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