overview of the hwr project: technology, management, es&h– cryogenic valve control system...

Overview of the HWR Project:

Technology, Management, ES&H

P.N. Ostroumov

Physics Division

March 5, 2012

March 5, 2012

P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review

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Content

Project motivation

Functional specifications of the HWR cryomodule

Technical developments

– Cryomodule design features

– Cavity design features

– High power RF coupler

Management

– ES&H, QA

– Project team

– M&S cost, Schedule

– Milestones

– Major procurements

Summary

Project Motivation

Acceleration of H beam from 2.1 MeV to 10 MeV in CW regime

Difficulty: transition from very low accelerating gradients in RFQ to much higher gradients in the SC section – not efficient use of SC structure

Total accelerating voltage 1.7 MV 8=13.6 MV

– First 2-3 accelerating periods - just 1 MV

Replaces 3 cryomodules of 325 MHz spoke cavities from the original design of Project X (beginning of 2011)

– More naturally fits to 162.5 MHz RFQ

Significantly reduces the cost of the front end (PXIE) as compared with the 325 MHz system

Favorable beam dynamics: higher accelerating gradients, less defocusing, linear motion in longitudinal phase space

Can be realized in reasonable length of the cryomodule below 6 meters

– Comparable with ATLAS cryomodules

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Functional Specifications (revision 2/21/2012)

Parameter Value

Minimum beam aperture (ID), mm 33

Overall module length; flange-to-flange, m 5.8 5.9

Maximum allowed heat load to 70 K, W 250 250

Maximum allowed heat load to 4.5 K, W 80 60

Maximum allowed heat load to 2 K, (target), W 25 24

Thermal intercept temperatures, K 5 and 45-80

Number of cavities 8

Operating Accelerating Voltage, cavities 1 and 2, MV/cavity 1.0

Operating Acc. Voltage, cavities 3 through 8, MV/cavity 1.7

Transverse alignment error, displacement, mm 0.5

Transverse alignment error, angle, mrad 2.5

Coupler Power Rating (full reflection), kW 10

Number of SC solenoids with steering correctors 8

Number of BPMs 8

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March 13, 2011

P.N. Ostroumov Lattice options for 40 MeV Linac SARAF ISC Meeting, March 13-15, 2011

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Basis for Cryomodule Development at ANL

ATLAS Energy Upgrade cryomodule, average voltage =2.1 MV/cavity, limited by VCX

Being used since July 2009, current performance is even better than original one

Carbon beam energy measured after each cavity

Basis for HWR Cryomodule Development: ATLAS

Efficiency and Intensity Upgrade

Experience with reduced- cavities and Cryomodules

5.2 meter cryomodule

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Performance of 170 MHz HWR (2004) and 72 MHz

QWR (2011) Technology has been improved since 170 HWR was built in 2003-2004

– Highly optimized EM design, reduced BPEAK and EPEAK

– Extensive wire EDM of all parts prior to EBW

– EP after all mechanical work is complete (+600C baking)

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Q

1010

109

=0.25 HWR, f0=172.5 MHz

1.8 MV/Cavity(4 K)

(See Kelly et al. THP06, LINAC 2004)

Cryomodule Layout

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In October 2011 we started with the cryomodule concept which included 9 cavities and 5 SC solenoids

Beam physics studies resulted in 8 cavities, 8 solenoids, 8 BPMs

The first upstream element is a SC solenoid to mitigate vacuum transition from NC to SC linac

Cryomodule Design Features

2K operation

Relatively short cryomodule, 5.9 m

– Reduction of the length by ~10” is being pursued

Compact lattice: short focusing periods to be able to apply high accelerating voltages

Compact SC solenoid

– no-iron, return coils to reduce stray fields

– H- and V-steering correctors

Improved alignment techniques

BPMs attached to each SC solenoid

Incorporate JT valve and heat exchanger into the cryomodule

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Preliminary Design of the Cryomodule

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Cavity, slow tuner and RF coupler are nearly final

Cavity and solenoid alignment hardware is identified and being implemented

Incorporate and position internal J-T valve & heat exchanger

Modify vacuum, helium manifolds

Develop cavity-BPM-solenoid design which is more compact and suitable for assembly in clean room

Beam

Cryomodule Interfaces

The following interfaces are identified in FRS

– Bayonet connections for helium supply and return

– Cryogenic valve control system connections

– Pumping and pressure relief line connections

– Cryomodule positioning and alignment supports

– Beam tube connections terminated by a low particulate vacuum valve

– RF cables to the input couplers

– Instrumentation connectors on the vacuum shell

– Power supply cables for the solenoid and correctors connections

– Alignment fiducials on the vacuum shell with reference to cavity position

Several items from the list are obvious (bayonets, pumping, RF transmission line, beamline connection, instrumentation)

All these interfaces have been discussed conceptually with FNAL experts

During FY12 we need to identify detailed design for all interfaces

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Resonator Design Features

Highly optimized

– Low BPEAK due to double conical shape of the CC and OC

– Increased shunt impedance

– “Donut” shape of the CC drift tube to eliminate quadrupole component of the accelerating field

Four 2-inch diameter ports for EP, 2 ports will be used for pumping and pick-up loops, one 2-inch port is for the high power coupler

– Blending radius on toroid-port joins is 0.5” – significant development by AES

to minimize BPEAK

Pneumatic slow tuners

10-kW RF coupler, fast tuner is not required

– 4-kW RF power will provide ~20

at 1 mA ( is the rms frequency noise)

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162.5 MHz Cavity Assembly (Dimensions are in cm)

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EM optimization

Excellent EM properties. Recommended design voltage is 1.7 MV which corresponds to EPEAK = 38 MV/m and BPEAK =44 mT

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Freq

MHz

βOPT LEFF

(cm)

EPEAK/EPEAK BPEAK/EPEAK

mT/[MV/m]

R/Q

Ω

G

Ω

162.5 0.112 20.7 4.6 5.0 271 48

No ports With ports

10-kW Adjustable Coupler

Based on successful development of 4-kW input coupler (1-5/8” coax) for 72 MHz cavities

Increased diameter of the outer conductor, 2”

1” stroke, 70K cooled alumina window, 4.6K intercept

The coupler is being fabricated

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Resonator port

To RF Amplifier

Electropolishing after all Mechanical Work is Complete

72 MHz QWR

162.5 MHz HWR

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Project Management EBIS Review

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ANL Laboratory Management System (LMS) and

ES&H

A primary objective of this project is to protect the environment and the safety of workers and the general public

The PXIE-HWR project fully complies with ANL LMS

– All work is controlled by Work Processing and Control Documents

– All Project Team members are fully trained for the tasks they perform

– Integrated safety management (ISM) is incorporated into the project planning and execution and includes

• Defining the work

• Analyzing all potential hazards

• Developing and implementing hazard controls

• Performing work within controls

• Providing feedback and continuous improvement

January 30-31, 2012


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LMS and ES&H (cont’d)

The Project complies with all applicable ANL and Physics Division ES&H requirements. – ANL ES&H Manual and the Physics Division Safety Policy,

– Physics Division Electrical Safety Manual,

– Physics Division Radiation Safety Manual,

– Physics Division Chemical Hygiene Plan,

– Building 203 Emergency Plan,

– ATLAS Operating Procedures

Technical and ES&H reviews: – General Safety Committee Reviews as needed at ANL

• We plan to invite FNAL safety committee members for these Reviews

– Next Review: cavity mechanical design as a pressure/vacuum vessel

January 30-31, 2012

Engineering and Technical Standards (FRS)

All vacuum vessels, pressure vessels, and piping systems will be designed, documented, and tested in accordance with the appropriate Fermilab ES&H Manual (FESHM) chapters.

– This includes the superconducting cavities and their associated helium vessels which must be designed, manufactured, and tested in accordance with FESHM chapter 5031.6, Dressed Niobium SRF Cavity Pressure Safety.

– Bellows shall be designed using the requirements of the Expansion Joint Manufacturers Association (EJMA).

– The cryomodule as a whole shall be designed to be free of frost and condensation when in operation in air with a dew point of 60 F.

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Quality Assurance

The quality culture is the cornerstone of the project management philosophy

Quality Assurance for the HWR Cryomodule Project is performed according to ANL LMS Policies and Procedures

Main purpose of the QA

– Meet all parameters defined in Functional Requirement Specification (FRS)

– Avoid costly reworks

– Reduced cost of the project

General guidance from Tom Mullen, PHY ES&H and QA engineer

The Project “Quality Professional” is Jim Morgan – an engineer with 30-year experience and previous experience with QA in large LCLS project

FRS: A complete cryomodule traveler is to be developed documenting all stages of materials inspection, cryomodule component fabrication, piping and weld inspection, cryomodule assembly, and test.

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Project Team

January 30-31, 2012


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Project Team Glenn Cherry (NE), designer FT Zack Conway, physicist PT Rick Fischer (NE), engineer FT Scott Gerbick, engineer PT Mark Kedzie, engineer PT Sang-hoon Kim (postdoc, starts on 4/2/12) FT Mike Kelly, physicist PT Sergei Kutsaev, postdoc PT Peter Ostroumov, physicist PT Jim Morgan (NE), engineer PT Ryan Murphy (HEP), engineer PT Brahim Mustapha, physicist PT Tom Reid (HEP), engineer PT Dale Schrage (TechSource), consult. <5% Kenneth Shepard (TechSource), consult. <5% Undergraduate Students

Project Support (less than 5% time) FNAL PXIE Team Albert Barcikowski (NE) Sergei Kondrashev Amichay Perry (PhD student) Arturo Ortega Bergado (visitor) Gary Zinkann ATLAS Electronics Group ATLAS Cryogenics Group

Schedule

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Testing of the prototype cavity complete August 2013

Fabrication, cleaning of production cavities complete August 2014

Cryomodule mock-up assembly December 2014

Cryomodule off-line testing complete November 2015

Project M&S Cost

Includes procurement and services of the ANL machine shop

Cost estimate was created in November 2011

Cost estimate has been done for the following configuration:

– one prototype cavity

– 9 production cavities with fast and slow tuners (8)

– 5 SC solenoids (8)

– No BPM (8)

– Includes 14% taxes and 3% escalation,

– No contingency is applied

– Cryogenic valve box is not included

– 10-kW RF amplifier is not included

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M&S Cost Distribution (k$), Created in Dec. 2011

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2015 TOTALS

WBS ITEM 1st HALF 2nd HALF 1st HALF 2nd HALF 1st HALF 2nd HALF 1st HALF

1.01 Project Management 0

1.02 Physics, Engr, & Des

Design Software 23 23

1.03 Prototyping

procure niobium 64 64

hydroforming dies & prototype cavity parts 228 228

machining, brazing, wire EDM 59 59

Fixturing (Sciaky/NPI/ADRON) 57 57

EBW 29 29

Chemistry (etching) and HPR during fabrication 6 6

Fixturing for EP and HPR 69 69

SS vessel 36 36

Prototype cavity RF surface processing 16 16

Design and fab of TC3 fixture 36 36

Install cavity into TC3 and test 21 2 23

1.04 Cryostat

Fabrication liaison, supervision, Q&A 0

box/lid, thermal shield 442 442

magnetic shield 63 63

beam valve spool assemblies (2) 37 37

cryo, vac plumbing/manifolds 69 69

cavity string support system 52 52

cavity vac sys (not including interlocks & controls) 41 41

insulating vacuum system 41 41

cryostat stands 28 28

alignment hardware 28 28

alignment labor 0 0

JTHX, 2K 76 76

Miscellaneous (He plumbing, feedthroughs,…) 88 88

2012 2013 2014

M&S Distribution(cont’d)

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1.05 Cavities (9)

procure cavity niobium 576 576

hydroforming, die forming 281 281

machining, brazing, wire EDM 546 546

EBW 116 116

chemistry (etching) 28 28 56

additional fixturing for production cavities 34 34

Install the cavities & sub-systems into TC3 & test 31 21 51

1.06 Sub-systems

SS LHe tanks 326 326

couplers 369 369

fast tuners 143 143

slow tuners 89 89

solenoids including He vessel, dipole coils 245 245

instrumentation (TCs, press gauges,..) 43 43

beam line systems 44 44

up-to-air system 12 12

current leads (<100 A ) + magnet hardware 31 31

1.07 Cleaning

Electropolishing, HPR effort 0

Consumables incl. disposal 16 112 32 160

Cleaning of aux components 0

1.08 Assembly, test

Various tools, equipment for assembly and testing 46 46

Cavity string clean assy incl mock-up clean assy 0

Cryomodule assembly 40 40

Cryomodule off-line test 40 40

Maintenance platform 6 6

1.09 Spare parts

HWR 0

SC solenoid and its LHe vessel 49 49

RF coupler 30 30

Fast tuner 16 16

Slow tuner bellows unit 3 3

1.1 Commissioning

TOTALS 663 662 1278 1761 389 131 80 4963

Comments on M&S Cost

We already see higher cost of die fabrication and forming of Nb parts for the prototype cavity as compared with our Dec. 11 prediction

Cost estimate will be updated after Conceptual Design is complete (June 2012)

– Apply FRS dated 2/21/2012

– Obtain quotes for fabrication of cryostat vessel, niobium, SC solenoids, RF couplers, BPMs, cavity He vessel

– Update the cost of cavity fabrication

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Project Milestones

# Milestone Date

1 Place contract for niobium dies and forming of the prototype cavity Q2FY12

2 Conceptual and Preliminary Design complete

Niobium for production cavities is delivered and inspected

Q4FY12

3 Complete fabrication drawings and start procurement of the cryostat vessel including

thermal and magnetic shields.

Fabrication of the prototype cavity including SS vessel

Q2FY13

4 Prototype cavity tested Q4FY13

5 Fabrication of the cryostat vessel complete Q2FY14

8 Fabrication of production cavities complete Q4FY14

7 Mock-up cavity string assembly Q2FY15

8 Cryomodule off-line testing complete Q4FY15

9 Cryomodule installed on PXIE beamline Q2FY16

January 30-31, 2012

Cavity Design Status

Multi-physics and engineering design of the niobium cavity is complete

Nb and SS vessel stresses are within specs

df/dp is +4.3 kHz/atm and can be nulled with further optimization of the SS vessel

Comfortable range of slow tuner – 85 kHz at 6000# of applied force

ProE model is created per AES request

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Major Procurements in FY12 and FY13

AES has quoted fabrication of dies for niobium forming and forming niobium parts for the prototype cavity

We are waiting for quotes both from Wah Chang and Denkai for niobium

Niobium for prototype cavity is available from existing inventory (should be replaced by new purchase)

Parts for the 10-kW RF coupler are being developed with the US industry

If funding is available, all major procurements must take place in FY12 and FY13

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Summary

HWR cryomodule project is well advanced

– Management plan was created

– Management of ES&H and QA are well understood

– Schedule and budget were developed

– Procurement plan exists and being implemented

Next steps are:

– Place contract with AES for Nb forming

– Continue engineering analysis and optimization of the jacketed HWR

– Start procurement of the prototype cavity parts (braze joints, bellows,..)

– Call Safety Committee to finalize mechanical design and engineering analysis of the dressed cavity

– Place contract to purchase Nb for production cavities

– Fabricate and test 10-kW coupler

– Complete Conceptual and Preliminary design of the cryomodule

– Revise and update cost estimate per most recent FRS and current status of the design