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Akira Yamamoto KEK/ILC-GDE on behalf of
GDE Project Managers and SCRF TA Collaborators
Report for Project Advisory Committee (PAC) Review, To be held at KEK, 13th December, 2012
ILC Accelerator Baseline Design (TDR-2):
SCRF Cavity and Cryomodule
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 1
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A. Yamamoto, ASC-2012 2Advances in SCRF for ILC
• We (GDE-PMs) would thank the ILC-GDE, SCRF collaboration with:
– DESY, INFN, CEA-Saclay, LAL-Orsay, CI, CERN, and Industry in Europe,
– FNAL, J-LAB, Cornell, SLAC, ANL, LANL, BNL, TRIUMF, and Industry in Americas,
– KEK, Kyoto, IUAC, RRCAT, BARC, TTIF, VECC, IHEP, PKU, PAL, KNU, PNU, and Industry in Asia
for their worldwide cooperation in TDR
Acknowledgments
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SCRF Reports for PAC
TDR2-Chapter 3• Main Linac Layout
– Common layout– Flat and Mountainous
topologies • by Marc Ross
• SCRF Technology – Cavity and Cryomodule
• by Akira Yamamoto– RF Power System
• by Shigeki Fukuda
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 3
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Outline
• Introduction– Baseline technologies achieved for TDR
• Cavity and CM Baseline Design for TDR– Cavity
• Production Specification (S-3.2) • Cavity Integration (S-3.3)
– Cryomodule • Cavity string and CM Design Incling Quad. (S-3.4)
– Cryogenic • Cooling Scheme (S-3.5)
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 4
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Introduction
• Progress to establish baseline technologies for ‘TDR’ – Cavity gradient (S0):
• Worldwide effort: G = 35 MV/m+/- 20%, satisfying <G> ≥ 35 MV/m – Cavity and Cryomodule (CM) integration (S1):
• ‘S1-Global’ verified baseline technologies– Beam acceleration with SCRF CM (S2):
• ‘FLASH’ demonstrated ILC beam current and the pulse-duration • “STF-QB’ demonstrated ILC beam pulse-duration
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 5
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Global Plan for SCRF R&D
Year 07 2008 2009 2010 2011 2012
Phase TDP-1 TDP-2Cavity Gradient in v. test to reach 35 MV/m Yield 50% Yield 90%Cavity-string to reach 31.5 MV/m, with one-cryomodule
Global effort for string assembly and test(DESY, FNAL, INFN, KEK)
System Test with beamacceleration
FLASH (DESY) , NML/ASTA (FNAL) QB, STF2 (KEK)
Preparation for Industrialization
Production Technology R&D
Communication with industry:
1st Visit Vendors (2009), Organize Workshop (2010) 2nd visit and communication, Organize 2nd workshop (2011)3rd communication and study contracted with selected vendors (2011-2012)
A. Yamamoto, ASC-2012 6Advances in SCRF for ILC
We are here
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Configuration: RDR to TDR
7A. Yamamoto, ASC-2012 Advances in SCRF for ILC
RDR-2007 TDR-2012
Cost containment Motivation:
• Single accelerator tunnel• Smaller damping ring• e+ target at high-energy end, • Cavity G. 31.5 MV/m +/- 20 %, • HLRF and tunnel layout:
– Klystron-Cluster on surface (KCS), or
– Distributed Klystron in tunnel (DKS)
Flat-land or Mountainous Tunnel Design
5 m
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Cavity Gradient: Production Yield, Yearly Progress
9
Year 2010 - 2012 1st cycle 2nd cycle
G≥ 28 MV/m 67 (+/-10) % 94 (+/-6) %
G≥ 35 MV/m 38 (+/-11) % 75 (+/-11) %
<G> above 28 MV/m 35.1 MV/m 37.1 MV/m
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Cavity Gradient: Production Yield Progress since 2006
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 10
2nd pass statistics for 2010 ~ 2012 period: Production yield: 94 % at > 28 MV/m, Average gradient: 37.1 MV/m
- Integrated statistics since 2006 in 2nd pass yield- Max. gradient achieved: > 45 MV/m
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Gradient Spread of +/- 20%
• Average gradient of 35 MV/m– with the spread of 28 ~ 42 MV/m (+/- 20%)– Cavity gradient: higher spread (+ 20%) absorb the lower
spread (- 20 %), • Cost-effective production by increasing yield
– gaining > 15% (19 %) higher production-yield, – corresponding to ~ 15% saving cavity production cost.
• ( investment cost, unchanged) • 75 % at ≥ 35 MV/m to 94 % at ≥ 28 MV/m
• Necessary trade-off with additional RF power – RF power addition required, but it less expensive.
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 11
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Cavity String and CM system integration: demonstrated by S1-Global
A. Yamamoto, LINAC12, 120913-b Status of ILC
DESY, FNAL, Jan., 2010
INFNand FNALFeb. 2010
FNAL & INFN, July, 2010
DESY, May, 2010March, 2010 June, 2010 ~
DESY, Sept. 2010
12
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13
Blade Tuner (INFN/FNAL) Saclay Tuner (DESY)
Slide-Jack Tuner (KEK)
TTF-III Coupler (DESY/FNAL/SLAC) STF-II Coupler (KEK)
TESLA Cavity (DESY/FNAL)Tesla-like Cavity (KEK)
Cavities, Tuners, Couplers in S1-G Cryomodule
110809, A. Yamamoto ILC-SCRF-Global-Effort
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TESLA (DESY) and TESLA-Like (KEK) Cavity
121005 KEK-LC-STF meeting 14
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Variety of Cavity and Tuner Assembly in S1-Global
121005 KEK-LC-STF meeting 15
Blade Tuner (originated by INFN)Slide-jack tuner at KEK EXFEL tuner
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S1-Global Progress ReportAvailable as an attached manuscript
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 16
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Cavities Performance:
C1 C2 C3 C4 A1 A2 A3 A4Before cryomodule installation
after cryomodule installation
7 cavities combined operation
31.5 MV/m
Average 30.0MV/m
Average 27.7MV/m
Average 26.0MV/m
GradientE. Kako, H. Hayano
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Stability in 6300 sec.LLRF stability study with 7 cavities operation at 25MV/m
Field Waveform of each cavity
- Vector-sum stability: 24.995MV/m ~ 24.988MV/m (~0.03%)- Amplitude stability in pulse flat-top: < 60ppm=0.006%rms- Phase stability in pulse flat-top: < 0.0017 degree.rms
vector-sum gradient
amplitude stability in pulse flat-top
phase stability in pulse flat-top
7-cavity operation by digital LLRF
A. Yamamoto, ASC-2012 Advances in SCRF for ILC 18
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Designs Demonstrated in S1-Global and the Baseline Technology selected for TDR
Element Varieties Notes Meet ILC req.
Baseline for TDR
Resonator Tesla/EXFELTesla-like
- Cell-taper: 13 deg., lower rigidity- Cell-taper: 10 deg., higher rigidity
YesYes
Tesla/EXFEL:Less expensive
Input Coupler TTF-IIIKEK-STF
- Bellows at cold-outer-pipe - Solid-cold-pipe, flex. inn-antenna
YesYes
TTTF-II; less-expensive
Tuner Scissor-EXFELBladeSlide-jack
- Require longer BP length- Lower-rigidity- Higher-rigidity
Out of scopeYesYes
Blade; less-expensive
He-tank EXFELBladeSlide-jack
- Simplest structure- Bellows at center- Motor placed outside
Out of scopeYesYes
Blade: less expensive
Mag. shield OutsideInside
- Installation during CM ass.- Installation in cavity fabr.
YesYes Inside; simplest
Beam flange Al-gasketHelico-flex
- Well experienced, world-wide- Experienced at KEK
YesNot taken
Al-gasket: well experienced
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 19
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Plug-compatible Conditions
Plug-compatible interface established
Item Variation TDR Baseline
Cavity shape TESLA / LL TESLA
Length Fixed
Beam pipe flange Fixed
Suspension pitch Fixed
Tuner Blade/Slide-Jack
Blade
Coupler flange (cold end)
40 or 60 40 mm
Coupler pitch Fixed
He –in-line joint Fixed
12/05/14 20KEK-LC-Meeting
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Beam Acceleration Parameters required for ILC-TDR
Parameters ValueC.M. Energy 500 GeVPeak luminosity 1.5 x1034 cm-2s-1
Beam Rep. rate 5 HzPulse duration 0.73 msAverage current 5.8 mA (in pulse)
Av. field gradient 31.5 MV/m +/-20%Q0 = 1E10
# 9-cell cavity 16024 (x 1.1)# cryomodule 1,855
# Klystron ~400
A. Yamamoto, ASC-2012 Advances in SCRF for ILC 21
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Progress in SCRF System Tests • DESY: FLASH
– SRF-CM string + Beam, • ACC7/PXFEL1 < 32 MV/m >
– 9 mA beam, 2009– 800ms, 4.5mA beam, 2012
• KEK: STF– S1-Global: complete, 2010
• Cavity string : < 26 MV/m> – Quantum Beam : 1 ms – CM1 + Beam, in 2014
• FNAL: NML/ASTA– CM1 test complete– CM2 operation, in 2013– CM2 + Beam, beyond
2013A. Yamamoto, ASC-2012 22Advances in SCRF for ILC
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Summary: SCRF Baselines Demonstrated and/or chosen for TDR
• Cavity gradient – Achieved 35 MV/m +/- 20 %, and < 37.1 MV/m> with
the production yield of 94%• Cavity and CM integration
– Demonstrated SCRF technologies available for TDR• Coupler : TTF-III• Tuner: Blade tuner• Magnetic shield : placed inside LHe tank
• Beam acceleration– Demonstrated ILC beam parameters
• Beam (RF) pulse duration: 1 ms• Beam current: 9 mA
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 23
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Outline
• Introduction– Baseline technologies achieved for TDR
• Cavity and CM Baseline Design for TDR– Cavity
• Production Specification (S-3.2) • Cavity Integration (S-3.3)
– Cryomodule • Cavity string and CM Design Incling Quad. (S-3.4)
– Cryogenic • Cooling Scheme (S-3.5)
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 24
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Cavity Design Parameters
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 25
YS-delivered: > 50 MPa -annealed: > 39 MPaP-design: 0.2 Mpa -test:: 0.3 MPa
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Cavity/Cryomodule Fabrication
A. Yamamoto 11/13/2012 26
He Tank
Material/Sub-component
Cavity Fabrication
Surface Process
LHe-Tank Assembly
Vertical Test =Cavity RF Test
CryomoduleAssembly and RF Test
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Cavity Fabrication/Test Process Flow
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 27
< 30 mm
Local repair, if it be economical
2nd pass, if G < 35 MV/m(as of today) 60 % go to 2nd pass
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Cavity Gradient: Production Yield, Yearly Progress
28
Year 2010 - 2012 1st cycle 2nd cycle
G≥ 28 MV/m 67 (+/-10) % 94 (+/-6) %
G≥ 35 MV/m 38 (+/-11) % 75 (+/-11) %
<G> above 28 MV/m 35.1 MV/m 37.1 MV/m
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Fabrication and Surface Treatment Process
29
Parameters to be further optimized
micron
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Subjects for Further Study• Vertical Test with LHe tank
– Production economical, but defects may not be localized with having LHe tank,
• Local repairs – More experiences needed to understand the cost-saving,– New definition for production yield including repair,
• Mitigation of field emission and radiation – Understand sources and mitigation technology
• Establish quantitative evaluation technology
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 30
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Cavity Integration
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 31
• 9-cell resonator• Input-coupler
– TTF-III coupler • Frequency tuners
– Blade tuner• He tank• Magnetic shield
– Inside He tank
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Input Coupler Design Specification
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 32
Design needs to be ready for upgrade
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Coupler Fabrication and Process
• Coupler fabrication– At industry
• Coupler Process– At industry or lab.
• String Assembly with CM– At lab.
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 33
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Baseline: TTF-III Coupler• Reasons
– Much experience at FLASH (DESY), ASTA (Fermilab)– Used in EXFEL– Demonstrating the ILC technical requirement – Less expensive
• Subjects for further study beyond TDR– Seeking for further optimum design with fixed (no-bellows) cold-
end outer-pipe, referring the KEK coupler design,– Simplifying the assembly process, with keeping less expensive
design
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 34
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TTF-III Coupler: various support jigs are required.
coupler assembly
KEK STF Coupler:self standing
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Tuner Design Specification
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 36
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Baseline: Blade Tuner
• Reasons– Demonstrating the ILC technical requirements (S1-
Global, ASTA) – Less expensive
• Subjects for further study beyond TDR– Judgment for MTBF/reliablity and maintain-ability of –
pulse-motors and piezo-motors– Seek for a further optimum design to allow
accessibility/maintain-ability for the motors,
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 37
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He Tank Design with Blade Tuner
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 38
Bellows at Center
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121005 KEK-LC-STF meeting 39
LHe Tank Comparison Lhe tank for Slide-jack Tuner
Lhe tank for Blade Tuner
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Baseline: LHe tank w/ Blade Tuner
• Reasons– Simpler and less expensive than the design with
slide-jack tuner,
• Subjects for further study beyond TDR– Further simple design for cost-reduction to be
comparable with the EXFEL LHe-tank
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 40
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cylindrical shield inside jacket
Pill-box end-cell shield, outside jacket(may be required for Tesla-Cavity design)
Conical shield inside endplate
Design concept: inside shield + cylindrical end shield outside
Magnetic Shield Inside LHe Tank
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For 2 KEK Cavities For 2 FNAL Cavities
16 Components per ca (shield outside 4 Components per Cavity (shield inside)
Comparison of Magnetic Shield
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Baseline: Magnetic-Shield Inside• Reasons
– Simplest and best shielding effect with the minimum connection-interfaces and holes
– Efficient installation work during cavity integration, and minimum work during cavity string assembly
• Subjects for further study beyond TDR– Industrialization of magnetic shield cylinder – Conical shield installation for TESLA type cavity
having spatial conflict at the end-cell contact to the conical flange
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 43
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Plug-compatible Conditions
Plug-compatible interface established
Item Varieties BaselineCavity shape TESLA / LL TESLA
Length Fixed
Beam pipe flange Fixed
Suspension pitch Fixed
Tuner Blade/Slide-Jack
Blade
Coupler flange (cold end)
40 or 60 40 mm
Coupler pitch Fixed
He –in-line joint Fixed
12/05/14 44KEK-LC-Meeting
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Outline• Introduction
– Baseline technologies achieved for TDR• Cavity and CM Baseline Design for TDR
– Cavity • Production Specification (S-3.2) • Cavity Integration (S-3.3)
– Cryomodule • Cavity string and CM Design Incling Quad. (S-3.4)
– Cryogenic system • Cooling Scheme (S-3.5)
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 45
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Cavity/Cryomodule Fabrication
He Tank
A. Yamamoto 11/13/2012 46
Material/Sub-component
Cavity Fabrication
Surface Process
LHe-Tank Assembly
Vertical Test =Cavity RF Test
CryomoduleAssembly and RF Test
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CM Assembly
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 47
12.652 m (slot length)
cavities (8) SC quad packageType-B moduleType-A has 9 cavities and no quadrupole
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Cryomodule Design
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Cryomodule Gradient Spread and Degradation Observed at DESY and KEK, as of Nov. 2010
• FLASH: – 3 PXFEL cryomodules
• ILC R&D:– S1-Global cryomodule– CM1 (S1-Local @ Fermilab)
• Current status: – 12/40 degraded with ~ 20 %
A. Yamamoto -110928 TDR ACC & SCRF Guidline 49
1 - AC129 2 - AC123 3 - AC125 4 - Z143 5 - Z103 6 - Z93 7 - Z100 8 - AC1130
510
15
202530
35
40
FLASH 30MV/m XFEL goal
13.07.2009
EA
CC [M
V/m
]
cavity
Cavity tests: Vertical ( CW ) Horizontal (10Hz) CMTB M8 (10Hz) CMTB (10Hz)
very
long
CW
cond
ition
ing
Cavities gradient limits
1 - Z141 2 - AC150 3 - Z133 4 - Z139 5 - AC122 6 - AC121 7 - AC128 8 - AC1150
5
10
15
20
25
30
35
Cavities gradient limits
XFEL goal
04.05.2010
EA
CC [M
V/m
]
cavity
Cavity tests: Vertical ( CW ) Horizontal(10Hz) CMTB (10Hz)
MP
1 - Z135 2 - AC124 3 - Z88 4 - Z134 5 - Z101 6 - AC127 7 - Z140 8 - Z970
5
10
15
20
25
30
35
Cavities gradient limits
XFEL goal
13.09.2010E
AC
C [M
V/m
]cavity
Cavity tests: Vertical ( CW ) Horizontal(10Hz) CMTB (10Hz)
MP
FE
FE
PXFEL-1 PXFEL-2 PFEL-3
S1-Global
D. Kostin & E. Kako
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Conduction-Cooled Split-able Quadruple
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 50
Advantages;- Q-magnet may be assembled separately,- Keep “best clean” during cavity string assembly- No additional cryostat and cryogenics- Highly accurate alignment without LHe vessel
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Heat Loads per CM
51
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Cooling Scheme of a Cryo-string
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 52
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ML Heat Load and Cryogenics Plant Size
53
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Cryogenics System Layoutto be explained by M. Ross
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 54
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Adaption to High Pressure Code • Basic design
– High pressure code to be applied • ASME (US), TUV (DE/EU), High Pressure Code (JP) basically
consistent, but some difference in detail
• Fundamental parameters (for example)• Design Pressure: 2 bar (difference) • Test pressure : 1.5 x 2 = 3 bar (in case of water)• 1.25 x 2 = 2.5 bar (in case of gas) • Maximum stress: 2/3 of 0.2 % yield strength at RT
– Meaning at weakest temperature
• Required test and plan: – Pressure test, leak-tight test – Documentation: fabrication/welding plan and sample test.
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 55
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Baseline: TESLA Type-IV Cryomodule
• Reasons– Well experienced and mass production in
progress, and very similar to EXFEL CM.– Assembly procedure well understood
• Subjects for further study beyond TDR– 5K radiation-shield (bottom part) removable for
cost-effective production and assembly – Gas-flow direction better to be reversed for more
efficient 5K thermal intercepts – Mitigation of cavity gradient degradation during
Cryomodule assembly.
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 56
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Two shield model One shield model
5K-shield partially removableFurther Study beyond TDR:
12/05/14 57KEK-LC-Meeting
- 5K-shield at bottom removable- Simplify the CM assembly work - Better accessibility
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KEK-LC-Meeting
SCRF Procurement/Manufacturing Model
Regional hub-laboratories responsible to regional procurements to be open for any world-wide industry participation
Regional Hub-Lab:E, & …
Regional Hub-Lab:
A
Regional Hub-Lab:
B
Regional Hub-Lab:
D
World-wideIndustry responsible to
‘Build-to-Print’ manufacturing
ILC Host-Lab
Regional Hub-Lab:C: responsible to Hosting System
Test and Gradient Performance
Technical Coordinationfor Lab-Consortium
: Technical coordination link : Procurement link
12/05/14 58
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Industrial Participation to ILC Cavity Production
• Progress in EXFEL (as of Oct. 2012) (courtesy by D. Reschke: the 2nd EP at DESY)
– RI: 4 reference cavities with Eacc > 28 MV/m, (~ 39 MV/m max.)– Zanon: 3 reference cavities with Eacc > 30 MV/m ( ~ 35 MV/m max.)
12/05/14 KEK-LC-Meeting 59
year # 9-cell cavitiesqualified
# of Labs reaching 35 MV/m processing
# of Industrial manufacturers reaching 35 MV/m fabrication
2006 10 1 DESY
2 ACCEL, ZANON
2011 41 4 DESY, JLAB, FNAL, KEK
4 RI, ZANON, AES, MHI,
2012 (45) 5 DESY, JLAB, FNAL, KEK,
Cornelland others joining soon
5 RI, ZANON, AES, MHI, Hitachi
and others joining soon
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KEK-LC-Meeting
The 3rd Cycle Communication with CompaniesFurther studies with contracts in 2011-2012
Date Company Place Technical sbject1 2/8, 2011 Hitachi Tokyo (JP) Cavity/Cryomodule
2 2/8 Toshiba Yokohana (JP) Cavity/Cryomodule, SCM
3 2/9 MHI Kobe (JP) Cavity / Cryomodule
4 2/9 Tokyo Denkai Tokyo (JP) Material (Nb) 5 2/18 OTIC NingXia (CN) Material (Nb, NbTi, Ti)
6 (3/3), 9/14 Zanon Schio (IT) Cavity/Cryomodule
7 3/4, RI Koeln (DE) Cavity
8 (3/14), 4/8 AES Medford, NY (US) Cavity
9 (3/15), 4/7 Niowave Lansing, MI (US) Cavity/Cryomodule
10 4/6 PAVAC Vancouver (CA) Cavity
11 4/25 ATI Wah-Chang Albany, OR (US) Material (Nb, Nb-Ti, Ti)12 4/27 Plansee Ruette (AS) Material (Nb, Nb-Ti, Ti)13 5/24 SDMS Sr. Romans (FR) Cavity14 7/6 Heraeus Hanau (DE) Material (Nb, Nb-Ti, Ti)15 10/18 Babcock-Noell Wurzburg (DE) CM assembly study16 11/11 SST Maisach (DE) Electron Beam Welder
6012/05/14
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KEK-LC-Meeting 61
Mass-Production Studiesin contracts
Company Mass production model
Contract funded/hosted by
Cavity RI in progress 100% (50%) DESY
AES 20 % DOE/Fermilab
MHI 20, 50, 100% KEK
Quadrupole Toshiba 100 % KEK
CM and assembly Hitachi 20, 50, 100% KEK
AES 25% DOE/Fermilab
CM assembly BN in progress 100, 33 % CERN
In parallel, EXFEL experience kindly informed by DESY, INFN, CES/Saclay
12/05/14
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Industrial study led by CERN/GDE• Study, based on EXFEL CM assembly specifications and Work
Break-down Structure (WBS) • But including ILC specificities (see below)
V. Parma
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63
Beam
8 July 2011
12/05/14 KEK-LC-Meeting
Cavity Fabrication and IndustrializationR&D Facility being realized at KEK
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Cryomodule Assembly work layout/flow for EXFEL at CEA/Saclay, as a reference
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 64
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EXFEL Cavity/Cryomodule Test Station as a reference
• If we may have ~ 3 of this test station, the ILC cavity/cryomodule test can be managed.
• We may consider ~ x 3 ( = 20 (or 15) / 2 period / 3 regions ) • Or, it is just enough, if 1/3 cryomodules to be tested in ILC
12/05/14 KEK-LC-Meeting 65
IT racks
IT racks
16
UV6UV4
UV3
Sicherheitslichtgerät
Hauptverteilung
UV8UV5
UV7
MPS
Subcooler
Valve
box
VC
1V
C2
Rac
ks V
C1
Rac
ks V
C2
MKS2 MKS2
Wav
egui
de A
ssem
bly
and
Test
Fac
ility
are
a
FRails
Control building
UV1HV
Mounting area cavities
Vertical cryostats
123567891013 12 111415
I
H
G
E
D
C
B
A
Tran
spor
t are
a
Tran
spor
t are
a
Storage areafor modules
MHF-sl,MVS racks
Reserve racksReserve racksReserve racks
MHF-sl racks MHF-sl racks MHF-sl racks
User's racksUser's racks
User's racksLHe tank
RF ar
eaMo
dulat
orTr
ans-
forme
rKl
ystro
n
RF ar
eaKl
ystro
nTr
ans-
forme
rMo
dulat
or
RF ar
eaMo
dulat
orTr
ans-
forme
rKl
ystro
n
Inco
min
g in
spec
tion
and
prep
arat
ion
area
MV
S e
quip
men
t
and
prep
arat
ion
area
Inco
min
g in
spec
tion
MV
S e
quip
men
t
and
prep
arat
ion
area
Inco
min
g in
spec
tion
MV
S e
quip
men
t
Wate
rdis
tributi
on
Wate
rdis
tributi
on
Wate
rdis
tributi
on
Courtesy: H. Weise (DESY)
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Production Process/Responsibility Step hosted Industry Industry/
LaboratoryHub-laboratory
ILC Host-laboratory
Regional constraint no yes yes yes
Accelerator - Integration, Commissioning
Accelerator sys. Integ.
SCRF Cryomodule - Perofrmance Test
Cold, gradient test
As partly as hub-lab
Cryomodule/Cavity- Assembly
Coupler, tuner, cav-string/cryomoduleassmbly work
As partly as hub-lab
Cryomodule component- Manufacturing
V. vessel, cold-mass ...
9-cell Cavity- Performance Test
Cold, gradient test
As partly as hub-lab
9-cell Cavity - Manufacturing
9-cell-cavity assembly, Chem-process, He-Jacketing
Sub-comp/material- Production/Procurement
Nb, Ti, specific comp. …
Procurement
12/05/14 KEK-LC-Meeting 66
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Cryomodule Test: Work Flow
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 67
- 1/3 of Cryomodules tested on surface - Additional 5 % tested for initial stage- Totally 38.5 % CMs tested on ground
Tested on surface Directly commissioned in tunnel
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Baseline: Cavity/CM Assembly and Test
• Cavity and Cryomodule components– Manufactured by Industry– Couplers need to be conditioned at industry or laboratory
• Cavity-string and CM assembly– Work hosted at Hub-laboratories w/ contracted work by
industry
• Cavity qualification tests– 100% (actually > 110 %) done at laboratories
• Cryomodule qualification tests– 33 + 5 % tests, at hub-laboratories, and others directly
installed in the ML tunnel and commissioned,
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 68
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Summary • Cavity design and fabrication
– Gradient: 35 MV/m +/- 20%, keeping <35 MV/m> and the production yield of > 90% within the 2nd pass surface process
– Design and fabrication process, referring TESLA/EXFEL experiences, except for ‘tuner’ design based on ‘Blade tuners’,
– Plug-compatible design for cavity integration and the boundary conditions fixed, and further improvement to be enabled under the plug-compatible interface condition,
– Cavity qualification tests• 100 % test • Vertical test w/ He tank is to be experienced by EXFEL
– Coupler, Tuner and LHe tank: Subjects for further study beyond TDR• Cryomodule design, fabrication, assembly, and tests
– Design, fabrication, and assembly process, referring FLASH/EXFEL, – Cryomodule qualification tests
• 33 + 5 % test in test facilitym and other CM directly installed into tunnel,– 5 K shield (bottom radiation shield) removable is a subject to be further
studied beyond TDR, for cost-saving,69
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A. Yamamoto, 2012.12.13 ILC-PAC SCRF 70
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backup
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 71
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He Tank Design Comparison
EXFEL/FLASH/TESLA LHe tank w/ Saclay/Desy tuner at the axial end
ILC LHe tank design with ‘Blade Tuner’ at the axial center
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 72
Note:Re-visiting overall design of tuner and LHe tank may be required
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FNAL cavity KEK-type1 cavityat S1-Global
Slide-jack tunerBlade tuner TTF-III coupler
KEK coupler
Tuner
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KEK STF Coupler TTF-III Coupler(2) Coupler
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75
Legend
Toward coupler sideToward pick-up side coupler side motor side
top
bottom
Driving unit support elements are already installed on the tuner halves.
Preassembled parts
121005 KEK-LC-STF meeting
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Plug-compatible Interfaces
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 76
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Plug-Compatible Interfaces
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 77
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From the slide by Don
Magnetic shield on FNAL cavities with blade tuner at S1-Global
Magnetic shield inside for KEK cavities
(3) Magnetic shield
no more work during cryomodule assembly
assembly work during cryomodule assembly
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Cavity Package
Frequency (“blade”) tuner
High-power coaxial input coupler
A. Yamamoto 11/13/2012 79
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Cryomodule Design for TDR-33. Magnetic shield design
– Outer magnetic shield and inner magnetic shield– Comparison of the procedures and the cost of assembly
in cryomodule
DESY cavity outer magnetic shield
FNAL cavity outer magnetic shield
KEK cavity inner magnetic shield (red line)
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Main Linac He Inventry
A. Yamamoto, 2012.12.13 ILC-PAC SCRF 81
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(2) Coupler
TDR Baseline candidate
TTF-III coupler (RDR baseline)
KEK coupler
Design Concept Two cylindrical window, coupling tunable
Two disk window, no outer bellows in cold part but tunable
merit Wide coupling range, low heat load
High power capability window, easy handling of cold part installation
drawback Complex installation jig and procedure required
demonstration FLASH cryomodules, S1-Global, FNAL CM-1(>50 couplers)
STF phase-1, S1-Global KEK cavities (8 couplers)
failure Bolts stuck in disassembly High heat load, breakdown,
Cost
Choice/decision choice, because of well established power transmission with low heat load.
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Tuner
TDR Baseline candidate
Blade tuner Slide-jack tuner
Design Concept Twist mechanism with torsion plates + LV-piezo + motor&gear-inside
Stiff end-plate + stiff slide-jack + HV-piezo + drive-feedthrough&motor-outside
merit fine step with small backlash
Small LFD small piezo stroke, motor maintenability
drawback He-jacket-bend-risk at tuner (Jacket center)
Precise mechanics alignment required, Mechanics heavy
demonstration S1-Global FNAL cavities(27MV/m), FNAL 14 cavities HTS test for CM-2(35MV/m)
STF phase-1 cavities, S1-Global KEK cavities(38MV/m)
failure (need design upgrade )
Motor-gear connection slip, piezo breakdown, drive CuBe screw stuck, motor wire short
mechanical stuck by slide-slope bending(weld-bend)
Cost (cost ratio) Choice/decision choice, because of low
cost
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(3) Magnetic shield
TDR Baseline candidate
Shield outside of cavity jacket
Shield inside of cavity jacket
Design Concept
avoid complex shield installation around tuner region
merit avoid complex shield installation around tuner region
drawback Complex installation required (16 pieces)
demonstration for each tuner candidate
S1-Global FNAL cavities ( 2 cavities )
STF phase-1 cavities, S1-Global KEK cavities (8 cavities )
failure none none
Cost
Choice/decision
choice, because of simple assembly benefit
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(4) Flange seal
TDR Baseline candidate
Al hexagonal Sn (In) coated Helicoflex
Design Concept metal-crash-seal concept stress-back-seal concept
merit Less contamination, HPR washable
Small torque fixing, spring-back force for heat cycle
drawback no reuse Risk of coat-metal powder contamination, contamination in spring housing
demonstration FLASH cavities, S1-Global FNAL,DESY cavities, FNAL CM-1 cavities ( >70 cavities )
STF phase-1 cavities, S1-Global KEK cavities ( 8 cavities )
failure met bad-coating lot
Cost ratio
Choice/decision choice, because of many demonstration results
* Flange aperture should be follow TESLA cavity (base-line) design
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HLRF-DKS upgrade option
18 Jan 2012 KEK, SC BTR 86
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5 K shield
18 Jan 2012 KEK, SC BTR
• Flow inversion allows removal of bottom 5K shield, but with important design modification– Rearrangement of module cross-section– Rerouting of thermal intercepts
• No time or resources to complete such and effort in TDR, comfortably leave it to the final «optimized» engineering stage– Assume for TDR the XFEL proven concept
• Risk free, huge data provided by XFEL tests– Reversal is «cost neutral»
• [besides design effort, piping is the same]
87
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5 K shield
18 Jan 2012 KEK, SC BTR
• Proposal for TDR the 5 K shield remains, however, it can be simplifed– We can allow a decrease in static efficiency
providing options to allow assembly operations or some access from vessel flanges to the string, if desired
– Shields at the module interconnections can be avoided
88