x-fel cryomodule development

1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

X-FELX-FELCryomodule DevelopmentCryomodule Development

XFEL-WP 10 ‚Module Test‘XFEL-WP 10 ‚Module Test‘Bernd Petersen DESY –MKS-

1st ILC-Workshop, KEK, November 2004


Overview

Industrial Cryomodule Assembly Studies

( Single-) Cryomodule Test Bench

X-FEL Cavity&Cryomodule Test Facility


‘In view of the European X-FEL-project and other FEL light sources like the BESSY-FEL-project, which will use the superconducting linear accelerator TESLA technologies, the already existing design and assembly procedures of prototype cryomodules have to be reviewed by industrial studies in respect to series production, reduction of efforts and costs, and increase of performance. This review shall be part of the EUROFEL design study work package DS6 ‘Cryomodule Technology Transfer.’ In addition, for the time being, the TESLA technology represents the most developed approach for a superconducting linear collider, which will be the basis for the design of the future International Linear Collider (ILC). ‘

Scope of the Industrial Module Assembly Studies


Industrial Studies on assembly ProceduresProcurement of cryomodules – legal restrictions

For the time being DESY can not start the complete cryomodule procurement ( only after final agreement with other XFEL- partners)

On the other hand: in order to adapt the cryomodule design to industrial series production, industry should be involved as soon as possible

-> Industrial assembly studies are separated from the final

procurement procedure for the cryomodules

EU-procurement for industrial studies will be started open to

industry

Results will be published open to public and industry

-> equal information and chances for industry at the start of the final module procurement


Industrial Studies on assembly Procedures

Specifications for the procurement of the studies :

- Review of present cryomodule design & design changes for XFEL

- Analysis and review of the present assembly procedures ( inside /outside cleanroom)

- Suggestions for design/ assembly changes in respect to performance, cost savings and series production


internal modul production number

design type status of planning

earliest date of assembly

comment

6 TTF-III scheduled May 2005 35 MV/m high gradient module

7 TTF-II scheduled December 2005 VUV-FEL linac spare module

8 X-FEL not yet scheduled

end of 2006 X-FEL prototype

9 ? not yet scheduled

? ?

At least 2 competent companies shall analyze the assembly of modules 6 an 8

Procurement of the studies is in Progress: December 2004

(Completely separated from the final cryomodule procurement procedure)

The studies will be published !


Industrial Studies on assembly procedures

CLR string assembly

assembly outside CLR

Preserve performance of cavities !

Save assembly costs !

-> Assembly procedures can be -> Assembly procedures can be verified only in verified only in module testsmodule tests


Objectives of the test bench:

• In general: cryomodule tests independent from TTF-linac operation• RF cavity processing / performance • processing of RF couplers • cryogenic performance• tests of vacuum systems• tests after repairs before installation into linac• tests of new design features ( 2K quad ...etc.)• dark current• Wire Position Monitors • thermal cycling• insulation vacuum / beam vacuum venting• ...etc.........


Types of CryomodulesTable 1: The presently known different cryomodule designs or basic concepts, which have to be tested on the CMTB ( for the (*)-marked types, no final designs exist yet ) Type of cryo module

Vacuum vessel diameter / mm

Number of cavities/ RF main couplers

Magnet package

2K-2-phase tube

Length /m Coupler distance/mm

TTF-type II 1089 8/8 4.5K end cap side

on top of cavity

12.2 1380.5 -1381

TTF-typeIII 965.2 8/8 4.5K end cap side

see fig.2 12.2 1380

TESLA type preliminary compressed 9-cell (*)

965.2 8/8 2K center of module

see fig.2 12.2 1319.2 ???

TESLA type compressed 9-cell (*)


see fig.2 17.136 1319.2

TESLA type 9-cell-super structure (*)


see fig.2 16.1306 2471.7

NN (*) NN NN NN NN NN NN

XFEL


CMTB test hall

TTF

Hall3


CMTB test hall (2)Cave cross section


Status of cryogenic components

feed box

(odered)feed cap

(ordered)

end cap (ordered)

cryomodule

supports

(designed)

feed cap transfer line

(ordered)


Line of construction

DN250 tranfer line

DN150 30mbar line

DN100 water pipe

RF wave guides

cable traces

______________

DN200 LP

DN80 HP


DN25 4.5K forward

DN50 4.5K return

DN25 40K forward

DN25 80K return

80K shield covered

DN250 vacuum tube

CMTB-transfer line (ordered)FEL-subcooler box -> CMTB feed box


cryogenic supply of the CMTB

HERA CB

HERA SCREWS

SC&V BOX

MOD TEST SMESVUV-FEL LINAC

TTF CB

TTF SCREWS

VD1 VD2 CHECHIA VD3

VC2 VC1

HEX

11/2005 12/2004


Cryo Module Test BenchSome details:

Cryogenic equipment:

After EU call for tender now in the process of making contracts

RF-equipment:

Modulator, puls-transformer on DESY site

Klystron ordered, will be delivered in 2005

Call for tender for wave guides etc….

Civil engineering:

Final specifications ready, procedures prepared and will be started now


Cryo Module Test Bench

ID Vorgangsname Duration Start Finish

1 Cryomodule Test Bench 429 dys Tue 01.06.04 Fri 20.01.06

2 Civil engineering/building 220 dys Mon 06.09.04 Fri 08.07.05

3 test hall 220 dys Mon 06.09.04 Fri 08.07.05

4 building permit 3 mons Mon 20.09.04 Fri 10.12.04

5 demolishing the Nissen hut 2 wks Mon 04.10.04 Fri 15.10.04

6 cutting trees 1 mon Mon 18.10.04 Fri 12.11.04

7 tubing the stream 1 mon Mon 18.10.04 Fri 12.11.04

8 hardening ground 2 wks Mon 15.11.04 Fri 26.11.04

9 specification for test hall 1 mon Mon 06.09.04 Fri 01.10.04

10 call for tenders 2 mons Mon 04.10.04 Fri 26.11.04

11 contract 2 mons Mon 29.11.04 Fri 21.01.05

12 erecting the hall 6 mons Mon 24.01.05 Fri 08.07.05

13 line of construction 80 dys Mon 13.09.04 Fri 31.12.04

14 specification 1 mon Mon 13.09.04 Fri 08.10.04

15 fundaments 30 dys Mon 11.10.04 Fri 19.11.04

16 manufacturing 30 dys Mon 11.10.04 Fri 19.11.04

17 mounting 30 dys Mon 22.11.04 Fri 31.12.04

18 shielding 85 dys Mon 06.09.04 Fri 31.12.04

19 specification 3 wks Mon 06.09.04 Fri 24.09.04

20 call for tenders 6 wks Mon 27.09.04 Fri 05.11.04

21 contract & 1st payment 40 dys Mon 08.11.04 Fri 31.12.04

22 Cryogenics 369 dys Tue 01.06.04 Fri 28.10.05

23 Feed-box,-cap, end-cap 369 dys Tue 01.06.04 Fri 28.10.05

24 call for tenders 79 dys Tue 01.06.04 Fri 17.09.04


26 design/construction 250 dys Mon 15.11.04 Fri 28.10.05

27 Transfer line 369 dys Tue 01.06.04 Fri 28.10.05

28 call for tenders 79 dys Tue 01.06.04 Fri 17.09.04


30 design/construction 11 mons Mon 15.11.04 Fri 16.09.05

31 installation 1.5 mons Mon 19.09.05 Fri 28.10.05

32 warm valves 265 dys Wed 01.09.04 Tue 06.09.05

33 specification 30 dys Wed 01.09.04 Tue 12.10.04

34 procurement 2 mons Wed 13.10.04 Tue 07.12.04

35 construction,delivery 6 mons Wed 23.03.05 Tue 06.09.05

36 warm gas tubing 120 dys Wed 23.03.05 Tue 06.09.05

37 construction 6 mons Wed 23.03.05 Tue 06.09.05

38 cryo-controls 178 dys Mon 03.01.05 Wed 07.09.05

39 hardware 120 dys Mon 03.01.05 Fri 17.06.05

40 software 143 dys Mon 21.02.05 Wed 07.09.05

41 RF-Euquipment 60 dys Mon 11.07.05 Fri 30.09.05

42 RF and LL-RF 3 mons Mon 11.07.05 Fri 30.09.05

43 commissioning 60 dys Mon 31.10.05 Fri 20.01.06

44 first operation 3 mons Mon 31.10.05 Fri 20.01.06

May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan2004 2005 2006

First operation / commissioning: November 2005


X-FEL Cavities: Test Scheme

Fabrication

Preparation

CLR BCP/EP

Tank Welding

Coupler etc

100% Tests

CHECHIA

Optional Tests

?

DESY Site

Out of DESY

about 1000 Cavities production rate: 8 / week


Test -Schedule for Vertical Tests 4.5 K liquefaction loads Status: 27.1003 B.Petersen DESY -MKS-Time / h 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31AssemblyPump & Purge,leak checksCool down 300K->4.5 K 0 0Cryostat filling 50 50pump down 4.5K->2K 50 50measurement 1 cavity 20 20measurement 1 cavity 8 8 8 8measurement 1 cavity 8 8 8 8measurement 1 cavity 8 8 8 8warm up 2k -> 300K 8 8 8 8Dis-assembly

Single Cavity Test Schedule

4 cavities tested in 31 h -> 2 Cryostats +1


Horizontal Test (CHECHIA) Test Schedule

Test of one cavity : 8 – 12 d

-> 2 cryostats

optional


Cryomodule Test Schedule

Test of one cryomodule: 14 d

Production rate: 1/ week

-> 3 (+ 1) Test Benches

100% Test of all cryomodules


X-FEL Test Hall Layout

optional


Test Hall Layout


Cryogenic Supply

overall design average heat loads

10 KW at 40/80 K ( HERA CB 20 KW) 1 KW at 4.5 K (HERA CB 6.8 KW)

( 0.6 KW at 2K)+ 50 g/s liquefaction at 4.5K ( HERA CB 20.5 g/s)

4.5 K peak loads will be buffered by one 10 m3 storage dewar

no 2K helium distribution system

distributed warm helium pumping units10 g/s ( 20 mbar) at module test benches

20 g/s ( 20 mbar) at vertical dewars


RF components

5+1 10MV Klystrons

5+1 Modulators

waveguide distribution / circulators for 3+1 module test benches and 2 horizontal test cryostats

350 KW/ coupler


X-FEL Testhall: Staff profile

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0peration: 3 years after start of project


Summary

Industrial XFEL-cryomodule assembly studies are started now

A cryomodule test stand will be in operation end of 2005

XFEL-cryomodule test hall will start operation in 2009

x-fel cryomodule development

Documents

industrial assembly

design assembly changes

assembly costs

assembly of modules

present assembly procedures

bernd petersen desyat

bernd petersen desyobjectives

assembly proceduresclr