IFJ PAN contribution to international projects

Transcription

1 IFJ PAN contribution to international projects D. Bocian, A. Kotarba, J. Ludwin, M. Stodulski, J. Świerblewski, M. Wiencek IFJ PAN - ESS meeting Lund, 25 th June 2013

2 Kraków (Cracow) 700,000 inhabitants ~880 km away from Lund former capital of Poland (between the 11th and the 16th century) cultural capital of Poland Student city 23 universties/colleges, ~200,000 students - Jagiellonian University - AGH University of Science and Technology - Tadeusz Kosciuszko University of Technology - Jan Matejko Academy of Fine Arts - Krakow University of Economics, - Pedagogical University of Krakow, - Agricultural University of Krakow, - Pontifical University of John Paul II, Dariusz Bocian IFJ PAN-ESS meeting 2

3 Outline General information Accelerator activities at IFJ IFJ PAN and selected projects European XFEL LHC consolidation and upgrade Wendelstein 7X Scientific equipment construction Summary Dariusz Bocian IFJ PAN-ESS meeting 3

4 General information 492 personnel Prof. 37, Assoc. Prof. 49, Ph.D. 106 PhD studies 70 students Interdisciplinary PhD studies 6 divisions: 28 departments centre of excellence centre of advanced technology 4 accredited laboratories Equipment and Scientific Infrastructure Construction Division (DAI) Dariusz Bocian IFJ PAN-ESS meeting 4

5 General information Main Research Fields Particle physics and astrophysics Nuclear and strong interactions physics Condensed matter physics Interdisciplinary and applied research Theoretical physics Dariusz Bocian IFJ PAN-ESS meeting 5

6 Accelerator activities at IFJ cyclotron AIC proton beam energy: 60 MeV - Proton Radiotherapy of Eye Melanoma Cyclotron Proteus C-235 National Centre for Hadron Radiotherapy under construction (2013) neutron generator 14 MeV VdG high stability 2.5 MeV Dariusz Bocian IFJ PAN-ESS meeting 6

7 IFJ PAN and international projects Running projects: XFEL, DESY, Hamburg, LHC, CERN, Geneva, ITER, Cadarache, Cherenkov Telescope Array (CTA), Completed projects LHC, CERN Geneva, Wendelstein 7X, IPP Greifswald, ATLAS, CERN Geneva, T2K, J-PARC Tokai, Krakow/J-PARC, Dariusz Bocian IFJ PAN-ESS meeting 7

8 IFJ PAN in-kind contribution to XFEL construction ( ) In December 2010 IFJ PAN signed the agreements with European XFEL GmbH and National Centre for Nuclear Research, Świerk Poland for performance of qualification tests of RF cavities, magnets and cryomodules as a Polish in-kind contribution for the European XFEL: cavities 840 x current leads 103 x magnets 103 x cryomodules 103 x Dariusz Bocian IFJ PAN-ESS meeting 8

9 IFJ PAN in-kind contribution to XFEL construction ( ) 1) Performance of acceptance tests of cavities for a series of 840 units on DESY infrastructure and delivering the corresponding test reports 2) Performance of acceptance tests of cryomodules for a series of 103 units on DESY infrastructure and delivering the corresponding test reports 3) Performance of acceptance tests of cold magnets for a series of 103 units on DESY infrastructure and delivering the corresponding tests reports common effort with DESY XFEL RF cavities tests XFEL quadrupole magnets tests XFEL cryomodules tests Dariusz Bocian IFJ PAN-ESS meeting 9

10 IFJ PAN in-kind contribution to XFEL construction IFJ PAN tasks Tests of cavities and cryomodules in the AMTF Hall Tests of cold magnets Each IFJ PAN task is split in two phases: Preparatory phase Knowledge acquiring (learning, trainings, meetings with DESY experts); Procedures writing; Software preparation; Performance of preseries tests: (3 cold magnets and 3 CL, 24 cavities and 3 cryomodules). Serial tests phase Performance of serial tests: Cold magnets 100 Current leads 100 Cavities 816 Cryomodules 100 Data analysis and reporting; Software upgrade. Dariusz Bocian IFJ PAN-ESS meeting 10

11 IFJ PAN in-kind contribution to XFEL construction IFJ PAN team structure IFJ PAN Team (Management) Teams of cold magnets tests (Technical Coordinator) Measurement Data Base and Software Development Teams of cavities and cryomodules tests (Technical Coordinator) Safety officer Mechanic Team: Dr Engineers 4 Engineers 23 Technicians 23 (currently at DESY 30 people) Expertise: Mechanics Electronics / Electrics Automatics / Robotics Software engineering Physics Computer science Vacuum Cryogenic RF Measurement Software Development Dariusz Bocian IFJ PAN-ESS meeting 11

12 IFJ PAN in-kind contribution to XFEL construction Cavity Test Flow chart We create 3 reports from each test and upload them to the EDMS: Incoming inspection report Final test report Outgoing inspection report Dariusz Bocian IFJ PAN-ESS meeting 12

13 IFJ PAN in-kind contribution to XFEL construction Cavity test: Incoming inspection & preparation for test Main tasks: Incoming Report Mechanical check of the cavity Vaccum check Electrical check Cavity spectrum check & HOM tuning Assembling cavity to the insert Connecting cavity to the vacuum line (in cleanroom conditions) Cables connection with TDR Leak check of the cavity Transport of the insert to the cryostat Connecting of the insert to the vacuum line Dariusz Bocian IFJ PAN-ESS meeting 13

14 IFJ PAN in-kind contribution to XFEL construction Cavity test: Cryogenic operation Cryogenic activities at AMTF: Cool down Maintenance during the test Warm up Cool down process from 300 K to 2 K Cryogenics operator s control panel for test cryostat (left) and subcooler box (right) at AMTF. Cavity cryostat at AMTF Dariusz Bocian IFJ PAN-ESS meeting 14

15 IFJ PAN in-kind contribution to XFEL construction Cavity test in vertical cryostat at 2K Part of software written by IFJ PAN engineers Q vs E measurement Vertical measurements application Cable calibration application Cavity test-stand, cryostat (left) and electronic racks (right) Dariusz Bocian IFJ PAN-ESS meeting 15

16 IFJ PAN in-kind contribution to XFEL construction Cavity test in vertical cryostat at 2K Maximal E acc (> 26 MV/m) Q 0 factor vs. E acc (>10 10 ) Radiation vs. E acc (<10-2 mgy/min) Results overview from IFJ PAN cavitiy database Example of series cavities test results Dariusz Bocian IFJ PAN-ESS meeting 16

17 IFJ PAN in-kind contribution to XFEL construction Cavity test: Disassembling and outgoing Main tasks Disconnecting of the insert from the vacuum line Transport of the insert to the preparation area Leak check of the cavity Disconnecting cavity from the vacuum line (in cleanroom conditions) Disassembling cavity from the insert Outgoing check Mechanical check of the cavity Vacuum check Electrical check Cavity spectrum check Preparation for shipment Dariusz Bocian IFJ PAN-ESS meeting 17

18 IFJ PAN in-kind contribution to XFEL construction Cavity test: Summary 60 prototype and pre-series cavities tested 800 production cavities to be tested Insertion of the cavity into the vertical cryostat Results of RF cavity measurement Measurement of the cavity fundamental mode spectra Dariusz Bocian IFJ PAN-ESS meeting 18

19 IFJ PAN in-kind contribution to XFEL construction Cryomodule test flow chart We create 3 reports from each test: Incoming inspection report Final test report Outgoing inspection report Dariusz Bocian IFJ PAN-ESS meeting 19

20 IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Incoming inspection and preparation for cold test Incoming checks Mechanical check Vacuum check Check of the cavities fundamental mode spectra Electrical check Cavities tuner check Shock loggers readout Load the cryomodule to the movable support Assembling cryomodule at the test stand Connecting cryomodule beam line to the test stand under clean room conditions Leak check of beam line interconnections and mass spectroscopy of the beam line Connecting of the waveguides and electrical cables Connect of all cryomodule process pipes to the test stands Leak check of cryomodule vessel (ISO-VAC) and cryogenic valves Assembly and isolating thermal shields Pumping down of vacuum insulation Dariusz Bocian IFJ PAN-ESS meeting 20

21 IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Coupler conditioning and cool down Warm coupler conditioning, coupler conditioning during cool down (couplers are required to be cleaned before start of cold test with klystron). Module cool down Keeping stable cryogenic conditions during test Tools developments Warm coupler conditioning application Temperature regions during automatic module cool down process Automatic module cool down process from 300 K to 4 K: inlet and outlet temperature Dariusz Bocian IFJ PAN-ESS meeting 21

22 IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Low Power RF measurements at 2K Cold cables calibration Spectra measurement Cavities tuning Coupler tuning HOM spectra measurements Spectrum measurement application (left) Cold cable calibration application Measurement of HOM spectra and Qload (right) Cavity tuning application Dariusz Bocian IFJ PAN-ESS meeting 22

23 IFJ PAN in-kind contribution to XFEL construction Cryomodule test : High Power RF measurements at 2K Cavities calibration Cavities flat-top measurement Heat loads measurements Cavities calibration application Heat loads application Cavity flat top application Example of Flat top masurement results Example of cryomodule RF test results Dariusz Bocian IFJ PAN-ESS meeting 23

24 IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Warm up with flooding of the insulation vacuum Module warm up Tools development During warm-up at 100K insulation vacuum of cryomodule is flooded with nitrogen to speed up the warm-up process Automatic module warm up from 2 K to 300 K process: inlet and outlet temperature Temperature regions during automatic module warm up process Dariusz Bocian IFJ PAN-ESS meeting 24

25 IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Disassembling and outgoing inspection Mass spectroscopy of the beamline Disassembly of thermal shields Disconnecting of the beamline (under clean room conditions) and all other cryomodule process pipes from the test stand Disconnecting of the waveguides and electrical cables Disassembling cryomodule from the test stand Outgoing checks Mechanical check Checking of the cavities fundamental mode spectra Electrical check Vacuum check Dariusz Bocian IFJ PAN-ESS meeting 25

26 IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Summary 3 prototype cryomodules tested 3 pre-series cryomodules - to be tested 100 series cryomodules to be tested Prototype module on existing test bench Calibration coefficient and check quality factors of the couplers during cryomodule RF test Leak test of vacuum pipes Dariusz Bocian IFJ PAN-ESS meeting 26

27 IFJ PAN in-kind contribution to XFEL construction Cold magnet test: Test-stand Hall 55 with cryogenic infrastructure for magnet tests Test stand for magnet tests at warm (top) and electronic rack (left). Test stand for magnet tests at cold (top) and electronic racks (right) CL electrical check test-stand Dariusz Bocian IFJ PAN-ESS meeting 27

28 IFJ PAN in-kind contribution to XFEL construction Cold magnet test: Preparation and test at warm Installation of the magnet at warm test-stand Preparation for warm tests: Incoming and visual inspections. Check of the quantity and quality components. Tightness check of magnet using helium leak detector. Polarity check of coils Insulation test using HV insulation meter. Put the magnet on special Al support and adjust it on an alignment frame in x,y,z axes. Magnet installation in warm test-stand Harmonic coil in the magnet Magnet at warm test stand with harmonic coil Magnet test at warm (Quadrupole - harmonics measurement) Dariusz Bocian IFJ PAN-ESS meeting 28

29 IFJ PAN in-kind contribution to XFEL construction Cold magnet test: Preparation and cold test Electrical check of current leads connections Magnet with CL installation in cryostat XMTS Thermal insulation CL and magnet Stretched wire test at 2K Results of stretched wire test at 2K Dariusz Bocian IFJ PAN-ESS meeting 29

30 Current leads incoming inspection IFJ PAN in-kind contribution to XFEL construction Current Leads tests: Incoming and visual check Current leads visual inspection Dariusz Bocian IFJ PAN-ESS meeting 30

31 IFJ PAN in-kind contribution to XFEL construction Current leads tests: Tightness, insulation and resistance Current leads tightness check Current leads test stand and insulation test Current leads resistance test Dariusz Bocian IFJ PAN-ESS meeting 31

32 IFJ PAN in-kind contribution to XFEL construction Cold magnets and current leads test: Field analysis 32 Field parameters: GL/BL Magnet Transfer Function (MTF) BL/I [Tm/A] for a dipole GL/I [T/A] for a guadrupole Angle & offset Re & img part of multipoles Correction parameters Magnetic multipoles for quadrupole (left) and dipole(right) Quadrupole transfer function (TF) Quadrupole deviation straight line from TF Dipole deviation straight line from TF Dariusz Bocian IFJ PAN-ESS meeting 32

33 [FTE] IFJ PAN effort to XFEL construction Total number of FTE s over 7 years ~150 Total number of trained IFJ PAN staff ~ Dariusz Bocian IFJ PAN-ESS meeting 33

34 IFJ PAN and LHC ( ) 1) design & construction of measuring/testing devices 2) preparation of necessary software and data bases 3) manufacturing of superconducting N-lines 4) development of measuring/testing methods 5) organization, performance & documentation of electrical measurements /tests 6) organization, performance & documentation of interconnection inspection Mobil test stations in LHC tunnel User interface Damaged PIM (Plug-In Module) Dariusz Bocian IFJ PAN-ESS meeting 34

35 IFJ PAN and LHC Motivation 1600 superconducting circuits 1700 magnet cryomodules (with their instrumentation) Each of those elements has to be checked after every thermal cycle of the machine Dariusz Bocian IFJ PAN-ESS meeting 35

36 IFJ PAN and LHC Measurements of the superconducting circuits For each superconducting circuit check of: Electrical insulation, Continuity and resistance, Continuity and resistance of voltage taps used for quench protection Distribution of signal from voltage taps along the circuit. Inductive and capacitive properties of the circuit. All measurements are performed both in the room temperature and in the cryogenic conditions Courtesy of Mateusz Bednarek Dariusz Bocian IFJ PAN-ESS meeting 36

37 IFJ PAN and LHC Measurements of the cryomodules For each LHC magnet cryomodule check of: Electrical insulation of quench heaters, Continuity and resistance of quench heaters, Continuity and resistance of voltage taps used for quench protection Those measurements are performed in room temperature and in cryogenic conditions Courtesy of Mateusz Bednarek Dariusz Bocian IFJ PAN-ESS meeting 37

38 IFJ PAN and LHC Measurements of superconducting circuits In total for the qualification of all superconducting circuits of the LHC at warm and at cold we have to perform: > voltage measurements > resistance measurements > 9600 high voltage insulation tests > 3800 transfer function measurements This are the actual numbers of measurements which were performed during last 4 monts. Dariusz Bocian IFJ PAN-ESS meeting 38

39 IFJ PAN and LHC Measurement system Large variety of tests to be performed on many different types of circuits called for design of universal mobile test benches coupled with advanced software and database system. Our measurement system is called TP4, what stands for Test Procedure 4. (Procedures 1-3 were performed on LHC components before assembly.) Dariusz Bocian IFJ PAN-ESS meeting 39

40 IFJ PAN and LHC Measurement system Recently the measurement system (hardware and software) was upgraded in the IFJ-PAN Each of 8 trolleys is equipped with: Gain/phase analyser, 36 V/ 6 A power supply. PXI computer with two DMM cards, Specially designed electronics with thermally controlled reference resistors, 4 channel current demultiplexer and 4 1-of-84 signal multiplexers, 80 channel high voltage insulation tester. Dariusz Bocian IFJ PAN-ESS meeting 40

41 IFJ PAN and LHC Electrical measurements and tests Thousands of electrical measurements/tests performed in terms of continuity, resistance and HV qualification of superconducting circuits in warm and cold states. The team, as the first, performed measurements of very low resistance of main bus bar connections at cold (without necessity of opening interconnections between magnets). The measurement results were essential for CERN groups developing a new Quench Protection System Upgrade of the measuring/testing devices Campaign of measurements/tests has started Measurements in the LHC tunnel ( ) Upgraded hardware and software ( ) Dariusz Bocian IFJ PAN-ESS meeting 41

42 IFJ PAN and LHC Measurement system Measurement results, test parameters and signal mappings are stored in the central database. The trolleys are wireless synchronising their local database with the central one. Most part of the system works under control of the NI LabView software. Set of web applications is available for follow-up and results viewing. Dariusz Bocian IFJ PAN-ESS meeting 42

43 IFJ PAN and LHC Software and hardware tools development For the cool-down and warm-up phase we have developed a measurement system for the insulation monitoring. The device applies periodically DC voltage of 48 V to the selected circuits and measures the leakage current. In case the limit is reached, alert messages are sent via and SMS. Our engineers are working on data mining software used for analysis of the measurement results produced during standard measurement campaigns over the years. Recently we cooperate with CERN on development of the current transformer tester that is going to be shipped later to the industry where it will be used to qualify transformers which are going to be installed in the LHC quench protection system. Dariusz Bocian IFJ PAN-ESS meeting 43

44 IFJ PAN and LHC Inspection of interconnections Scope of inspection: Pre-inspection of a single magnet (visual inspection of all magnet components, checking of beam lines by means of endoscopy and microwave reflectometry methods) Visual inspection of interconnections (after orbital and ultra-sonic welding) Microwave reflectometry measurements of the beam lines in series of connected magnets Final visual inspection just before the closure of each interconnection In collaboration with CERN staff, the team developed a method for the localization of damaged PIMs method is two times more precise than that employed before. method could be used without opening the interconnections between magnets. Dariusz Bocian IFJ PAN-ESS meeting 44

45 [FTE] IFJ PAN and LHC Summary Just recently group of 25 people (engineers and technicians) from the IFJ-PAN was performing the reference measurements before consolidation of the LHC superconducting circuits during Long Shutdown 1. The measurements are now completed. Exactly the same tests will be performed before machine startup. Currently we are monitoring to the circuits health during the consolidation. Part of the team is working on investigation and solving of the nonconformities revealed during standard measurements: short circuits caused by thermal cycle, abnormal resistances, etc Total number of FTEs over 8 years: ~160 Total number of trained IFJ PAN staff: ~ Dariusz Bocian IFJ PAN-ESS meeting 45

46 FTE IFJ PAN contribution to W7-X construction ( ) IFJ PAN was responsible for the assembly of the bus bar system powering 70 superconducting coils on five modules of the stellarator. The bus bars are made of the NbTi superconductors in an aluminium jacket. There are 24 bus bars on each module. Bus bar cross section Total number of FTE over 6 years > 160 Example of bus bars routing on one module Total number of trained IFJ PAN staff > Dariusz Bocian IFJ PAN-ESS meeting 46

47 IFJ PAN contribution to W7-X construction Joints assembly Mechanical and electrical connection of the superconductors Electrical connection of 81 triplets Connected triplets squizzed with clamps and covered by stainless steel caps Dariusz Bocian IFJ PAN-ESS meeting 47

48 IFJ PAN contribution to W7-X construction Electrical insulation of joints (wet wrapping) Electrical insulation of the assembled joints (divided into three steps) All joints (184) passed successfully tightness and HV tests Installation of 24 bus bars on the module and final shaping of the bus bar ends Module Separation Plane set of six joints painted and clamped Dariusz Bocian IFJ PAN-ESS meeting 48

49 Scientific equipment construction Cherenkov Telescope Array (CTA) 1) Small Size Telescope Structure - prototype to be built by end 2013 dish diameter 4 m; focal length 9.6 m; weight 8.8 t 3-D model based on the technical documentation Dariusz Bocian IFJ PAN-ESS meeting 49

50 Scientific equipment construction Cherenkov Telescope Array (CTA) 2) Open structure mirrors for Medium Size Telescope 10 prototypes under tests hexagonal shape 1.2 m f-t-f, curvature radius 32 m, weight 35 kg Front (left) and rear (right) view of the prototype mirrors Dariusz Bocian IFJ PAN-ESS meeting 50

51 Medical equipment construction Proton radiotherapy at IFJ PAN Components of eye melanoma setup to be finished in 2013 Device for immediate proton beam cut-off, so called shutter Supports for the end of beam line range discriminators and beam collimators Holders for digital x-ray recorders Adjustable supports for x-ray lamps Dariusz Bocian IFJ PAN-ESS meeting 51

52 Scientific equipment construction Finger detector at GSI Darmstadt Mechanics for one detector completed in 2012 Dariusz Bocian IFJ PAN-ESS meeting 52

53 Scientific equipment construction Stellarator W7 - X Mechanics for 30 sets of polychromators completed in 2011 Dariusz Bocian IFJ PAN-ESS meeting 53

54 Scientific equipment construction ATLAS Assembly Aluminium frame to install Muon Chambers completed in 2006 The frame used during installation in the ATLAS cavern The frame at IFJ PAN Dariusz Bocian IFJ PAN-ESS meeting 54

55 Conclusions Expertise: XFEL (construction) LHC (construction, consolidation, upgrade) W7-X (construction) AIC-144 (construction, medical applications) Proteus C235 (medical applications, research) Team: Scientists: 5 Engineers: 34 Technicians: 65 IFJ PAN groups contribute to major world experiments in particle physics, astrophysics and nuclear physics. IFJ PAN contributes to XFEL and LHC IFJ PAN is involved in fusion projects (W7X, ITER) Dariusz Bocian IFJ PAN-ESS meeting 55