SPX - CavityWBS U1.02.01.02.05, U1.03.03.05, U1.03.03.12

Genfa WuSRF ScientistAccelerator Systems Division/RF Group

DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

Outline

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

WBS Scope of SRF Cavities for SPX Requirements Design Risks considered ES&H Cost Schedule Summary

SPX Cryomodules / Cavities Scope and WBSU1.02.01.03 & U1.03.03

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Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 3,388 11,556 1,198 1,450 17,592 U1 02.01.03 - SPX R&D 1,451 4,323 96 535 6,405

02.01.03.05 - Cryomodule R&D 868 2,963 72 333 4,237 02.01.03.07 - Cavity/Tuner/Damper System R&D 583 1,360 24 202 2,168

U1 03.03 - SPX Production 1,937 7,233 1,102 915 11,187 03.03.05 - Cavity & Cryomodule - ANL 1,937 518 332 560 3,346 03.03.12 - Cavity & Cryomodule - JLAB - 6,715 770 356 7,841

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Fabricate, process and test 8 deflecting cavities for two SPX cryomodules

Attach helium vessels to cavities and qualify the cavities for string assembly

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

HOM Damper

LOM Damper

HOM Damper

Mark-II CCA3 design

Input Coupler

Deflecting Cavity and TunerCavity Parameter Value Unit

Operating frequency 2815.486 MHz

Operating Deflecting Voltage 0.5 MV

Vertical Test Acceptance Field 0.6 MV

Peak Surface B field (0.5 MV) 100 mT

Peak Surface E field (0.5 MV) 41 MV/m

R/Q including TTF 37.1

Niobium wall thickness 3.5 mm

Geometric Factor 227.8

Operating Q0 109

Dynamic heat load 7 W

Qext of Power Coupler 106

Magnetic Shielding 20 Milli-Gauss

RF source available 10 kW

Tuner Parameter Value UnitRange ±200 kHzResolution 40 HzFast detuning 60 KHzFast detuning response time 1 ms

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Cavity Fabrication, Processing and Testing Large grain ingot slicing

– Niobium RRR 300 CNC machining Chemical etching/polishing E-beam welding Chemical polishing (BCP) Hydrogen bake out at 600C 10 hours Light chemical polishing (BCP) HPR/clean room assemble Low temperature baking Vertical testing Helium vessel dressing Vertical testing Horizontal testing (optional)

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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Deflecting Cavity Performance

Mark-II Cavity CCA2 exceeds the gradient and Q0 specification

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

CCA2 used indium seal CCA3-1 used Al/Mg seal CCA3-1 used Al/Mg +

Be/Cu RF shield

LOM coupler Qext was sensitive to the coupler symmetry (solved)

Heating on Al/Mg gasket and RF shield limits performance

Particulates in high surface B field area

Further processing and test Additional HPR Better RF shield Or adopt indium seal

Cavity Q0 Bpk [mT] Seal

CCA2 1.2x109 120 IndiumCCA3-1 0.9x109 68 Al/Mg without RF shieldCCA3-2 (To be tested)CCA3-3 0.3x109 52 Al/Mg with RF shield

0 20 40 60 80 100 120 1401E+07

1E+08

1E+09

1E+10CCA2design goalCCA3-1CCA3-3

Bp [mT]

Q0

T=1.99K

Mark-II Cavity Vertical Tests at ANL

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Cavity Vacuum Seals

Cavity flange ports use Al/Mg seals on round flanges Broad band RF transmission requires RF shield to remove the RF pocket

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

HOM Damper

LOM Damper

HOM Damper

Input Coupler

FPC/HOM LOM

Magnetic field in LOM coupler

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SPX0/SPX Helium Vessel DesignHelium Return

Helium Supply

Tuner Attachment Points

Nitronic Rod Mount

Slide from K. WilsonDOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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SPX0/SPX Tuner DesignTuner Specification Value UnitOperating frequency 2815.486 MHzRange ±200 kHzResolution 40 HzFast detuning 3 KHzFast detuning response time 1 msSPX Tuner ParametersCavity Related ParametersTuning Sensitivity 9000 KHz/mmStiffness 170,000 lbs/inDeflection for 200KHz shift 22 µmForce of 200KHz shift 149 lbsTuner Related ParametersStepper Motor Resolution 800 Steps/revHarmonic Drive Ratio 100Ball Screw Pitch 2 mm/revStepper Freq. Resolution -Full Step Frequency shift 31.6 Hz/increment -Half Step Frequency Shift 15.8 Hz/increment -Quarter Step Freqeuncy Shift 7.9 Hz/incrementPiezo Range -Drive Axis 60 µm -Cavity Axis 75.8 KHzPiezo Resolution -Drive Axis 0.13 nm -Cavity Axis 0.16 Hz

Courtesy of Joe MatalevichDOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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SPX0/SPX Tuner Design Status: Cavity Measurements

SPX Cavity (CCA3-1) Exercised in Modified JLAB Tuner Test Stand – Cavity instrumented with 4 strain gages– Axial Force, Length, and Frequency measured as

cavity stretched

Courtesy of Joe MatalevichDOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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SPX0/SPX Tuner Design Status: Cavity Measurements

Tuning Sensitivity (Mhz/mm)*

Cavity Stiffness (klbs / in)**

Predicted 12.2 113.5Measured 13.0 101.6

* - The tuning sensitivity with a He vessel is expected to decrease by 26%** - The stiffness with a He vessel is expected to increase by 12%

Modeling Validated

Courtesy of Joe Matalevich

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Horizontal Test Stand

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Horizontal cavity test at ANL/ATLAS 5 kW amplifier 64 W Cooling @2K Analog and Digital RF

Horizontal test of a dressed cavity is scheduled in December 2012

Courtesy of Joel Fuerst

Verify helium vessel and tuner design

Test LLRF control Measure RF noise Measure microphonics Test fast detuning

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

SPX Cavity Risks

Cavity gradient and Q0 degradation– We plan to use other processing and state of art post processing

methods to both increase gradient limit and Q0.

SPX Cavity ES&H

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Integrated Safety Management System (ISMS)– APS-U Project following Argonne’s ISMS program requirements – Argonne Integrated Safety Management System (ISMS) Description

recently revised and submitted to DOE ASO• Describes framework for integrating ESH requirements with

mission objectives• References Argonne LMS procedures which implement specific

portions of the ISMS Identify General Safety Requirements to Specific WBS Level

• RF, Radiation, oxygen deficiency, and cryogenic hazards are mitigated through training, administrative control and engineering control

• Chemical hazard (BCP) are mitigated through training, administrative control and engineering control at collaborating site (JLAB)

• Chemical hazard (EP) are mitigated through Fermilab’s training, administrative control and engineering control

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

SPX Cryomodules / Cavities Scope and WBSU1.02.01.03 & U1.03.03

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Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 3,388 11,556 1,198 1,450 17,592 U1 02.01.03 - SPX R&D 1,451 4,323 96 535 6,405

02.01.03.05 - Cryomodule R&D 868 2,963 72 333 4,237 02.01.03.05 - ACWP (includes ANL and JLAB) 204 1,027 - 76 1,307 02.01.03.05.01 - Cryomodule (JLab #21351) 514 1,887 63 218 2,682 02.01.03.05.02 - Cavity Alignment (JLab #21352) - 49 0 2 52 02.01.03.05.03 - SPX0 Installation & Checkout 151 - 9 37 197

02.01.03.07 - Cavity/Tuner/Damper System R&D 583 1,360 24 202 2,168 02.01.03.07 - ACWP (includes ANL and JLAB) 269 741 - 102 1,112 02.01.03.07.01 - Damper 301 257 16 83 657 02.01.03.07.02 - Tuner (JLab #21372) - 84 1 3 88 02.01.03.07.03 - Window 13 175 5 9 203 02.01.03.07.04 - Cavity Design (JLab #21374) - 100 2 4 107 02.01.03.07.06 - Helium Vessel (JLab #21376) - 2 0 0 2

U1 03.03 - SPX Production 1,937 7,233 1,102 915 11,187 03.03.05 - Cavity & Cryomodule - ANL 1,937 518 332 560 3,346 03.03.05 - ACWP 15 - - 4 19 03.03.05.01 - Cavity Design Improvement - ANL 249 186 56 80 570 03.03.05.02 - Cryomodule Design Improvement - ANL 399 147 27 109 683 03.03.05.03 - Inter-Cavity Bellows - ANL 58 94 12 17 181 03.03.05.04 - Cavity & Cryomodule Quality Assurance 783 83 156 228 1,250 03.03.05.05 - Cavity & Cryomodule Support 197 - 15 49 261 03.03.05.06 - Cryomodule Installation & Function Verification 235 8 66 72 381

03.03.12 - Cavity & Cryomodule - JLAB - 6,715 770 356 7,841 03.03.12.01 - Cryomodule Design Improvement - JLAB - 557 46 29 632 03.03.12.02 - Cavity Alignment - JLAB - 440 45 23 508 03.03.12.03 - Cryomodule Production - JLAB - 5,718 679 304 6,701

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

SPX Cryomodules / Cavities Obligation Profile U1.02.01.03 & U1.03.03

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

SPX R&D and Production Milestones U1.02.01.03 & U1.03.03

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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u START: Preliminary Design - SPX0 4/10

u START: Preliminary Design - SPX 2/12

u COMP: PDR - SPX0 7/12

u COMP: PDR - SPX 1/13

u SHIP: SPX0 Cryomodule to ANL 4/14

u COMP: SPX0 Cryomodule Test 6/14

u START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)

u COMP: SPX0 Installation 10/14

u AVAIL: SPX0 Ready for Operation 1/15

u START: Final Design - SPX 6/14

u COMP: Final Design 9/15

u START: Major Procurement 10/15

u AWARD: Cryoplant Contract 10/15

u START: Cryoplant Installation 9/17

u COMP: Cryoplant 3/18

SHIP: Cryomodule #1 to ANL 10/17 uSTART: Cryom #1 Installation 5/18 u

COMP: Cryom #1 Installation 6/18 uAVAIL: Cryomodule #1 Ready for Operation 8/18 u

SHIP: Cryomodule #2 to ANL 8/18 uSTART: Cryom #2 Installation 12/18 u

COMP: Cryom #2 Installation 1/19 uAVAIL: Cryomodule #2 Ready for Operation 3/19 u

SPX SYSTEM

FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17

SPX0Cryomodule

SPXCryomodules

SPX Cryomodules / Cavities Milestones U1.02.01.03 & U1.03.03

DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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q COMP: SPX0 Cavities Production with Helium Vessel 10/12

q COMP: SPX0 Tuners Production 11/12

q AVAIL: Tuner Test Result for JLAB 4/13

q COMP: SPX0 Cryomodule Fabrication 12/13

q COMP: SPX0 Cryomodule Qualifications 3/14

q SHIP: SPX0 Cryomodule to ANL 4/14

q COMP: SPX0 Cryomodule Test 6/14

q START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)

q COMP: SPX0 Installation 10/14COMP: SPX0 Installation 10/14

q AVAIL: SPX0 Ready for Operation 1/15

q START: Final Design - 6/14

q COMP: Final Design 9/15

q RCV: WPM Components from ANL 4/16

q RCV: Dampers from ANL 5/17

q START: Cryomodule #1 Assembly at JLAB 2/17

q COMP: Cryom # 1 Assembly & Test 7/17

START: Cryomodule #2 Assembly at JLAB 9/17 qSHIP: Cryomodule #1 to ANL 10/17 q

START: Cryom #1 Installation 5/18 qCOMP: Cryom #1 Installation 6/18 q

AVAIL: Cryomodule #1 Ready for Operation 8/18 qCOMP: Cryom # 2 Assembly & Test 7/18 q

SHIP: Cryomodule #2 to ANL 8/18 qSTART: Cryom #2 Installation 12/18 q

COMP: Cryom #2 Installation 1/19 qAVAIL: Cryomodule #2 Ready for Operation 3/19 q

CRYOMODULE

& CAVITIES

FY16 FY17 FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15

SPX Cryomodules / Cavities Summary Schedule U1.02.01.03 & U1.03.03

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

SPX Cryomodules / Cavities BOE Contingency U1.02.01.03 & U1.03.03

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Work after CD-2

Complete SPX0 cavity processing and prepare for SPX0 cryomodule assembly

Develop a cavity temperature mapping system for SPX cavity processing and testing

Develop other processing and state of art post processing methods to increase both gradient limit and Q0

Summary

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

• Deflecting cavity prototypes proof of principle completed• Three Mark-II Cavities are fabricated, processed and being

tested for SPX R&D• Prototypes of Helium vessel is completed• Horizontal cavity test is scheduled in December(2012) to

verify tuner design• If tuner test shows good performance, its design will be

final for SPX cavities • The cost is $17,592k

• Niobium Material is $355k. Fabrication is $137k• Cavity unit cost is $61,397.28

• We are ready for CD2