Work Package Status Report

Transcription

1 Work Package Status Report Date: August 2018 Work Package: WP5 Elliptical cavities and cryomodules Author: Pierre Bosland, Roger Ruber, Daniele Sertore, Mike Ellis, Christine Darve 1. Accomplishments by CEA WP05 M-ECCTD Cryomodule: o Cryomodule assembly: The M-ECCTD assembly is complete and the cryomodule is now installed in the test stand. Up to now we could follow the list of operations without any issue. The instrumentation connections have been checked. The 4 doorknobs have been mounted using of the new tooling and the wave guides are now connected to the couplers. 3 of the 4 power couplers have been already commissioned at room temperature with the standard procedure. No outgassing occurred and the duration of the sequence for each coupler was very short, 4 hours (see fig below of cav3). 1

2 The insulating vacuum is now being pumped down. The effect of the different vacuum configuration of the cryomodule of the cavities position is checked as well the cavity frequency shifts. The cooling down of the cold mass is in preparation and will start as soon as the insulating vacuum is pumped.. H-ECCTD: o High beta cavity test at Uppsala University: The cavity package prepared by CEA has been tested successfully at UU during a short period in summer. General conclusions before the test report are: RF power conditioning at warm up to 1.1MW and RF pulse length of 2.3ms done. Cooling down to 2K done. Increase of the cavity field done without big issue, but the large uncertainty of the gradient value measurement doesn t allow a clear conclusion (19MV/m or 13MV/m). Few electron field emission appearing during gradient increase could be easily and quickly processed. The slow tuner behaves as expected (good linearity of 17.3kHz/screw turn, low hysteresis) Tests of the piezo stacks done. Tuning range is as expected. We are waiting for the test report for more details about Lorentz detuning compensation and mechanical modes of the cavity) o High beta prototype cavities: o 4 of the 5 cavities have been sent to ZANON for the final preparation for the tests in vertical cryostat. 2

3 o Cavities 1 and 2 have been delivered to CEA. Cavity 1 is installed in vertical cryostat ready for cooling down and test on W38. o Couplers: Series cryomodules: o The third coupler pair of the pre series has been prepared for the RF processing. The following table summarizes the status of the main procurements for the series production: Vacuum vessels Contract awarded to ACPP, manufacturing of the first unit in progress, delivery expected mid of June Power couplers Coupling boxes for coupler conditioning Thermal shieldings Spaceframe Cold Tuning Systems (mechanical part) Motors for cold tuning systems Cryogenic heat exchanger Magnetic shielding MLI Internal instrumentation Intercavity bellows, coldwarm transitions Cavity supporting systems (tie rods) Cryogenic circuits, diphasic tubes, tubes for rupture disks, coupler bells Contract awarded to PMB, the 6 couplers of the preseries are delivered. Contract awarded to SDMS, all units delivered. Contract awarded to SDMS, first unit delivered middle of March SAT OK. Contract awarded to SDMS, first unit delivered middle of March SAT OK. Contract awarded to YVON BOYER kick-off meeting done in September, manufacturing in progress. Pre series manufacturing in progress. Contract awarded to TSA (PHYTRON), 48 motors received Contract awarded to SDMS, two first units delivered. Contract awarded to MECA MAGNETIC, kick-off meeting done, fabrication in progress. Intermediate FAT with mockup assembly done. Contract awarded to SODITECH, kick off meeting done Contract awarded to SODITECH, kick-off meeting done, manufacturing files validated the 15 th of February, fabrication of the first unit in progress Contract awarded to SDMS, kick-off meeting done Contract awarded to SPG Cryogenic circuits awarded to CRYODIFFUSION Di-phasic tubes awarded to SDMS Ti bellows: offers received 3

4 Cryogenic valves CV01 and CV02 Level sensors Temperature sensors Safety valves Controlled safety valves Rupture disks RF cables RF feedthroughs Pressure transmitters Screws for clean room assembly Vacuum components Contract awarded to VELAN, kick off meeting done, fabrication in progress Contract awarded to CRYOFORUM, all the components received Contract awarded to CRYOFORUM, several batches already delivered Contract awarded to LESER Contract aw<arded to Velan Contract awarded to BS&S Contract awarded to HABIA Contract awarded to MDC Vacuum Call for tender in progress Several contracts awarded Almost all item ordered HV90 purge valves: contract awarded to VAT. Standard pumps and gauges awarded to Pfeiffer Vacuum pumping groups Contract awarded to Cryomodule assembly Contract awarded to B&S 1.1. Accomplishment by UU Hb cavity package test in HNOSS In August we did a 2nd run of the elliptical cavity package. - Cooldown of cryostat and cavity - RF re-conditioning at cold - Measurement Q0 and Lorenz force detuning - test of Polish electronics for cold tuner system 2. Accomplishment by LASA Medium-beta cavity WP05.2 (June to August) Present Status During these months, INFN team visit OTIC for the quality control of sheets foreseen for the 3 rd batch. The inspection was successful and finally we released the delivery of the 148 sheets to INFN. Sheets arrived on July 6 th at LASA and were delivered to DESY July 11 th. DESY completed the scanning of all sheets and only 13 sheets were sent for further analysis. Finally only 3 sheets have geometrical defects and no inclusions have been detected. For the debugging of the DESY VT infrastructures and for the qualification of all VT infrastructures, in accordance with ESS and CEA, the dressed cavity prototype P05 will be used after a retreatment cycle at EZ (cavity sent to EZ in July). Once ready, this cavity will be cold tested at LASA and after at DESY to cross check the two infrastructures. Afterwards, this cavity will be also tested at CEA. 4

5 After the fabrication of the first 3 Half Cells (namely IC_N128; PC_N015, EC_N069) of the series production at EZ, the mechanical and RF measurements (done with Co.Co.De semi-automatic apparatus developed by EZ) checks have been done and the LASA-DMS (Data Management System) based on ALFRESCO was debugged for the managing of the documents between EZ and INFN. The first Terminal Dumb Bell (TD) is produced (namely TD_ICN128_PCN015) using first two IC and PC, to cross check the mechanical and RF measurement behavior after the EB welding process. Since a larger shrinkage than the expected has been measured, further checks on this TD has been done to obtain all necessary info before launching the series production. After some optimization (relative to the EZ production strategy and fabrication tools, and also of the HCs overmetal lengths), the production of the HCs of three types of the first lot (necessary for the production of 6 cavities) was released. All measurements done by EZ have been exchanged between EZ and INFN by using the LASA-DMS system. The HCs for six cavities have been produced and the coupling of HCs to Dumb Bells have been provided to the company. During August, DBs for the first two cavities have been produced. As already reported last month, the construction of the third INFN MB LG prototype (MBLG003) is used to debug, as far as possible, the overall production procedure. During this months, DBs and EGs have been measured after the INFN trimming instruction. The cavity composition has been sent to Zanon in preparation of the cavity welding in September with the new tool that should improve the alignment of the cavity components. As part of the debug process, we have used the LASA-DMS system to import documents and validate them. At LASA, the modifications of our Vertical Insert to accept cavity in series configuration has been completed and the insert has been tested at cold. On the vertical test at DESY, in July INFN team together with DESY team performed the cold RF test of the INFN MBLG002, confirming results obtained at LASA. During the test, the CEA mockup was in the insert to debug the real behavior of the system with a configuration similar to the one that we will have for the series cavities tests. This visit was also used to better clarify the kind of data to be collected by DESY for the qualification test, the outgoing/incoming documents to be prepared, the managing of information exchange between INFN and DESY. After this visit several issues have been clarified, only minor details are still to be completed. In June the Kyocera PUs arrived at LASA. INFN performed the thermal cycling and all vacuum leak tests confirming the expected quality of feedthroughs. EZ checked the dimension of the Ti 2-phase line seamless tube received from CEA, after the cutting operation (July 6 th ). Measurements show thickness variation not negligible while the external diameter is constant and in tolerance. This info have been given to CEA and we had the confirmation that they can be used. Future Progress a) Prototypes (1) Large Grain (LG003) welding, treatments and tuning b) Series Cavities i) Niobium 3 rd batch, deliver to EZ after EDS at DESY. ii) Follow up cavity production start-up process at vendor premises. In particular, further analysis of the measurements of produced HCs and composition instruction for the DBs fabrication. Measurement of EG. Trimming instruction for DBs and EGs 5

6 3. Accomplishment by STFC High-beta cavity WP05.3 Project Management Efforts are ongoing both to increase the team size and to prepare the team organization structure for cavity manufacturing. The CDR charge for the cavities is agreed in principal with ESS, although given the proposed change to STFC drafting the final design drawings this may require revisiting. For STFC this will be a critical point for ESS to confirm the final design, correct drawing revisions, and to ensure that during prototype testing (i.e. CEA s 5 HB cavities and the P01 test at Uppsala) has not identified any issues requiring design change to the cavity. Infrastructure: Control racks for the UHV systems and for offline cryostat insert checks are installed, as well as cable connection panels. Cable installation is ongoing. Cables for cryostat sensors, controls, and vacuum are complete pending final check The first UHV slow pump / slow vent system has completed assembly and is pending leak check. RF rack is progressing with additional cryocooler (coaxial resonator) testing scheduled for October. It is still the STFC target that first tests of the cryostat to cool down, develop processes etc will start at the beginning of October, but this is at risk due to staff availability in September. STFC s current target is to be able to start RF operations on the P02 cavity from 1 st week of November. The first scheduled test is final LLRF validation. SRF cavity measurements are not expected until Jan Cavity & material procurements A formal Kick-off meeting was held with Research Instruments on 4 th Sept, attended by RI, STFC, CEA, and an ESS representative. A lot of progress was made on key issues such as the final diphase line length, helium inlet, manufacturing infrastructure review etc. A follow up meeting is proposed in late September or early October to close remaining issues and to review the quality control requirements in detail. There is some urgency to approve the Acceptance Level 1 mechanical design drawings. This was proposed by STFC to be part of a formal review with ESS, which must be arranged urgently. The most recent official drawing release from ESS/CEA for the HB cavities is Rev E, although the provisionally agreed latest version is actually Rev H. This should be closed formally urgently between ESS, CEA and STFC. RI s proposed schedule is still in accordance with the SRF scheduling meetings, however there is a high level of risk and uncertainty about being able to release manufacture on schedule due to the drawing review process. This schedule shows the first 2 undressed pre-series cavities to be ready for test at DESY in Feb/Mar 2019, and after this testing, then jacket integration at RI, they would be at STFC by ~May ready for final testing. The actual testing would not start until Sept/Oct 2019 after completion of the infrastructure commissioning and benchmarking at STFC. Eddy current scanning has been completed on all of the first three batches of discs shipped to DESY. Batch 4 micrographs were received in late August and are currently being reviewed by STFC. High level discussions have been held with DESY to re-confirm the possibility of testing the pre-series cavities at their facility in ~Feb 2019 and ~April This is not expected 6

7 to have any impact on the medium beta testing schedule providing the interfaces to the cavity are matching with the medium beta (e.g. mechanical frame, valve and antennae positions / angles etc). Slow pump slow vent system assembled ready for leak check in the clean room 4. General See the minutes of the weekly Vidyo interface meetings at: Weekly Fridays meeting action items - ESS/SRF Collaboration Bi-Weekly Fridays meeting - Activities Plan (restricted) Weekly Tuesday meeting action items - ESS/CEA Weekly Tuesdays - TS2 coordination meeting and TS2 CM meeting Weekly Thursdays - ESS Linac Group meeting notes August 7-8: CEA - M-ECCTD and Hb cavity 7

8 5. Issues By CEA: FAT of the modulator scheduled on week 38 delayed by some weeks due to some technical issues. By STFC: STFC commissioning is currently conducted with 1 cavity P02, which means a lot of testing of different parts of the Vertical Test system in series. This extends the schedule due to serial operation and puts a very high risk on the schedule in the event of any incident taking the cavity offline. STFC have been searching for additional cavities to support commissioning but so far have not been able to identify any high-gradient jacketed cavities suitable. We would therefore like to formally request ESS support in identifying ESS-type jacketed cavities which could be available from Q4/2018 or Q1/2019 to help accelerate and de-risk the STFC vertical test facility. This will fundamentally reduce the risks on cavity delivery to ESS/CEA for the High Beta Cryomodules. ESS has proposed / requested that STFC use its cavity supplier to complete the final design drawings. It is anticipated that both the cost and time to create the drawings at RI will be small; however, STFC or RI cannot accept final cavity design responsibility so will need a review and approval with ESS and CEA. This final review could be the proposed CDR, and must be scheduled as soon as possible after RI will have the drawings ready; arranging this formal process is now highly likely to impact delivery and production of cavities. Since the Technical Annex will be changed and the approval of drawings may be delayed having schedule impact, this will need suitable change control approval between ESS and STFC. The CDR charge provisionally agreed with ESS will require some more input from STFC than expected, including potential for final drawing reviews as above. The proposed schedule for CDR is after STFC expect to have the kick-off meeting with the cavity vendor. STFC now propose to use the following strategy: o 1) kick-off meeting using current data package o 2) manufacturer starts preparations for tooling, manufacturing etc o 3) vendor and STFC create final cavity drawings and distribute for approval o 4) ESS CDR: this MUST be held prior to STFC authorizing the cavity vendor to manufacture any cavity Half Cells, End groups or other parts Anticipated production schedule starts component manufacture in Sept/Oct 2018 o 5) After successful CDR, STFC will authorize start of production at the vendor If Cavity Acceptance Criteria are to be changed to include an X-ray radiation limit, this will require a change control request to be produced and to be agreed between STFC and ESS. 8

9 One of the cryogenic engineers assigned as a core team member has resigned and will leave in mid September. The process to recruit a replacement has started, as well as arranging short-term expert cryogenic support to minimize delays in the cryostat commissioning. 6. Current and near Future Variances in Project Plan By STFC The delayed installation and commissioning will now impact delivery dates of cavities; the technical annex milestones in version 1.7 are not achievable and should be re-baselined by change control after the cavity manufacturing kick-off meeting in September. However, STFC s best estimated schedule has been provided and included in the updated ESS s joint SRF schedule v This delivers cavities to ESS (/CEA) ahead of the scheduled High beta CM builds, currently with around 3 months free float. To date, the cavity tender bids & winning bid are both compatible with the schedule referenced above. However, it is likely that the cavity fabrication may be delayed if drawing approval cannot be completed formally urgently. STFC critical path currently includes infrastructure commissioning. Any additional ESS cavities could help accelerate this, for example, MP05 and HP01 which are currently in use by INFN (at DESY) and at Uppsala respectively. If these were available for use by STFC from Q until Q3 2019, the commissioning for STFC s infrastructure could be accelerated and de-risk our delivery schedule of cavities. Final deliveries of Niobium are expected slightly ahead of schedule. STFC is coordinating regularly with DESY to ensure as much as practical a continuous supply of Niobium for their eddy current scanning activity. No impact on the cavity production is currently foreseen. 9