cold Mass Assembly Lines at
  CAF-ICB to receive assembled cavity strings. Work
  one shift
• This will assure 1 cold mass assembly every 7
  work days
• Have 2 parallel Big Bertha Fixtures in the Vacuum
  Vessel Assembly Area at CAF-ICB. Work one shift
• This will assure 1 final cryomodule assembly
  every 5 work days
• With the above assumptions, one cryomodule can
  be assembled in 20 work days. This is adequate
  for PrX CM production.
• This throughput assumes that trained personnel
  are available as needed and the duplicated
  assembly fixtures are installed
• Incremental costs are small

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1.3 GHz CMs
CM1
CM2
CM3
CM4
CM5
CM6
Px CM
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Notes to CM plan

• Multiple opportunities to conduct S1 tests
• DESY experience is that cavities in a CM is not
  the same as cavities in HTS!
• S2 test
• ILC RF unit CM3-5,
• CM1-2 are not ILC type. Do not have quads. May
  have to be reworked.
• PrX CM
• CM4 is first PrX prototype CM
• beta 0.81 CM can not be tested with beam. Plan
  to test it at CTS

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Cryomodule test facilities

• The Tesla Test Facility (FLASH) at DESY has
  provided a valuable system test for many elements
  of the SRF technology. However, several
  important changes to the TESLA design are being
  planned for the ILC. These will include a higher
  cavity gradient, relocation of the quad,
  shortening of the cavity end-group, and a new
  tuner design. Such changes will likely be
  introduced in several steps, with the first one
  being called a Type-IV cryomodule design.
• Layout of the former TESLA test facility TTF or
  FLASH at DESY

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Cryomodule test facilities

• ILC S2 WG The minimum size system test needed to
  confirm the performance of such a new design is a
  single RF unit (3 cryomodules) with an ILC-like
  beam. As many tests are statistical in nature, a
  larger test or multiple tests are likely to be
  required.
• Barry Barish Cryomodule string tests are
  essential element in preparing to propose a
  robust ILC project for construction. We will
  carry out such tests using ILC cavities and
  cryomodules in the future in projects both at KEK
  and Fermilab.

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RF Unit Test Facility at NML
Existing Building
New ILC like tunnel
ILC RF unit
Diagnostics
Gun
3rd har
2nd ILC RF unit
CC I,II
Bunch Compressor
Laser
Test Area
New Enclosure
Test Areas
RF Equipment

• Overall Plan Test RF units Px, ILC S1 S2
  goals
• 3-6 CM, Klystron, Modulator, LLRF
• The only US facility to test 1.3 GHz CMs
• Move A0 Injector to provide ILC like beam
• New Tunnel Extension design to allow 2nd RF
  unit, diagnostic beam lines, AARD facility
• New Building Cryoplant, Cryomodule Test Stands

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ILC-like beam?

• 3.2 nC/bunch _at_3 MHz, up to 3000 bunches _at_ 5Hz
• DESY-type rf photo-cathode gun
• 10 mA (ILC)
• PrX beam parameters will be partially achieved
  (no protons, not 325 MHz bunches)
• Bunch length 300-µm rms
• Transverse emittance not important (5 µm)
• Energy 30-40 MeV (to avoid overfocusing in the
  CM operating at 31 MV/m)
• Need known and frozen beam parameters at the
  cryomodule entrance
• The AARD program requires more flexibility,
  mostly in terms of peak current.

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From 2007 review New Cryo Plant

• Phase 1 cryo system (being installed now)
• New Cryo plant
• Must be flexible to allow a wide range of heat
  loads, including 5-Hz operation
• Must meet specifics of the ILC operating
  temperature levels of 2.0 K, 5 K, and 40-80 K
• Long lead time
• Requires a 15m x 25m building the plan is to
  combine it with the NML extension.
• Engineering studies complete, have a quotation.

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NML Project Overview

• Overall Goal
• Build an RF Unit Test Facility at the New Muon
  Lab Building (NML)
• One RF Unit (2 or 3 Cryomodules)
• 10-MW RF System
• Beam with ILC/Project-X parameters (3-6 nC/bunch
  _at_3 MHz, Up to 3000 bunches _at_ 5Hz, 300-µm rms
  bunch length)
• Phase-1 (FY07 - FY09)
• Prepare Facility for Testing First Cryomodule
  (CM1) without Beam
• Infrastructure, RF Power, Cryogenics
  (Refrigerator 1)
• Install First Cryomodule (CM1) and Capture
  Cavity-2 (CC2), Cooldown, and RF Test

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NML Project Overview

• Phase-2 (FY10 - FY11)
• Prepare for First Beam
• Civil Construction to Expand Facility (Capability
  for 2 RF Units)
• Install Gun, Injector, Test Beamlines, Beam Dump,
  Second Cryomodule (CM2)
• Phase-3 (FY11 - FY13)
• Complete RF Unit
• Upgrade RF System to 10 MW, Install Third
  Cryomodule (CM3)
• Operate Full RF Unit with Beam
• Commission New Cryogenic Plant
• Begin Installation of 2nd RF Unit

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NML

• NML has the potential to be a unique facility
• Electron energy range of 40 1500 MeV beam
  power up to 80 kW pulse train up to 3000
  bunches flat beams
• Infrastructure capability (cryogenics, RF,
  lasers, floor space for experiments,
  expandability)
• In scope similar to DESY FLASH. Provides unique
  opportunity to train Fermilabs personnel and to
  gain operational experience.

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1st Cryomodule moving to NML
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1st cryomodule
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Progress at NML
CM Feed Can
Large Vacuum Pump
1st Cryomodule Test fit
He Refrigerator
Capture Cavity II _at_ NML
RF dist system (from SLAC)
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Phase-1 Layout of NML
Cryomodule-1 (CM1) (Type III)
Capture Cavity 2 (CC2)
5 MW RF System for CM1
CC2 RF System
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Future Expansion of NML Facility
New Cryoplant Building (300 W Cryogenic Plant, 2
Cryomodule Test Stands, space for 2 Horizontal
Test Stands, 10 MW RF Test Area)
New NML Underground Tunnel Extension (Space for 6
Cryomodules (2 RF Units), AARD Test Beam Lines)
Existing NML Building
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NML Facility Milestones Goals

• Phase-1 Cryogenic System Operational (Aug. 2007)
• Delivery of First Cryomodule to NML (Aug. 2008)
• Cryomodule Ready for Cooldown (Summer 2009)
• Cold RF Testing of Cryomodule (Fall 2009)
• Delivery of 2nd Cryomodule to NML (S1) (2010)
• Install Gun and Injector (2011)
• First Beam (2012)
• Full RF Unit Testing (3 Cryomodules) (S2) (2012)
• Significant project delays occurred due to
  funding cuts in 2008

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Advanced Accelerator RD

• NML applications beyond ILC and PrX
• AARD whats required?
• high-peak current
• tunable, measurable beam parameters
• flexible controls system
• room to accommodate several experiments
  concurrently.
• Unique beam parameters anticipated at NML
• Record high peak current of 14kA possible (with a
  3rd harmonic cavity)
• 30 um beam spot size (FWHM)
• Beam energy up to 1 GeV
• Structure 3000 bunches or a witness bunch 300 um
  behind

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Plan for NML users facility
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NML collaborations

• SLAC (funded by ILC/ART) couplers, RF power dist
  system, 10 MW Klystron
• DESY injector rf systems etc (many more)
• KEK rf gun, diagnostics
• ANL controls, AARD
• LBNL LLRF
• INFN cryomodules, photo cathode
• Rochester laser
• NIU AARD, injector

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Cryomodule Test Stand

• Test stand for ILC S1 studies (gt31.5 MV/m cavity
  gradient in a cryomodule)
• We know we will need it for ß0.81 by FY2012
• Location New Cryoplant Building
• Much larger than a typical Fermilab magnet test
  stand due to the shielding cave
• Comparable in scope to Phase-1 of NML
• Motivations for cryomodule tests
• Measure gradients
• Mechanical checks
• Alignment of tubes, flanges, etc.
• Leak checks of all volumes
• Conditioning of main RF-couplers
• Cryo load measurement, Q and Eacc
• SC magnet power test
• Dark current measurements
• Starting point is the DESY design

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XFEL Module RD Test Stand
From Yury Bozkho, Bernd Petersen (DESY)
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Summary

• Fermilab has a plan for designing and
  constructing seven cryomodules through FY12
• Infrastructure nearly complete
• one CM per month plan exists
• Fermilab is constructing the NML facility to test
  the ILC RF unit (3 CMs) with beam at ILC-like
  parameters by FY12.
• Building extension and new cryo plant are needed
  to meet demands of users (ILC, PrX, AARD).
• Will use the NML for accelerator research and
  training develop partnerships with NIU and other
  local universities. Collaborations with SLAC,
  KEK, DESY and ANL.
• Building extension required to make it a users
  facility with competitive and flexible beam
  parameters.
• Plan to construct one Cryomodule Test Stand by
  FY12.