WP5 Elliptical Cavities Cryomodules Pierre BOSLAND, CEA Saclay External WP5 leader Christine Darve, ESS deputy WP leader TAC11 1rst April 2015 The elliptical cavity cryomodules in the ESS linac Klystron gallery MEDIUM-β HIGH-β 0.67 0.86 # CM 9 21 Cav. /CM 4 4 # Cav. 36 84 6.584 6.584 77 179 β CM L [m] Sector L [m] 1st April 2015 Proton Beam Elliptical cavities Cryomodules Medium-b and high-b ESS TAC11 2 Framework of the cryomodules development and production 1. Two prototype cryomodules: 2. medium beta: M-ECCTD 3. High beta: H-ECCTD <= FR-SW agreement <= CEA FR In Kind Contribution 2. Production of cavities of the series with RF tests: 3. medium beta cavities <= LASA - IT In Kind Contribution 4. High beta cavities <= STFC - UK In Kind Contribution 3. Production of all other components: <= CEA FR In Kind Contribution (including coupler production with RF power processing) 4. Cryomodule assembling : <= CEA FR In Kind Contribution 5. RF power tests of the cryomodules <= ESS Lund 1st April 2015 TAC11 3 FR in kind activities starting at Saclay (“early in kind”) ESS - AB ACCSYS ACCSYS ACCSYS ICS ICS Technique : Technical Board ESS - AB Management : Coordination C. Collaboration C. In Kind Review C. WP 3 WP 5 WP 7 WP 6 WP 10 Responsables IRFU reorganization 2015: Cellule Qualité on the 1rst of June ESS - IRFU A Bruniquel C. Cloué Florence O.Sécurité Ardellier: Kuster Pierre Bosland : WP Tests IPHI B. Pottin WP Bunker 352 MHz JP. Charrier WP ECCTD F. Peauger M-ECCTD CdP: P. Bosland Adjoint: A. Daël WP Cryomodules de série P. Bosland/XXX IKC H-ECCTD ACCSYS WP5 1st April 2015 Scientifiques G. Devanz D. Uriot O. Piquet Projet ESS / IRFU Project Office planning: X. Hanus ressources: L. Lecourt secrétaire: XX Project Manager Scientific Director WP RFQ B. Pottin WP Diagnostics F. Sénée WP Contrôle Commande F. Gougnaud WP Test injecteur B. Pottin ACCSYS WP7 ICS WP 6 / 10 ACCSYS WP3 Design RFQ IKC RFQ ACCSYS WP3 TAC11 4 Overview of the design of the cryomodules and components First results on prototype high beta cavities On behalf of the CEA Saclay, IPN Orsay team and ESS team: C. Arcambal, G. Devanz, P. Bosland, E. Cenni, P. Hardy, F. Leseigneur, J. Plouin, G. Ferrand, F. Eozenou, C. Servouin, D. Roudier, L. Maurice, X. Hanus, C. Madec, JP. Poupeau, N. Bazin, N. Berton, V. Hennion, JP. Charrier, O. Piquet, P. Carbonnier, B. Renard, P. Sahuquet, A. Hamdi, CEA Saclay G. Olivier, JP. Thermeau, IPN Orsay C. Darve, N. Elias, G. Costanza ESS 1st April 2015 TAC11 5 Cryomodule design and prototyping Fr-SW agreement Collaboration IPNO – IRFU IPNO in charge of the cryostat – design and fabrication Vacuum vessel Space frame – cavity supports Thermal screen Superinsulation Internal cryogenic pipes Instrumentation G. Olivier IRFU in charge of the “cavity package”, the cryomodule assembly and RF power tests: Cavities + helium tank Power coupler Piezo tuner Magnetic shield Tooling: field flatness, cavity preparation, assembling, … Cryomodule assembly Tests stand for cryogenic and RF power tests Tests of the ECCTD cryomodule cryomodule Medium beta prototype cryomodule M-ECCTD Generic design for medium & high beta cryomodules The level-4 requirements for the medium and high beta cryomodules are listed in the DOORS management system (Dynamic Object-Oriented Requirements System). Conformance of the design with these requirements has been presented at a-TAC (October 2013). 1st April 2015 TAC11 6 Cryomodule design G. Olivier Similar to CEBAF/SNS cryomodule concept with 4 cavities per cryomodule Common design for medium (6 cells) and high beta (5 cells) cavities Jumper connection Heat exchanger Spaceframe support Magnetic shielding Regulation He valve Vacuum valve Thermal Alignement fiducial shielding Diphasic He pipe Proton Beam Cold to warm transition 1st April 2015 Intercavities belows Power coupler TAC11 Cavity with Helium tank 7 Cavities design Magnetic shielding Tank (Ti) High beta (0,86): 5 cells Length 1316,91mm Cold tuning system Medium beta (0,67): 6 cells Length 1259,40mm Medium High 94 120 1.22 1.8 0.54 1.2 2.36 2.2 Bpk/Eacc (mT/(MV/m)) 4.79 4.3 Maximum. r/Q (W) 394 477 0.705 0.92 196.63 241 Iris diameter (mm) Cell to cell coupling k (%) p and 5p/6 (or 4p/5) mode separation (MHz) Epk/Eacc Optimum b 11 DEC 2014 G (W) Geometrical beta Frequency (MHz) Operating temperature (K) Maximum surface field in operation (MV/m) Nominal Accelerating gradient (MV/m) Nominal Accelerating Voltage 57,5 mm (MV) Q0 at nominal gradient Cavity dynamic heat load (W) Qext Medium High 0.67 0.86 704.42 2 44 44 16.7 19.9 14,3 18,2 > 5e9 4,9 7.5 105 6,5 7.6 105 Challenging accelerating gradients and Q0 No HOM couplers • HOM frequencies and internal cavity shape must be carefully controlled G. Devanz, J. Plouin, G. Constanza Tests of the 2 prototype cavities in vertical cryostat P01 - E. ZANON P02 - RI Protypes with HOM ports for RF measurement Both prototype cavities met the ESS requirements after the first test: very encouraging results! Slight degradation of performances after thermal treatment for hydrogen removing (pollution) 1st April 2015 ESS TAC11 9 Tests of the 2 prototype cavities in vertical cryostat EFFECT of BCP on the frequency Tuning sensitivity DF/Dz (kHz/mm) ESS067 ESS086 Calculated 214.8 197 Measured 190 Stiffness (kN/mm) ESS067 ESS086 1.286 2.59 (3.6 mm thick) 3.3 (4.5 mm thick) Calculated Measured • Measured LFD coefficient: KL = -7.65 Hz/(MV/m)² • Close to the calculated value of -8.9 Hz/(MV/m)² in free ends conditions 3 Frequency shift DF due to cooldown and vacuum (kHz) 300K to 4.2 K Calculated Measured Ɛr to Ɛo 1st April 2015 Measured TAC11 ESS086 +1.0067 +1.00138 +0,211 +0.211 300K to 4.2K ~ +1.08 Ɛr to Ɛo +0.015 Frequency shift DF due to cooldown and pressure (kHz) Calculated ESS067 ESS067 ESS086 4.2 K to 2 K ~ + 0.207 10 Dangerous Higher Order Mode close to 1408.8 MHz Both high beta prototype cavities are not conform with the ESS HOM Requirement Reminder: « All higher order modes (HOMs) shall be at least 5 MHz away from integer multiples of the beam-bunching frequency (352.21 MHz) for any HOMs whose resonant frequencies are below the cut-off frequency of the beam-pipe.” Slater coefficient analysis which represents frequency sensitivity to volume changes: 704 MHz 1421,32 MHz 3D measurements of the cavity shape have been performed Shape reconstructed in the simulation software HFSS Calculated with Calculated with Measured on measured measured ESS086-P02 shape (HFSS) shape (HFSS) Design (at 300K) Measured on ESS086-P01 1418.178 1402.254 1403.8 1407.848 1418.674 1404.666 1406.8 1408.258 On P01 cavity (from ZANON), a strong internal shape deviation in this dome region (more than 1 mm instead of 0.3 mm) explains very well the frequency decrease of the two dangerous HOM Study under progress on P02 cavity (from RI) Cells reshaping has to be implemented in the fabrication process of future cavities 1st April 2015 TAC11 11 Titanium Helium tank of ESS086-P01 welded (ZANON) DF = +9 kHz only due to tank welding Pressure and leak test done successfully Delivery at CEA in 1 or 2 weeks for CV test only (not compatible with the cryomodule) 1st April 2015 TAC11 12 Start of production of the ½ cell for 6 medium beta cavities 6 cavities ordered at ZANON, 4 of them will be integrated into the M-ECCTD cryomodule Niobium received and sent to ZANON Deep drawing tests on copper plates Preparation of RF measurement equipements for half cells and dumbbells 1st April 2015 TAC11 13 Power coupler procurement in progress → For the prototype cryomodules, the coupler procurement is divided into three parts 8 x RF window+antenna → TOSHIBA 1st April 2015 6 x double wall external conductor → 2 companies in tender ESS TAC11 6 x Door Knob → Spec. in progress 14 Power coupler conditioning set-up Assembled in clean room Tested with a 1.1 MW klystron and variable short circuit / matched load 1st April 2015 ESS TAC11 15 Tooling design finalized for the assembly of the cavity string clean room Coupler / cavity assembly vertically Tooling compatible for both cavity types Adjustment of the coupler position relative to the cavity flange Cart in two parts with clean room rails Each cavity is supported by two posts and beam valves on one post Cavity string put under vacuum for the first prototype 1st April 2015 ESS TAC11 N. Bazin, C. Madec, JP Poupeau, Ph. Hardy, F. Leseigneur 16 Test stand new cryolines installation Test bunker (cryomodule will be installed inside) Pumping line DN250 He return line 1st April 2015 Dewar LHe 2000 L Cryogenic line He Supply, 50 m long (from CERN) ESS TAC11 JP Charrier, P. Sahuquet, B. Renard 17 704 MHZ - 1 MW RF power source upgrade A. Hamdi, M. Desmons, F. Ballester increase the pulse length from 2 ms to 3.5 ms HVPS C R2 C’ R’ C//C’=10µF (Energie=60,5kJ) R’//R2=25 Ohms (tenue: 84kJ) Load Additional capacitors and resistances in parrallel on the HV modulator 1st April 2015 Conditionning of the CPI 1.15 MW klystron up to the ESS duty cycle was done with success ESS TAC11 18 18 Compliance with European PED 97/23/EC Cryo pipes designed to reduce the overpressure in case of beam vacuum failure TUV Nord analysis report: The elliptical cryomodules are classified according to PED article 3.3 2 F=100 bursting disks at each extremity continuous diphasic pipe F=100 with large curvatures • • • Volumes of the helium circuits and vessels < 50 l 1,431 bars< Working pressure Ps = 1,9 bars 1st April 2015 TAC11 19 Overall WP5 planning 1st April 2015 TAC11 20 WP5 planning compliant with RFI dates Task name PROTOTYPES ECCTD duration start date end date 34 ms Jeu 01/01/15 Lun 13/11/17 27 ms Jeu 01/01/15 Mar 11/04/17 Tests 4 ms Lun 10/10/16 Mer 08/02/17 Mid-test flag 0 ms Ven 09/12/16 Ven 09/12/16 PRR review decision 0 ms Ven 23/12/16 Ven 23/12/16 End of the tests - Disassembly 2 ms Jeu 09/02/17 Mar 11/04/17 28 ms Lun 06/07/15 Lun 13/11/17 Tests 2 ms Mer 13/09/17 Lun 13/11/17 Mid-test flag 0 ms Ven 13/10/17 Ven 13/10/17 PRR review decision 0 ms Ven 13/10/17 Ven 13/10/17 49 ms Ven 23/12/16 Mer 10/02/21 21 ms Ven 23/12/16 Mar 02/10/18 12 ms Jeu 28/09/17 Mar 02/10/18 39 ms Ven 27/10/17 Mer 10/02/21 30 ms Jeu 02/08/18 Mer 10/02/21 M-ECCTD H-ECCTD CAVITIES Medium beta production (INFN) (36) Cavity delivery (3 cav/m.) High beta production (STFC) (84) Cavity delivery (3 cav/m.) COUPLERS 64 ms Lun 01/06/15 Mer 21/10/20 Conditioning stand 24 ms Lun 01/06/15 Mer 07/06/17 Manufacturing & RF processing (36+84) 51 ms Lun 01/06/15 Mar 17/09/19 Pre-serial manufacturing (4) 13 ms Ven 09/12/16 Ven 12/01/18 RF conditionning Pre-serial (2 pairs) 6 ms Jeu 08/06/17 Ven 08/12/17 Restart serial prod delay 4 ms Ven 08/09/17 Mar 09/01/18 manufacturing MBC 1-36 (6cpl./m.) 6 ms Mer 10/01/18 Jeu 12/07/18 RF conditionning MBC (4 cpl./m.) 10 ms Mar 13/03/18 Lun 14/01/19 manufacturing HPC 1-84 (6cpl./m.) 14 ms Ven 13/07/18 Mar 17/09/19 RF conditionning HBC 1-44 (4 cpl./m.) 11 ms Mar 15/01/19 Mer 18/12/19 RF conditionning HBC 45-84 (4 cpl./m.) 10 ms Jeu 19/12/19 Mer 21/10/20 CRYOMODULES 2015 2016 2017 2018 2019 Hb cavities delivery Couplers procurement assembly and tests Conditionning stand Manufacturing & RF processing Mb couplers processing Hb couplers processing Hb couplers processing Cryomodules procurement assembly and tests CM manufacturing MBL cryomodules MBL assembly Ven 14/01/22 54 ms Mar 01/09/15 Jeu 19/03/20 MBL Modules assembly 16 ms Ven 29/12/17 Lun 06/05/19 14 ms Ven 29/12/17 Mar 05/03/19 n°1 4 ms Ven 29/12/17 Mar 01/05/18 n°2-3 4 ms Mer 02/05/18 Ven 31/08/18 n°4-9 6 ms Lun 03/09/18 Mar 05/03/19 6 11 ms Ven 01/06/18 Lun 06/05/19 MBL tests n°1 2 ms Ven 01/06/18 Mer 01/08/18 n°2-3 3 ms Jeu 02/08/18 Jeu 01/11/18 n°4-9 6 ms Ven 02/11/18 Lun 06/05/19 HBL Modules 33 ms Ven 05/04/19 Ven 14/01/22 Assembly 31 ms Ven 05/04/19 Lun 15/11/21 n°1-11 16 ms Ven 05/04/19 Lun 10/08/20 n°12-21 15 ms Mar 11/08/20 Lun 15/11/21 31 ms Jeu 06/06/19 Ven 14/01/22 16 ms Jeu 06/06/19 Ven 09/10/20 15 ms Lun 12/10/20 Ven 14/01/22 RF st power tests at Lund 1 n°1-11 April 2015 n°12-21 2022 P. Michelato Mb cavities P. McIntosh Hb cavities Hb cavities production 75,64 ms Mar 01/09/15 RF power tests at Lund 2021 Cavities production Mb & Hb Mb cavities prod Mb delivery Components manufacturing Assembly 2020 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 1 2 1 2 6 HBL cryomodules Assembly 21 HBL 11 HBL 10 HBL TAC11 21 tests 21 HBL 11 HBL 11 HBL Milestones for tendering • Cavity test in vertical cryostat (Nominal performances Eacc & Qo) Required prior tendering for niobium production for series Test of the 1st medium beta cavity scheduled on 01 October 2015 OK for High beta cavities: 2 prototypes already tested • RF power tests at 2K of the ECCTD + Critical Design Review Required prior tendering cavities , couplers and all components of the cryostats M-ECCTD: CDR on the 23/12/2016 => Mb cavities + couplers + cryostats H-ECCTD: CDR on the 13/10/2017 => Hb cavities only needed CDR (Critical Design Review) ~ Production Readiness Review 1st April 2015 TAC11 22 Planning main assumptions made to reach the goal of the RFI dates for MBL 1. Success oriented planning to match the ESS schedule: no margin, assumed no non-conformity for all cavities, couplers and components; 2. The first results of the M-ECCTD are successful and the series production of Mb cavities, power-couplers and cryostat components are launched 2 weeks later (CDR). This implies that the tendering is finalized, the contracts are awarded at the time of CDR and the series fabrication starts; 3. Rate of cavities production and delivery at Saclay after RF test: 3/month (Mb & Hb cavities); 4. Delivery of the 1st serial cavity tested and qualified 6 months after the start of the cavity production; (required previous preparation by LASA and STFC of the industry and labs for cavity production, cavity treatments and cavity tests) 6. Rate of the coupler RF processing = 4 couplers/month will be confirmed end of 2015 (ECCTD couplers); 7. Rate of the cryomodules assembly: • • • 1st cryomodule: 2nd & 3rd : 4th to 9th: 4 months 2 month / CM 1 month/CM 8. The RF test stand at Lund shall be fully operational for the 1st cryomodule (Q1 2018) and the testing rates are: • 1st cryomodule: 2 months • 2nd & 3rd : 1,5 month / CM th th • 4 to 9 : 1 month/CM 9. The cryomodule assembly in Saclay by the new industrial team is qualified after the test of the 1st cryomodule. 10. The 2nd and 3rd cryomodules need to be assembled before the end of the tests of the 1st cryomodule. 1st April 2015 TAC11 23 Overall WP5 planning Task name PROTOTYPES ECCTD duration start date end date 34 ms Jeu 01/01/15 Lun 13/11/17 27 ms Jeu 01/01/15 Mar 11/04/17 Tests 4 ms Lun 10/10/16 Mer 08/02/17 Mid-test flag 0 ms Ven 09/12/16 Ven 09/12/16 PRR review decision 0 ms Ven 23/12/16 Ven 23/12/16 End of the tests - Disassembly 2 ms Jeu 09/02/17 Mar 11/04/17 M-ECCTD H-ECCTD 28 ms Lun 06/07/15 Lun 13/11/17 Tests 2 ms Mer 13/09/17 Lun 13/11/17 Mid-test flag 0 ms Ven 13/10/17 Ven 13/10/17 PRR review decision 0 ms Ven 13/10/17 Ven 13/10/17 49 ms Ven 23/12/16 Mer 10/02/21 21 ms Ven 23/12/16 Mar 02/10/18 12 ms Jeu 28/09/17 Mar 02/10/18 39 ms Ven 27/10/17 Mer 10/02/21 30 ms Jeu 02/08/18 Mer 10/02/21 CAVITIES Medium beta production (INFN) (36) Cavity delivery (3 cav/m.) High beta production (STFC) (84) Cavity delivery (3 cav/m.) COUPLERS 64 ms Lun 01/06/15 Mer 21/10/20 Conditioning stand 24 ms Lun 01/06/15 Mer 07/06/17 Manufacturing & RF processing (36+84) 51 ms Lun 01/06/15 Mar 17/09/19 Pre-serial manufacturing (4) 13 ms Ven 09/12/16 Ven 12/01/18 RF conditionning Pre-serial (2 pairs) 6 ms Jeu 08/06/17 Ven 08/12/17 Restart serial prod delay 4 ms Ven 08/09/17 Mar 09/01/18 manufacturing MBC 1-36 (6cpl./m.) 6 ms Mer 10/01/18 Jeu 12/07/18 RF conditionning MBC (4 cpl./m.) 10 ms Mar 13/03/18 Lun 14/01/19 manufacturing HPC 1-84 (6cpl./m.) 14 ms Ven 13/07/18 Mar 17/09/19 RF conditionning HBC 1-44 (4 cpl./m.) 11 ms Mar 15/01/19 Mer 18/12/19 RF conditionning HBC 45-84 (4 cpl./m.) 10 ms Jeu 19/12/19 Mer 21/10/20 CRYOMODULES 2015 2016 2017 2018 2019 Cavities production Mb & Hb Mb cavities prod 1) Mb cavities contract awarded Mb delivery 1) Hb cavities contract awarded Hb cavities production Hb cavities delivery Couplers procurement assembly and tests Conditionning stand RF power source ready for coupler Mb couplers processing Hb couplers processing Hb couplers processing Cryomodules procurement assembly and tests Cryomodule components contract awarded CM manufacturing MBL cryomodules MBL assembly Ven 14/01/22 Mar 01/09/15 Jeu 19/03/20 MBL Modules assembly 16 ms Ven 29/12/17 Lun 06/05/19 14 ms Ven 29/12/17 Mar 05/03/19 n°1 4 ms Ven 29/12/17 Mar 01/05/18 n°2-3 4 ms Mer 02/05/18 Ven 31/08/18 n°4-9 6 ms Lun 03/09/18 Mar 05/03/19 6 11 ms Ven 01/06/18 Lun 06/05/19 MBL tests n°1 2 ms Ven 01/06/18 Mer 01/08/18 n°2-3 3 ms Jeu 02/08/18 Jeu 01/11/18 n°4-9 6 ms Ven 02/11/18 Lun 06/05/19 HBL Modules 33 ms Ven 05/04/19 Ven 14/01/22 Assembly 31 ms Ven 05/04/19 Lun 15/11/21 n°1-11 16 ms Ven 05/04/19 Lun 10/08/20 n°12-21 15 ms Mar 11/08/20 Lun 15/11/21 31 ms Jeu 06/06/19 Ven 14/01/22 16 ms Jeu 06/06/19 Ven 09/10/20 15 ms Lun 12/10/20 Ven 14/01/22 1 n°1-11 April 2015 n°12-21 processing & RF processing 2)Manufacturing Power couplers contract awarded 54 ms RF st power tests at Lund 2022 H-ECCTD CDR review decision 75,64 ms Mar 01/09/15 RF power tests at Lund 2021 M-ECCTD CDR review decision Components manufacturing Assembly 2020 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 1 2 1 2 Planning Ready For Installation OK with ESS schedule: 03/09/18 => 02/05/19 1CM/month 6 HBL cryomodules Planning Ready For Installation OK with ESS schedule: Q1 + Q2 2021: installation of HBL n° 1 to 11 TAC11 Q1 + Q2 2022: Installation of HBL n° 12 to 21 Assembly 21 HBL 11 HBL 10 HBL 24 tests 21 HBL 11 HBL 11 HBL 1st April 2015 TAC11 25 Conclusion • The design of the elliptical cavities and cryomodules complies with the ESS requirements. • The prototype cryomodules M-ECCTD and H-ECCTD will validate the design. • The preliminary planning for the design/prototyping and for the production of the elliptical cryomodules has been proposed in compliance with the RFI dates. • This planning is success oriented with major risks identified • The coordination between the In-Kind partners has to be quickly placed to start the work as soon as possible: Coordination between CEA, CNRS, INFN, STFC and ESS We have to established a "partnership of ESS with INFN and STFC, which will permit to make use of the best European competences in the field of SRF". 1st April 2015 ESS TAC11 26 Open discussion 1. 2. 3. 4. 5. 6. Requirements and interfaces Schedule and Reviews list Integrated production plan Nb procurement Industrialization and lessons-learned Acceptance criteria (production, test, conditioning) 7. Data management and filing of NC 8. Risk assessment (TD, beam impact) 9. Transportation 1st April 2015 TAC11 27