Production Preparations at JLAB
JLab SRF Team
EDMS – PLM DESY TeamCenter Meeting at
SLAC
31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
Outline
• Strategy
• Preparations for LCLS-II Cavity Production at Vendors
• Preparations for Cryomodule Production at JLab
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Vertical Test Area (VTA)
Horizontal Test Bed (HTB)
Cavity String Assembly
Cold Mass Assembly
CMTF (Cryomodule Test Facility)
Prototype, Acceptance and Commissioning Tests
• Issues / Challenges
• Summary
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Strategy – One Design, Two Production Lines
Designs for Prototype and Production CMs
• Identical Prototypes - utilize as much existing hardware as possible to reduce
schedule risk and reduce overall cost while achieving the same performance
as the production CMs
• Identical Production Designs - utilize as much of the DESY/XFEL design as
practically possible to reduce schedule risk and reduce overall cost
Identical Parts Received at Partner Labs
• Well-developed drawing packages, clear requirements and specifications
• Concurrent reviews within LCLS-II project
• Procurement activities – lead technical contacts at Jlab/FNAL work together
during all phases (SOTRs)
Identical Tooling Interfaces
• Interfaces between CM hardware and tooling are identical
• Avoid adding custom features to CM
• Adapt non-CM hardware interfaces to Jlab-specific tooling
Equivalent Processes yielding Equivalent Performance
• Recognize that some tools are different at each lab (e.g. HPR, vertical testing
systems, vacuum leak checking equipment, etc.)
• Monitor key process variables in consistent fashion (e.g. samples to verify
etch rates)
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Preparations for Cavity Procurement
• Approach – procure dressed cavities processed with high-Qo
recipe from multiple vendors
• Niobium to be purchased and provided to cavity vendors
• FNAL leads niobium procurement activities and is developing spec
• Capture best-available high-Qo process to be included as part of
cavity specification
• Three-lab collaboration proceeding with development
• Cavity procurement activities led by JLab
• Need well-developed drawing packages, clear requirements and
specifications
• XFEL specification is considered point-of-departure
• Need to define level of oversight at cavity and component suppliers to
ensure performance
• Reviewing acceptance criteria, processing steps and hold points
(where necessary)
• Lead technical contacts at Jlab/FNAL work together during all phases
(SOTRs)
• JLab/FNAL/SLAC involved during evaluation of offers
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Cavity Procurement – High Level Comparison
• SNS – 81 bare cavities, 2 types, 1 supplier
• Niobium supplied to vendor
• Reactor-grade end groups required post-purification by JLab
• No performance guarantee; Vendor needed to demonstrate that
proscribed manufacturing process was followed
• Visits to vendor to monitor progress
• C100 – 85 bare cavities, 1 supplier
• Niobium procured by vendor
• Received with bulk BCP and initial tuning
• No performance guarantee; Vendor needed to demonstrate that
proscribed manufacturing process was followed
• Visits to vendor to monitor progress
• XFEL – 800 dressed cavities, 2 suppliers
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Multiple niobium procurements
Receive ready for vertical testing
Performance guarantee?
Availability and use of in-process data?
Support at vendor’s facility?
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
CM Production Preparations
• Adapt existing infrastructure to accommodate LCLS-II
components, sub-assemblies, final assembly and testing
• Define processes required for component handling, assembly
and testing
• Develop test plans – key activities are cavity qualification from
vendors and cryomodule acceptance testing
• Employ SRF QA Tools used for 12 GeV 100 MV CW
cryomodules (aka C100) production and SNS production
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Vertical Test Area / Horizontal Test Bench
VTA
• Up to four test stands available for production acceptance
testing capable of testing one cavity at a time
• Utilize same cavity hardware (test flanges, feedthroughs, etc.)
provided by project to cavity suppliers
• Small modifications required to existing supports
• Ensure low magnetic field environment (“magnetic hygiene”)
HTB
• Plan to conduct five tests during production effort to provide
feedback on cavity assembly process or for production
development activities
• Modifications to top hat for XFEL-style FPC and small
modifications to existing supports
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Cavity String Assembly in Clean Room
• “Lollipop” supports for each cavity
• TBD for SC magnet and bpm
• Use mobile rail system rather than rail-in-floor used at DESY,
CEA/Saclay and FNAL
• Transfer to CM assembly rails for cold mass assembly
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Cold Mass / VV Assembly
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“Lollipop” supports for each cavity
TBD for SC magnet and bpm
Use two-rail system to transfer cavity string onto Return Pipe
Use two-rail system to transfer cold mass into vacuum vessel
Crane access in high-bay for shipping
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
CMTF
• HPRF system suitable for individual cavity testing or 8
cavities in short duration steady state
• TBD system for testing SC magnet
• Magnetic shielding encloses testing volume reducing external
fields to ~50 mG
• Cryogenic capacity for testing individual cavities in CW mode
• End Caps – specific for LCLS-II CM testing
• Interface to CM piping and existing junction box using u-tubes
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
CM Testing
• Three types of CM testing should be considered:
• Prototype Testing that may include additional (non-routine)
activities for system verification
• Acceptance Testing in CMTF includes some CMTF-specific
checks
• CMTF procedures may vary from in-tunnel procedures
• HP RF equipment may not be identical
• Commissioning Tests in-situ may include tests that
• Require additional equipment (Network Analyzer)
• Verify RF zone operations (EPICs controls, Klystrons, etc.)
EDMS PLM DESY TeamCenter Mtg at
SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
Comments on Prototype Testing
• Testing Facility (CMTF) Checks
• Electrical, water, cryo, controls, LLRF, HPRF, Data acquisition
• Includes collection of tests envisioned for production CMs
• Both Low Power and High Power
• Includes specific tests that may verify CM performance, but
might not be conducted on all CMs
• FPC Qext range vs. CM heat load
• Detailed microphonics studies
• LLRF development activities
EDMS PLM DESY TeamCenter Mtg at
SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
C100 CM Production : LP RF Tests*
*Major Steps taken from C100 Low Power RF Test Traveler
• Cavity ID's
• Warm Frequencies
• Mechanical Tuners: Tuner Range and Hysteresis
• Cold Frequencies including pass-bands and loaded Q’s
• Mechanical Tuner Resolution
• Piezo Tuner Range and Hysteresis
• Piezo Tuner Resolution
• Piezo Tuner Impulse Response
• Microphonics
• Mechanical Mode Measurements
• HOM Coupler Qext's and HOM Survey
• Cavity Detuning for Warm up
EDMS PLM DESY TeamCenter Mtg at
SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
C100 CM Production : HP RF*
*Major Steps taken from C100 HP RF Traveler
• Checklist
• Qext's, FPC's and HOM's
• Maximum Gradient Determination (Emax)
• Extended (One Hour) Run (Emaxop)
• Field Emission Measurements
• Qo Measurements / Static Heat Load - Primary Circuit
• Pressure Sensitivity Measurements
• Static Lorentz Measurement
• Swept AM Lorentz Transfer Function
EDMS PLM DESY TeamCenter Mtg at
SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
C100 CM Production : HP RF Checklist
• Record Cavity ID #’s
• Calibrate RF Cables
• Verify Interlocks
• Arc Detectors / IR Sensors
• Beamline / Waveguide Vacuum
• G-M Tubes
• Inspect waveguide connections
• Inspect Heliax cable connections
• Verify Personnel Safety System (PSS)
EDMS PLM DESY TeamCenter Mtg at
SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
C100 CM Production : Testing in Tunnel*
*Major Steps taken from C100 Commissioning Traveler
• Low Power RF
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Initial Cold Frequencies
Cavity Tuning
Final Cold Frequencies and Passbands
HOM Measurements
• Interlock Checkout
• High Power RF
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Emax Determination: Qext’s and Probe Calibrations
Emax Determination: Emax
Emaxop Determination (One Hour Run)
Field Emission Survey
Qo vs. Eacc Measurements
Static Heat Load
Microphonics
Eight Cavity Run (at low duty cycle)
EDMS PLM DESY TeamCenter Mtg at
SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14
Shipping Method
XFEL CM
Shipping Fixture
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LCLS-II CMs will be shipped from
partner labs to SLAC using shipping
fixture on flat-bed trailer with cover
• Plan to use identical shipping fixtures
and covers as for XFEL
Design verification can be accomplished
with the first article LCLS-II cryomodule.
• Instrument cavity string, quadrupole,
piping and vacuum vessel with triaxial
accelerometers to measure shock
attenuation and vibration isolation
during transport
• Evaluate performance before / after
simulation of loading and shipping
environment
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RF performance
Static heat loads
Alignment
Shipping Covers - provide
hermetic seal and piping
support
Aeroflex Isolator - wire rope spring
provides triaxial shock attenuation and
vibration isolation
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Issues / Challenges
• Defining level of oversight at cavity and component suppliers
• Defining acceptance criteria and hold points where necessary at
cavity and component suppliers
• Defining requirements for niobium inspection – e.g. correlating
eddy current scanning to cavity performance
• Goal for production of CMs at Jlab/FNAL is “identical design,
identical parts, equivalent processes to yield equivalent
performance”
• Developing coherent QA plan with appropriate QC systems across
project partner labs
• Developing travelers for CM production lines at two labs that utilize
equivalent processes  “local customization”
• Availability of XFEL design information and production QA tools as
point of departure for LCLS-II design
• Success-oriented schedule
• Others?
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14
Summary
• Goal for production of cavities at vendors is “identical design,
identical parts, equivalent processes to yield equivalent
performance”
• Goal for production of CMs at Jlab/FNAL is “identical design,
identical parts, equivalent processes to yield equivalent
performance”
• Need to identify appropriate QA tools to use during vendor
production and lab CM production
EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR
2014
SRF_BizPlan_31Oct2010_Rev_14