Infrastructure and Test Facilities in the U'S'

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• Infrastructure and Test Facilities in the U.S.

Robert Kephart Fermilab
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Work packages in this talk support

• ILCTA test facilities _at_ FNAL
• Vertical and Horizontal test of Cavities
• Determine the maximum operating gradient of each
  cavity
• Evaluate gradient spread, Q0 and their
  operational implications.
• Measure dark currents, cryogenic loads, and
  radiation levels.
• Test of Cryomodules
• Measure gradient of cavities in cryomodules
• Measure vibration of components, system trip
  rates recovery times
• Beam Based Measurements
• Beam energy, stability, energy spread
• Wakefield measurements, HOM based alignment
  LLRF issues
• Goal Are the cryomodules good enough for the
  ILC ?
• RF Activities _at_ SLAC FNAL
• Develop high power RF components for Main Linac
• Development of LLRF and multi-cavity control
  systems
• RF systems in support of ILCTA _at_ FNAL

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ILCTA ILC RF unit at Fermilab
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08
07
Plan is to build one RF unit to be tested with
Beam by 2009.
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07-08
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Work Packages for this talk

• 5.8
• 5.8.1 1.3 GHz RF Power Source SLAC
  Adolphsen
• 5.8.2 ILCTA support
  SLAC Cassel
• 5.8.2.1 HA Modulator IGBT Switch array
• 5.8.2.2 ILCTA Cryo design
• 5.8.3 RF Power
  FNAL Nagaitsev
• 5.8.4 LLRF Controls
  FNAL Carcagno
• 5.9
• 5.9.1 Cavity Horizontal Test Stand
  FNAL Hocker
• 5.9.2 Cavity Vertical Test Stand
  FNAL Ginsburg
• 5.9.3 Cryogenics for test stands
  FNAL Theilacker

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1.3 GHz RF Power Source

• Description (WBS 5.8.1) SLAC
• Build a 1.3 GHz RF 5 MW power source to test ILC
  RF components
• HV modulator that is on loan from SNS, 1.5 ms
  pulses at 5 Hz
• A 5 MW klystron
• High power RF distribution system (3 ATM N2 Gas)
• Epics based LLRF system
• Goal
• Process developmental couplers
• and perhaps process production couplers for FNAL
• Test normal conducting positron capture cavity at
  NLCTA, including accelerating beam with them.
• Longer Range Goal
• In the next few years, build and test ILC
  prototype klystrons and modulators, and by FY10,
  have six industry-built ILC prototype rf sources
  (modulator, klystron and controls) in operation
  (one unit to be used at FNAL to drive three
  cryomodules).

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Status Plans

• Status
• Drove a Thales 2104U klystron with the SNS
  modulator
• 120 kV, 80 A, 5 Hz with 1 msec pulses
• In an initial rf test, produced 3 MW, 0.7 msec rf
  pulses at 5Hz
• Will receive a Thales 2104C tube in a few weeks
  for 5 MW operation
• Received parts from LANL to upgrade SNS modulator
  to drive the TH2104C and ILC prototype 10 MW
  klystrons
• Plans
• Complete system checkout with the Thales 2104U
  klystron
• Upgrade SNS modulator (test at 95 A and 130 A
  with a resistor load)
• Install the TH2104C klystron, complete waveguide
  runs to test areas, and process system with high
  power RF
• On track to finish 1.3 GHz Source in FY06

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1.3 GHz Source _at_ SLAC
SNS Modulator
Current RF source with isolator and load
Thales 2104U Klystron
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Modulator IGBT Switch

• Description (WBS 5.8.2) SLAC
• Design, build, test and deliver two solid state
  switches for the Bouncer modulator operating at
  10 kV and 1800A peak.
• Project is SLAC contribution to ILCTA program.
• Motivation
• Improve reliability through solid state n/N
  redundant switch structure and redundant serial
  switches to protect klystron in case of switch
  failure.

Scope
WBS 5.8.1 WBS 5.8.2

Note that actual cost of IGBT is more like
172 K see next slide
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5.8.2.1 Progress FY06

• Status
• Design 100 complete fabrication and testing 75
  complete.
• Awaiting delayed IGBTs delivery from vendor
• Delivery 1 month after all parts received.
• Budgets
• SLAC funded one switch (75K) in FY05
• Later design requirements changed to two switches
  for redundancy, increasing engineering,
  fabrication cost estimate to 172K.
• Project on track to complete within re-estimate.

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IGBT Switch Array
First Assembled Unit
Design Complete
IGBTs
Gate Drive Board
IGBT Stack
6 Plastic Stand-Off
Diode Stack
Aluminum Plate
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RF Power (WBS 5.8.3)

• WBS 5.8.3 RF For ILCTA _at_ FNAL
• Purpose RF Power (Modulator, Klystron,
  distribution system) for Horizontal Vertical
  Test Stand and ILC cryomodule.
• Small RF System 1 for HTS/Capture Cavity II
• Klystron Phillips YK1240 ( 300 KW)
• Modulator 600 KW
• LLRF Simcon 2.1 ( More on this later)
• Status
• System installed and operational in MDB
• RF has been applied to Capture cavity II
• System will move to HTS when this is ready

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MDB Small RF System 1
Charging supply and Series Tube Modulator
Klystron 300 KW
RF Controls
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RF Power (WBS 5.8.3)

• Large 10 MW Modulators (2 being built, ILC PD)
• Klystrons 1.3 GHz Thales, CPI, or Toshiba
• Modulator FNAL Bouncer type
• Status
• Both modulators are being assembled
• 112 HV Pulse transformers have arrived
• Plans
• PD modulator in FY06 in MDB (325 MHz klystron)
• On track to install 1st large ILC modulator in
  ILCTA_NM (New Muon lab) in FY07
• Modulator will be used to supply RF power for the
  test of the first U.S. built cryomodule (TTF
  type III)

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Large Modulator
112 HV Pulse transformer For PD 4.5 mS
Capacitor Frame
Capacitor Frame, Main Capacitors and Bouncer
Capacitors On site Bouncer Choke, High
Voltage Stripline, and Bus
On Site High Voltage Resistors and Undershoot /
Snubber Capacitors On site Cabinets and First
IGBT Switch from SLAC scheduled to arrive April
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Scope and Schedule

• FY06
• Scope
• Status Schedule
• Small RF system for HTS/Cap Cav II done
• Big Modulators PD in May 06, ILC in FY07
• VTS RF system (small CW) in late FY06

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Low Level RF (WBS 5.8.4)

• Purpose
• Develop LLRF for ILCTA test areas, work towards
  ILC LLRF system
• Stand alone RF systems for ILCTA VTS, HTS, New
  Muon
• LLRF Capture Cavity II/HTS
• FPGA based Simcon 2.1 LLRF system from DESY
• Master Oscillator 8 channel timer designed at
  FNAL
• Status
• System installed and operational in MDB
• RF has been applied to Capture cavity II
• System will move to HTS when this is ready
• Plans
• Develop multi-cavity control system for New Muon
  FNPL cryomodule
• Evaluating Simcon 3.1 boards from DESY
  alternatives

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Stand-alone LLRF System

• VME Modules
• Sparc CPU-56 running DOOCS and Matlab
• 8-Ch Timer Module (FNAL design)
• 8-Ch, 10 MHz fast digitizer (DESY design)
• 8-Ch Function Generator board (DESY design)
• Simcon 2.1 FPGA board (DESY design commercial
  FPGA board)

The CC2 LLRF Portable Rack was commissioned at A0
and is ready to support CC2 operations
Drive Vector Modulator and Downconverter Vector
Modulator/Mixer (New FNAL design, upgradeable to
3.9 GHz operation)
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New DESY Simcon 3.1 Board
3 prototypes received from DESY Jan 06. This can
control 8 Cavities from one Klystrons.
Fermilab (AD, TD, CD) in collaboration with DESY
and Poland are working on developing and
debugging this new board. Expanding the
collaboration on LLRF to include UPenn, SLAC and
INFN.
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Scope and Schedule

• FY06
• Scope
• Status Schedule
• LLRF system for HTS/Cap Cav II done
• LLRF for VTS FY07
• LLRF system for New Muon FY07

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Vertical Test Stand (WBS 5.9.2)

• Our goal is to rapidly advance the intellectual
  understanding of SCRF surface physics and
  establish process controls to reliably achieve
  high gradient ( 35 MV/M) SCRF cavity operation
• Approach Establish a tight loop processing and
  test infrastructure in the U.S.
• Tight loop elements
• Cavity fabrication improvements ( e.g. single
  crystal)
• BCP Electro-polish facilities
• High purity water and High pressure rinse
• Vertical test facilities
• SCRF experts materials program to interpret
  results
• Vertical test facilities exist at Cornell and
  TJNL (bare cavities)
• These are being modified for near-term use by ILC
  RD
• On a longer term ( 2007) new Vertical Test Stand
  (designed for 35 MV/M) cavity testing is being
  built at FNAL

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ILCTA_VTS

• A Vertical Test Stand VTS is sited in IB1 because
  this building currently houses the Magnet Test
  Facility ? large refrigerator capable of 60 W at
  1.8 K
• Bare 1.3 GHz 9-cell Tesla-style cavities
• Measure Q vs. T and Q vs. Eacc
• 250 W (CW) RF power required at maximum gradient
  (Q5x109, Eacc35 MV/m)
• Installed in a vertical pit in the Floor
• Shielding against X-rays and Neutrons is an
  important issue for 35 MV/M cavities
• Maintain Controlled Area status in IB1
• lt5 mrem/hr immediately outside shielding
• lt0.25 mrem/hr in normal working areas

LHe vacuum lines
Industrial Building 1
Cornell
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VTS Status Plans

• Cryostat Design
• Added phase separator to DESY design to improve
  He Quality
• Estimated RF duty factor possible based on IB1
  cryogenic capacity
• Started cryogenics controls modifications
• Cryostat design in progress
• Radiation Shielding
• Estimated x-ray flux from DESY data
• Finalizing shielding design prerequiste for
  finalized civil construction design
• Secure OK from Safety, then proceed with Civil
  work 2 months
• RF instrumentation
• Instrumentation design has begun
• Rack layout, etc
• Input coupler design will start soon

VTS Civil Design
One or two 9 cell cavities
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VTS Scope Schedule
FY06 Scope
Schedule

• Some costs will spill over to FY07. On track to
  have a Vertical Test System to test high gradient
  cavities at Fermilab in 2007

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Horizontal Test Facility

• Purpose Verify dressed cavity performance (Eacc
  vs. Q0) to qualify cavities for assembly into a
  cryomodule
• Bare cavities that pass vertical test are
  dressed with LHe cryostat, coupler, tuner
  then tested with RF pulsed power
• Usually referred to as Horizontal Test since
  this test is performed in this orientation at
  DESY in the Chechia facility
• Horizontal Test Systems (HTS) are under design
  for ILCTA_MDB (Meson Detector Building) and
  ILCTA_IB1 (Industrial Bldg 1)

Bare 1.3 Ghz 9 cell Cavity
Horizontal Test_at_DESY
4 cavities received from ACCEL 4 cavities on
order at AES 2 cavities on order at TJNL 4
cavities expected from KEK
Dressed Cavity
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HTS (WBS 5.9.1)

• ILCTA_MDB HTS
• Cryostat
• Accepts single dressed cavities, 1.3 GHz or
  3.9 GHz
• Similar to the DESY HTS but has access at both
  ends.
• Cryogenics
• MDB has an existing 1800 W _at_ 4 K cryogenic system
• New distribution system built to supply cavity
  test areas
• Large vacuum pump has been added to achieve 60 W
  at 1.8 K
• Cryogenic costs for this are in WBS 5.9.3
• RF System
• 300 KW klystron modulator provides pulsed RF
  power
• Costs associated with RF system are in 5.8.3
• ILCTA_IB1 HTS
• A second HTS will be built for IB1
• Improved throughput (HTS is bottleneck _at_ DESY)
• Design improvements
• Accepts two 1.3GHz cavities simultaneously.

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HTS Status Plans

• ILCTA_MDB
• Phase I Qualify six 3.9 GHz cavities for DESY
  TTF-VUV-FEL
• Phase II Qualification and RD for 1.3 GHz
  cavities for ILC
• Cryostat being fabricated at PHPK (Columbus, OH)
• Delivery date 14-APR-2006
• Cryo lines to cave installed, interface to
  cryostat (feed can) under construction
• Working 1.3 GHz RF system in MDB
• Operated daily (A0 Capture Cavity 2 testing)
• Gathering components for 3.9 GHz

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HTS Scope and Schedule

• Scope
• Schedule
• Delivery of MDB cryostat in mid-April
• Connect to MDB cryo system and commission
• RF commissioning in parallel
• Ready for 3.9 GHz cavity testing by end June
• FY07 Construction of 2nd HTS in IB1
• Exploits existing facility to increase cavity
  throughput
• Allows LLRF RD on driving multiple cavities w/
  one klystron

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Cryogenics (WBS 5.9.3 5.8.2.2)

• WBS 5.9.3 Cryogenics for Test Stands _at_ FNAL
• Purpose Develop cryogenic capability to cool
  cavities in Vertical and Horizontal Test Stands
• WBS 5.8.2.2 ILCTA Cryogenics Designer from SLAC
• Funded via SLAC core vs GDE provided funds
• HTS
• Upgrade the existing 1800 W (4K) refrigerator
  system at the Meson Detector building at Fermilab
  to supply 60 W of 1.8 K refrigeration for the HTS
• Transfer lines extended from upstream locations
  to MDB
• Build and install Feed cans
• Install New Large Vacuum pump skid and associated
  plumbing and infrastructure
• Modify cryogenic controls
• Near-term Goal Cool 1st 9 cell ILC cavity to 4 K
  (Cap. Cavity 2)
• Next Goal Achieve 60 Watt capacity at 2K by May
  06.

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Cryogenics

• VTS
• Connect existing VTS to existing 60 W 1.8 K
  refrigerator system in IB1 for the HTS
• Modify existing IB1 LHe transfer and vacuum lines
  to connect to VTS top plate
• Must wait until LHC quad testing is complete (end
  of Apr)
• Modify cryogenic controls
• Goal Achieve 60 Watt capacity at 2K to VTS by
  the end of FY06.

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Scope and Schedule

• FY06
• Scope
• Current Labor is yyy FTE
• Status Schedule
• Transfer line and feed cans done
• Refrigeration connected to capture cavity 2
• Capture Cavity 2 cooled to 4 K with RF power
• Vacuum Pump skid refurbished installed
• Electrical, water, piping, controls in progress
• Plan 2K capability to Cap Cavity 2 in April
• Plan 2K capability to HTS cryostat by June 06

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MDB Transfer Lines feed cans
This feed can was designed at SLAC and built at
FNAL WBS 5.8.2.2
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Capture Cavity II Cold RF power
First 1.3 GHz TESLA Cavity in MDB Cold and RF
power
MDB Cryogenics 60 W _at_ 1.8 K
25 MV/M _at_ 4.5 K Reasonable Dark Current
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Vacuum Pump Connected in MDB
Electrical Installation
Mechanically Installed
This is a BIG vacuum pump 2 motors total 300 hp!
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ILCTA_NM Cryogenics

• ILCTA_NM
• Installing Cryogenics, vacuum pump, plumbing,
  electrical infrastructure, laser room, controls,
  etc
• Plan to move FNPL photo-injector to New Muon in
  07
• Will provide ILC like beam to test cryomodules
• Building transfer lines, feed cans, etc.
• FY06 Funded from Fermilab SCRF infrastructure
  from core program funds at FNAL ? ie not via
  GDE
• FY06 progress is limited by available cash
• Needs serious funding in FY07
• Need to procure a new large refrigerator
• Will provide test of 1st U.S. built Cryomodule in
  2007

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ILCTA_NM _at_ Fermilab
New Muon Lab
FNPL Photo-injector
11/05

• Building a ILC cryomodule test area in the New
  Muon Lab (ILCTA_NM)
• Cleaning out building (Done) except for CCM
• Bid package out remove CCM
• Plan to move Photo-injector
• Work is in progress to install interim cryogenic
  solution in FY06
• Will build part of the cryogenic distribution
  system in FY06
• Funding ? Can not start Cryomodule feed cans
  until FY07

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NML Heat xchanger LN2 Dewar
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Cryomodule end cans Delayed to FY07 ()
Cryomodule Test at DESY TTF
End Cans
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Current Status

• New Muon Lab
• He storage tanks - 60 complete
• LN2 storage tank was refurbished
• Drawings and specification for Mycom piping
  contract - done
• PS-1 heat exchanger relocation done
• Helium piping and purifiers bid package - 70
  complete
• Designing test cave distribution system
• Cryogenic controls - 30 complete
• Budgetary estimate for the ILC CM feed and end
  caps done
• PLANS
• Long Term goal is one ILC RF unit (3 cryomodules,
  modulator, 10 MW klystron, LLRF, etc by 2009

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Conclusions

• Our prime objective is to build and evaluate the
  components of the ILC main Linac
• Also we need to acquire experience expertise in
  the U.S. on SCRF technology
• We are building extensive infrastructure at
  Fermilab and SLAC in support of these goals
• Cavity test facilities ( horizontal and vertical)
• High Power RF test systems
• LLRF test systems
• Cryomodule Test facilities ( including beam tests
  )
• Significant Technical Progress in FY05?06
• Progress is limited by the available funding