In collaboration with STFC 1
Procurement & Quality Control
Mike Ellis
STFC Daresbury Laboratory, UK
ESS High-Beta Cavities
In collaboration with STFC
ESS High Beta Cavities
2
• Introduction
• STFC & IKC scope for ESS HβC
• Schedule & concurrent engineering challenges
• Procurement – Nb + cavity fabrication strategy
– Cavity fabrication responsibilities
• Quality Assurance schemes – Overview
– Acceptance levels
– Detailed scheme
• Spare slides: HβC (H) Vertical Test Facility preparations
In collaboration with STFC
STFC Scope for ESS Hβ Cavity
3
STFC UK In-Kind Contribution:
• Bespoke 704.42 MHz ‘horizontal’ Vertical Test Facility
• Niobium procurement
• Manage Eddy Current Scanning (DESY)
• Validation of industry processes using ‘pre-series’ cavities • Cavity fabrication of 84 (+4) high beta cavities in industry
• 2K RF qualification of cavities to 20.9MV/m, Q0 ≥ 5 x 109
• Transport to Saclay
Outside STFC Scope
• Cavity design – STFC strategy mix: mainly “build-to-print” – only essential adaptations for industry (prototypes fab @ CEA)
• Prototype cavities (CEA Saclay)
In collaboration with STFC
ESS Cryomodule IKC Collaborators
Procure &
build
Production + assembly
x 21 Hβ Cryomodules
Cavity Design & Specification
x 84(+4) Hβ
SRF cavities
In collaboration with STFC
Hβ Cavity Schedule
5
Concurrent engineering
• May accelerate schedule
• Risk of change vs
opportunity for early test
data
• Requires robust systems for:
– Change control system
– Configuration mgmt
– Communications
– Risk mgmt
In collaboration with STFC
Procurement: Cavity & Nb
6
Single vendor for all Nb, Single vendor for all cavities – Don’t have team bandwidth to validate & manage 2+ vendors
– Vendors’ capacity sufficient (faster than STFC testing!)
Open tenders – Schedule & budget did not allow pre-qualification
– Requires very careful procurement selection questions & quality measures
Cavity design specification: – Mechanical drawings
– RF & ‘performance’ requirements
– Quality control measurements & checks
– Cavity treatment specifications (BCP, heat + vacuum, etc)
Specification development: – Original aim to launch tenders with precisely defined specification
– Ongoing development of cavities & cryomodules (CEA Saclay)
– More flexible approach: high level specification for tender
– Final specification agreed in formal kick-off mtg
In collaboration with STFC
Procurement: Cavity & Nb
7
Open questions:
• Cavity fabrication: Precise, detailed specification vs ‘flexible’ specification & use of industrial know-how? – Experienced suppliers know how to make cavities
• Concurrent engineering: – ‘Indicative’ vs ‘final’ specification in OJEU tender process?
– Which specification elements most drive cavity cost / schedule?
– Incorporating learning from prototypes (CEA) into series (STFC)?
• Responsibility: – What constitutes “cavity design”?
– Collaborative vs build-to-print?
In collaboration with STFC
Preseries Fabrication Procurement
8
Industry: – Manufacturing drawings, tooling, final process specifications
– Produce pre-series undressed cavities
– Propose trimming, cavity component selection
– Optimise / validate treatment processes
– All treatments (BCP, tuning, annealing, HPR etc)
– Collect all QA data & reports – Dimensional, RF frequency /spectra, vacuum etc – Treatment process parameters – Align to acceptance levels required
– Helium tank integration after 2K undressed test
Cavity undressed testing @ 3rd party (TBD) – 2K test of undressed cavities
STFC: – Specify “high level” QA data required & approve manufacturer’s QA report templates
– Supervision of all steps
– Approve manufacturing plans & detailed manufacturing drawings
– Approve treatment processes
– Approve component trimming, composition etc
– Review & approve Acceptance Level data
– Cold RF test of dressed cavities
In collaboration with STFC
Series Fabrication Procurement
9
Industry: – Optimise QA data & reports for series (joint with STFC)
– Mechanical fabrication of cell & cavity components – (Starts in parallel with treatments of pre-series cavities)
– Propose trimming, cavity component selection
– All treatments (BCP, tuning, annealing, HPR etc)
– Collect all quality data & reports – Dimensional, RF frequency /spectra, vacuum etc – Treatment process parameters – Align to acceptance levels required
– Helium tank integration
STFC: – Optimise QA data & reports for series (joint with industry)
– Supervision of all steps
– Approve component trimming, composition etc
– Review & approve Acceptance Level data
– 2K RF test of dressed cavities
– Shipping of qualified cavities
– 1x HPR of non-conforming cavities where required after 2K RF test
In collaboration with STFC
Quality Assurance
10
• (H) Vertical Test Facility – Design process w/ formal checkpoints – Commissioning process fully documented – Qualification against known cavity performance
• Niobium supply – Industry provides Nb ingot & sheet samples – DESY to perform Eddy Current Scanning (directly contracted to ESS)
• Cavity fabrication – Industry provides QA measurements – STFC approve – STFC / ESS (+CEA Saclay ) jointly review Non-Conformances
• Cold testing – Incoming, outgoing inspections & tests – 2K cavity RF testing by STFC – If required, 1x HPR per cavity + retest at STFC – Defined, controlled & repeatable processes for all steps
In collaboration with STFC
QA: Facility Validation
11
• Facility commissioning & validation plan in development – Cleanroom & HPR process validation – Commissioning each subsystem independently – Integration of hardware & controls – Process development & staff training – RF measurement repeatability & accuracy: cross-reference to other labs? – Transport, shipping & cavity handling tools & processes
• Collaborative effort (STFC, ESS, CEA, INFN) to define:
– Document storage systems – Reports & data parameters / criteria – Cavity material & fabrication data requirements – SRF test data
In collaboration with STFC
QA: Cavity Fabrication
12
Acceptance level
Assembly stage Data types Data from Approver
0 (tbc) Half-cells End groups
Mechanical, RF, visual Mfg Mfg Preseries: STFC?
1 Assembled cavity Surface treatment
Mechanical, RF, vacuum, visual Mfg STFC
2 Tank integration, final treatment
Mechanical, RF, vacuum, treatments, tank
Mfg STFC
3 Final assembly Treatment, RF, vacuum, transfer measurements, accessory BoM, visual, packing, Factory Outgoing
Mfg STFC
4 After 2K RF test STFC Receiving, RF performance, STFC outgoing, HPR (if performed)
STFC ESS (CEA?)
5 Ready for CM string assembly
CEA incoming (visual inspection, G-shock log reading, vacuum, RF antennae?)
CEA ESS
In collaboration with STFC
QA: Cavity Fabrication
13
Acceptance level
Assembly stage Data types Data from Approver
0 (tbc) Half-cells End groups
Mechanical, RF, visual Mfg Mfg Preseries: STFC?
1 Assembled cavity Surface treatment
Mechanical, RF, vacuum, visual Mfg STFC
2 Tank integration, final treatment
Mechanical, RF, vacuum, treatments, tank
Mfg STFC
3 Final assembly Treatment, RF, vacuum, transfer measurements, accessory BoM, visual, packing, Factory Outgoing
Mfg STFC
4 After 2K RF test STFC Receiving, RF performance, STFC outgoing, HPR (if performed)
STFC ESS (CEA?)
5 Ready for CM string assembly
CEA incoming, visual CEA ESS
• Formal review points • Aligned to INFN proposal
for ESS Mβ cavities • Based on proven XFEL
schemes • Consistent across ESS
collaborators
In collaboration with STFC
QA: Cavity Fabrication
14
• Detailed STFC cavity QA scheme in development
• Aligning with known systems – XFEL, LASA, industrial experience
• Incorporate prototype learning
• Incorporate any requirements specific to ESS Cryomodule design
• Will include all required control measurements
– RF frequency, FF, HOM spectra
– Mechanical dims, CMM etc
– Visual inspections, ultrasound
– Treatment parameters
– Mass measurements
Nb (cell), Nb/Ti (flange) and Ti (He vessel) Material Certification Inspection Test/Measurement Procedure Analysis Data Type Frequency
Cavity Cell Nb Material
Vendor certification Y
RRR Y Data Array (from RRR instrument) Single Measurement
Thickness Y Data Array (from CMM) Single Measurement
Eddy current qualification (possible) Y
Water test verification Y Y
Magnetic field characterisation Y Y Y Data Array (from Hall Probe) Single Measurement
Qualification and test procedures Y Procedure Document
Flange Nb/Ti Material
Vendor certification Y
Dimensional comformance Y Y Data Array (from Hall Probe) Single Measurement
Magnetic field characterisation Y Y Y Data Array (from Hall Probe) Single Measurement
Ti helium vessel
Vendor certification Y
Dimensional comformance Y Y Data Array (from Hall Probe) Single Measurement
Magnetic field characterisation Y Y Y Data Array (from Hall Probe) Single Measurement
Cavity Fabrication
Receipt of Nb and Nb/Ti material from vendor Y Inspection Report
Cavity fabrication process Y Procedure Document
Cavity cell forming validation (CMM) Y Y Y Data Array (from CMM) Single Measurement
Cavity cell forming validation (RF) Y Y Y Data Array (from Network Analyser) Single Measurement
Cavity cell wall unifomity Y Y Y Data Array (from CMM) Single Measurement
Cell preparation prior to EBW (BCP) Y Procedure Document
EBW parameters Y Y Y Procedure Document
Dumbell frequency verification Y Y Y Data Array (from Network Analyser) Single Measurement
Cavity alignment Y Y Y Data Array (from CMM) Single Measurement
Cavity frequency tuning Y Y Y Data Array (from Network Analyser) Single Measurement
Field flatness Y Y Y Data Array (from Bead-pull system) Single Measurement
HOM characterisation Y Y Y Data Array (from Network Analyser) Single Measurement
BCP procedure Y Y Y Y Procedure Document
HPR procedure Y Y Y Y Procedure Document
Probe coupling measurement Y Y Y Data Array (from Network Analyser) Single Measurement
Vacuum leak check Y Y Y Y Procedure Document
RGA scan Y Y Y Y Data Array (from RGA) Single Measurement
Cavity QL measurement Y Y Y Y Data Array (from Network Analyser) Single Measurement
Helium vessel Fabrication and attachment
Receipt of Ti material from vendor Y Inspection Report
Helium vessel fabrication process Y Procedure Document
Attachment of helium vessel to cavity Y Procedure Document
HOM characterisation Y Y Y Data Array (from Network Analyser) Single Measurement
Probe coupling measurement Y Y Y Data Array (from Network Analyser) Single Measurement
Vacuum leak check Y Y Y Y Procedure Document
RGA scan Y Y Y Y Data Array (from RGA) Single Measurement
Cavity QL measurement Y Y Y Y Data Array (from Network Analyser) Single Measurement
Cavity VTF Assembly
Receipt of Cavities from industry Y Inspection Report
Dimensional and RF measurements Y Y Y Data Array (from NA and CMM) Single Measurement
Assembly onto insert in Cleanroom Y Y Y Y Procedure Document
Diagnostics assembly (thermocouples) Y Procedure Document
Assembly in VTF Y Procedure Document
Interface connections (RF, vacuum, Cryo, diagnostics) Y Y Procedure Document
Application of LHe Y Y Y Procedure Document
Cavity Performance Testing
RF, temp and vacuum measurements during cooldown Y Y Y Data Array (from control system) 60 secs (?)
Cryogenic pressure stability Y Y Y Data Reading Single Measurement
Cryogenic temperature Y Y Data Reading Single Measurement
VTF LHe level Y Y Data Reading Single Measurement
RF power Y Y Data Reading (from control system) Single Measurement
Cavity temperature (cavity x2, end group x2, helium jacket x2, flanges x2) Y Y Data Array (from control system) Single Measurement
Cavity vacuum Y Y Data Reading (from control system) Single Measurement
Cavity frequency Y Y Data Reading Single Measurement
QL Y Y Y Data Reading Single Measurement
Gradient Y Y Data Reading Single Measurement
Qo Y Y Data Reading Single Measurement
Microphonics Y Y Y Data Array Single Measurement
Cavity Test Configuration
To be included in this section:
1. Full details of all test and measurement equipment used
(Make, model, serial number, configuration settings etc)
2. Relevant calibration information
3. Serial number and location on VTF insert
Cavity Test Diary
A full chronological record of all significant events in the testing process including:
1. Date/Time
2. Details of test or procedure
3. Person responsible
4. Comments
Nio
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Acc
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A.L
. 2
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Leve
l 3
Thanks & acknowledgement to DESY, INFN, CEA for guidance & advice on series QA
In collaboration with STFC
Additional slides
15
• VTF & shielding design cut-away view
• Cryostat & inserts
• Modular cleanroom / VTF assembly area
• Cryoplant subsystem
• Modular Cleanroom
• Main cleanroom & HPR
• RF system
• VTF overview
• Cavity interfaces to STFC cryostat
In collaboration with STFC
VTF & Shielding Overview
16
Cryostat pit >1.86m
concrete all sides CSI
Cryostat Thermal radiation shield Magnetic shield
Existing mezzanine
Helium Liquefier LHe Dewar
→ To
cleanroom & HPR
In collaboration with STFC
Cryostat & Inserts
17
• ‘Horizontal’ VTF
• Previously presented by Shrikant Pattalwar, TTC 2015
Radiation shield being manufactured at Criotec (26/01/2017)
Inner vacuum vessel being manufactured at Criotec
(26/01/2017)
Cryostat Outer dia. 2.2m Height 4.25m
Mag shield <1uT in cavity zone
2K box Cryo valves
JT valve 2K Heat exchanger
In collaboration with STFC
Cryostat & Cryoplant Scheme
18
Cavity 1
Cavity 2
Cavity 3
Helium bath
Inle
t 4
0K
Pu
rge
40
K
Inle
t 4
K
Boil off bath
Return 40K shield
Return 2K
2K heatexchanger
TT1010K50
TT1011K20
TT1009K2
TT1000K2
TT1002K2
TT1003K2
TT1005K2
TT1006K2
TT1008K2
TT3005K50
TT3004K50
TT3003K50
TT3001K50
TT3002K50
TT3000K50
TT1012K300
TT2002K2
TT2003K2
TT2004K2
TT2010K4
TT2006K50
TT2007K50
TT2008K50
TT2000K4
HT2040kW6 HT2044
kW5
HT2041kW2.5
PRV2182
barg5
PRV2184
barg10
PRV2183
barg5
TT2001K4
HT2042W100
Ph
ase
sep
arat
or
PT2150bar1-2
PRV2180
barg2.5
LI2090m1
PT1162bar1-2
LI1090m2
PT1161mbara10-100
TT1007K2
TT1004K2
TT1001K2
Ph
ase
separato
r
PRV1180
mbarg250
PRV1182
mbarg100
BD1170mbarg450
HT3044W600
PT2152bara1-2
PRV2181
barg0.1
VG2156mbara10-6
PRV1181
barg0.1
VG1160mbara10-6
TT2005K300
TT2011K300 TT2009
K300
2K pump
Recovery
compressor
Raw gas storage
Helium liquefier
Liquid helium storage (3000 l)
Gas bag
HP pure helium storage
Aux LHe
TT1013K2
HT1046W200
Warm helium gas
FM2230
g/s4
FM2232
g/s1.5
FM2231
g/s2.5
HT3045W600
PRV3180
barg0.1
VG3150mbara10-6
TT1014K2
TT1015K2
Pu
rge
pu
mp
CSI vacuum
pump
LI1091m2
OVC vacuum
pump
2K box vacuum
pump
PV1200NCPV
PV1201NCPV
PV1202NCPV
PV1203NCPV
PV2206NCPV
PV2207NCPV
PV2208NCPV
PV2209NCPV
CV2210NCCV
CV2211NCCV
HV2212NCHV
PT2151mbara10-100
CV2201NCCryo
PV2204NCCryo
CV2205NCCryo
PV2203NCCryo
CV2202NCCryo
CV2200NCCryo
Oil/water removal system
Kaiser
compressor
Oil removal system
Dryer
WP
3
WP
4
WP3WP4
In collaboration with STFC
STFC Cryo plant – first plant arriving
19
15 Jan 2017: Delivery 1
- Compressor
- Oil removal system
Right:
View overlooking future cryostat & radiation shielding bunker
Cryoplant components should be moved to compressor building this week
Remaining components due late Feb 2017
In collaboration with STFC
Modular cleanroom concept
20
Modular cleanroom for UHV cavity connections
Two options under test / evaluation
1. Glovebox
− reduced cleandown
2. Walk-in area
− simpler ergonomics
Dummy cavity manufactured from SS316
Ultrasonic clean & degrease
Particle counting just downstream of UHV valve area
Good initial results in large walk-in volume
Also now developing ‘glove box’ solution to test ergonomics.
← To cryostat & bunker
In collaboration with STFC
Modular cleanroom / CSI stand
21
Concept design for VTF assembly area
• Support 2x cryostat inserts
• Access to UHV & cryo instrumentation on top flanges
• Access to cavity connections on lower section
• Flexible / modular options for integration particulate control systems
– Fan filter units
– Laminar flow units
– Screens
– Glovebox
In collaboration with STFC
Cleanroom & HPR
22
In collaboration with STFC
RF System
23
High level design complete LLRF detailed design ongoing
• based on JLab / T Powers LLRF • Adapted by STFC (K Dumbell, P Smith, F
Palade) Rack design near-complete Validation with coaxial resonators ongoing
• Cu resonators for basic system functionality • LLRF validation tests planned using 704.42
MHz Nb SRF coax resonator
In collaboration with STFC
ESS: STFC (H)VTF
24
• Bespoke vertical test
cryostat for ESS HB
cavities
• 3 cavities in cryostat
– Horizontal test
configuration
– 1500L LHe per test
– <4g/s He(g) HVTF
– Conventional config:
• 7500L He(l)
• 20g/s He(g)
• 2 week test cycle
– 1 week potential
In collaboration with STFC
STFC (H)VTF Cavity Interfaces
25
1. Helium diphase outlet CF/ISO flange welded to extended pipe
2. Helium inlet port CF to flexible pipe
3. Beam Pipe Vacuum Coupler Port (ISO flange + DN40 angle valve (not shown))
4. RF input coupler Antenna mounted on flange on main input port
5. RF pick up Pick up point 5 (pickup will remain with cavity in CM)
6. Mounts for T-sensors Custom instrumentation belt in design, 3 temp sensors
7. Film Heater 50 W
Items 3,4 and 5 factory mounted on the cavity
Cavity transported in Vacuum
2 4
3
5
Modification
6
7
1