Infrastructure and Test Facilities in the U.S. Robert Kephart Fermilab

Work packages in this talk support: ILCTA test facilities @ FNAL Vertical and Horizontal test of Cavities: Determine the maximum operating gradient of each cavity Evaluate gradient spread, Q0 and their operational implications. Measure dark currents, cryogenic loads, and radiation levels. Test of Cryomodules: Measure gradient of cavities in cryomodules Measure vibration of components, system trip rates & recovery times Beam Based Measurements: Beam energy, stability, & energy spread Wakefield measurements, HOM based alignment & LLRF issues Goal: Are the cryomodules “good enough” for the ILC ? RF Activities @ SLAC & FNAL: Develop high power RF components for Main Linac Development of LLRF and multi-cavity control systems RF systems in support of ILCTA @ FNAL Fermilab Apr 4-6, 2006 ILC ART Review

ILCTA: ILC RF unit at Fermilab 08 09 07 Plan is to build one RF unit to be tested with Beam by 2009. 06 07-08 Fermilab Apr 4-6, 2006 ILC ART Review

Work Packages for this talk 5.8 5.8.1 1.3 GHz RF Power Source SLAC Adolphsen 5.8.2 ILCTA support SLAC Cassel 5.8.2.1 HA Modulator IGBT Switch array 5.8.2.2 ILCTA Cryo design 5.8.3 RF Power FNAL Nagaitsev 5.8.4 LLRF Controls FNAL Carcagno 5.9 5.9.1 Cavity Horizontal Test Stand FNAL Hocker 5.9.2 Cavity Vertical Test Stand FNAL Ginsburg 5.9.3 Cryogenics for test stands FNAL Theilacker Fermilab Apr 4-6, 2006 ILC ART Review

1.3 GHz RF Power Source Description (WBS 5.8.1) SLAC Build a 1.3 GHz RF 5 MW power source to test ILC RF components HV modulator that is on loan from SNS, 1.5 ms pulses at 5 Hz A 5 MW klystron High power RF distribution system (3 ATM N2 Gas) Epics based LLRF system Goal: Process developmental couplers and perhaps process production couplers for FNAL Test normal conducting positron capture cavity at NLCTA, including accelerating beam with them. Longer Range Goal: In the next few years, build and test ILC prototype klystrons and modulators, and by FY10, have six industry-built ILC prototype rf sources (modulator, klystron and controls) in operation (one unit to be used at FNAL to drive three cryomodules). Fermilab Apr 4-6, 2006 ILC ART Review

Status & Plans Status Plans Drove a Thales 2104U klystron with the SNS modulator 120 kV, 80 A, 5 Hz with 1 msec pulses In an initial rf test, produced 3 MW, 0.7 msec rf pulses at 5Hz Will receive a Thales 2104C tube in a few weeks for 5 MW operation Received parts from LANL to upgrade SNS modulator to drive the TH2104C and ILC prototype 10 MW klystrons Plans Complete system checkout with the Thales 2104U klystron Upgrade SNS modulator (test at 95 A and 130 A with a resistor load) Install the TH2104C klystron, complete waveguide runs to test areas, and process system with high power RF On track to finish 1.3 GHz Source in FY06 Fermilab Apr 4-6, 2006 ILC ART Review

1.3 GHz Source @ SLAC SNS Modulator Current RF source with isolator and load Thales 2104U Klystron Fermilab Apr 4-6, 2006 ILC ART Review

Modulator IGBT Switch Motivation Scope * Description: (WBS 5.8.2) SLAC Design, build, test and deliver two solid state switches for the Bouncer modulator operating at 10 kV and ~1800A peak. Project is SLAC contribution to ILCTA program. Motivation Improve reliability through solid state n/N redundant switch structure and redundant serial switches to protect klystron in case of switch failure. Scope WBS 5.8.1 WBS 5.8.2 * * Note that actual cost of IGBT is more like $ 172 K… see next slide Fermilab Apr 4-6, 2006 ILC ART Review

5.8.2.1 Progress FY06 Status Budgets Design 100% complete; fabrication and testing 75% complete. Awaiting delayed IGBTs delivery from vendor Delivery ~ 1 month after all parts received. Budgets SLAC funded one switch ($75K) in FY05 Later design requirements changed to two switches for redundancy, increasing engineering, fabrication cost estimate to $172K. Project on track to complete within re-estimate. Fermilab Apr 4-6, 2006 ILC ART Review

IGBT Switch Array Design Complete First Assembled Unit IGBT’s Gate Drive Board IGBT Stack 6” Plastic Stand-Off Diode Stack Aluminum Plate Fermilab Apr 4-6, 2006 ILC ART Review

RF Power (WBS 5.8.3) WBS 5.8.3: RF For ILCTA @ FNAL Purpose: RF Power (Modulator, Klystron, distribution system) for Horizontal & Vertical Test Stand and ILC cryomodule. Small RF System #1 for HTS/Capture Cavity II: Klystron = Phillips YK1240 ( 300 KW) Modulator = 600 KW LLRF = Simcon 2.1 ( More on this later) Status: System installed and operational in MDB RF has been applied to Capture cavity II System will move to HTS when this is ready Fermilab Apr 4-6, 2006 ILC ART Review

MDB: Small RF System # 1 Charging supply and Series Tube Modulator Klystron 300 KW RF Controls Fermilab Apr 4-6, 2006 ILC ART Review

RF Power (WBS 5.8.3) Large 10 MW Modulators (2 being built, ILC & PD): Klystrons = 1.3 GHz: Thales, CPI, or Toshiba Modulator = FNAL Bouncer type Status: Both modulators are being assembled 1:12 HV Pulse transformers have arrived Plans PD modulator in FY06 in MDB (325 MHz klystron) On track to install 1st large ILC modulator in ILCTA_NM (New Muon lab) in FY07 Modulator will be used to supply RF power for the test of the first U.S. built cryomodule (TTF type III) Fermilab Apr 4-6, 2006 ILC ART Review

Large Modulator Capacitor Frame 1:12 HV Pulse transformer For PD = 4.5 mS Capacitor Frame, Main Capacitors and Bouncer Capacitors: On site Bouncer Choke, High Voltage Stripline, and Bus: On Site High Voltage Resistors and Undershoot / Snubber Capacitors: On site Cabinets and First IGBT Switch from SLAC scheduled to arrive: April Fermilab Apr 4-6, 2006 ILC ART Review

Scope and Schedule FY06 Scope Status & Schedule Small RF system for HTS/Cap Cav II: done Big Modulators: PD in May 06, ILC in FY07 VTS RF system (small CW) in late FY06 Fermilab Apr 4-6, 2006 ILC ART Review

Low Level RF (WBS 5.8.4) Purpose: Develop LLRF for ILCTA test areas, work towards ILC LLRF system Stand alone RF systems for ILCTA: VTS, HTS, New Muon LLRF Capture Cavity II/HTS: FPGA based Simcon 2.1 LLRF system from DESY Master Oscillator & 8 channel timer designed at FNAL Status: System installed and operational in MDB RF has been applied to Capture cavity II System will move to HTS when this is ready Plans Develop multi-cavity control system for New Muon FNPL + cryomodule Evaluating Simcon 3.1 boards from DESY + alternatives Fermilab Apr 4-6, 2006 ILC ART Review

Stand-alone LLRF System The CC2 LLRF Portable Rack was commissioned at A0 and is ready to support CC2 operations VME Modules: Sparc CPU-56 running DOOCS and Matlab 8-Ch Timer Module (FNAL design) 8-Ch, 10 MHz fast digitizer (DESY design) 8-Ch Function Generator board (DESY design) Simcon 2.1 FPGA board (DESY design + commercial FPGA board) Drive Vector Modulator and Downconverter Vector Modulator/Mixer (New FNAL design, upgradeable to 3.9 GHz operation) Fermilab Apr 4-6, 2006 ILC ART Review

New DESY Simcon 3.1 Board 3 prototypes received from DESY Jan 06. This can control 8 Cavities from one Klystrons. Fermilab (AD, TD, CD) in collaboration with DESY and Poland are working on developing and debugging this new board. Expanding the collaboration on LLRF to include: UPenn, SLAC and INFN. Fermilab Apr 4-6, 2006 ILC ART Review

Scope and Schedule FY06 Scope Status & Schedule LLRF system for HTS/Cap Cav II: done LLRF for VTS: FY07 LLRF system for New Muon: FY07 Fermilab Apr 4-6, 2006 ILC ART Review

Vertical Test Stand (WBS 5.9.2) Our goal is to rapidly advance the intellectual understanding of SCRF surface physics and establish process controls to reliably achieve high gradient ( 35 MV/M) SCRF cavity operation Approach: Establish a “tight loop” processing and test infrastructure in the U.S. Tight loop elements: Cavity fabrication improvements ( e.g. single crystal) BCP & Electro-polish facilities High purity water and High pressure rinse Vertical test facilities SCRF experts & materials program to interpret results Vertical test facilities exist at Cornell and TJNL (bare cavities) These are being modified for near-term use by ILC R&D On a longer term ( 2007) new Vertical Test Stand (designed for 35 MV/M) cavity testing is being built at FNAL Fermilab Apr 4-6, 2006 ILC ART Review

ILCTA_VTS A Vertical Test Stand VTS is sited in IB1 because this building currently houses the Magnet Test Facility  large refrigerator capable of 60 W at 1.8 K Bare 1.3 GHz 9-cell Tesla-style cavities Measure Q vs. T and Q vs. Eacc 250 W (CW) RF power required at maximum gradient (Q=5x109, Eacc=35 MV/m) Installed in a vertical pit in the Floor Shielding against X-rays and Neutrons is an important issue for 35 MV/M cavities Maintain “Controlled Area” status in IB1 <5 mrem/hr immediately outside shielding <0.25 mrem/hr in normal working areas LHe & vacuum lines Industrial Building 1 Cornell Fermilab Apr 4-6, 2006 ILC ART Review

One or two 9 cell cavities VTS Status & Plans Cryostat Design Added phase separator to DESY design to improve He Quality Estimated RF duty factor possible based on IB1 cryogenic capacity Started cryogenics controls modifications Cryostat design in progress Radiation Shielding Estimated x-ray flux from DESY data Finalizing shielding design; prerequiste for finalized civil construction design Secure OK from Safety, then proceed with Civil work ~ 2 months RF & instrumentation Instrumentation design has begun Rack layout, etc Input coupler design will start soon VTS Civil Design One or two 9 cell cavities Fermilab Apr 4-6, 2006 ILC ART Review

VTS Scope & Schedule FY06 Scope: Schedule: Some costs will spill over to FY07. On track to have a Vertical Test System to test high gradient cavities at Fermilab in 2007 Fermilab Apr 4-6, 2006 ILC ART Review

Horizontal Test Facility Purpose: Verify dressed cavity performance (Eacc vs. Q0) to qualify cavities for assembly into a cryomodule Bare cavities that pass vertical test are “dressed” with LHe cryostat, coupler, & tuner then tested with RF pulsed power Usually referred to as “Horizontal Test” since this test is performed in this orientation at DESY in the Chechia facility Horizontal Test Systems (HTS) are under design for ILCTA_MDB (Meson Detector Building) and ILCTA_IB1 (Industrial Bldg 1) Bare 1.3 Ghz 9 cell Cavity Horizontal Test@DESY 4 cavities received from ACCEL 4 cavities on order at AES 2 cavities on order at TJNL 4 cavities expected from KEK Dressed Cavity Fermilab Apr 4-6, 2006 ILC ART Review

HTS (WBS 5.9.1) ILCTA_MDB HTS ILCTA_IB1 HTS Cryostat: Cryogenics: Accepts single “dressed” cavities, 1.3 GHz or 3.9 GHz Similar to the DESY HTS but has access at both ends. Cryogenics: MDB has an existing 1800 W @ 4 K cryogenic system New distribution system built to supply cavity test areas Large vacuum pump has been added to achieve 60 W at 1.8 K Cryogenic costs for this are in WBS 5.9.3 RF System: 300 KW klystron & modulator provides pulsed RF power Costs associated with RF system are in 5.8.3 ILCTA_IB1 HTS A second HTS will be built for IB1 Improved throughput (HTS is bottleneck @ DESY) Design improvements Accepts two 1.3GHz cavities simultaneously. Fermilab Apr 4-6, 2006 ILC ART Review

HTS Status & Plans ILCTA_MDB Phase I: Qualify six 3.9 GHz cavities for DESY TTF-VUV-FEL Phase II: Qualification and R&D for 1.3 GHz cavities for ILC Cryostat being fabricated at PHPK (Columbus, OH) Delivery date: 14-APR-2006 Cryo lines to cave installed, interface to cryostat (feed can) under construction Working 1.3 GHz RF system in MDB Operated daily (A0 Capture Cavity 2 testing) Gathering components for 3.9 GHz Fermilab Apr 4-6, 2006 ILC ART Review

HTS Scope and Schedule Scope Schedule Delivery of MDB cryostat in mid-April Connect to MDB cryo system and commission RF commissioning in parallel Ready for 3.9 GHz cavity testing by end June FY07: Construction of 2nd HTS in IB1 Exploits existing facility to increase cavity throughput Allows LLRF R&D on driving multiple cavities w/ one klystron Fermilab Apr 4-6, 2006 ILC ART Review

Cryogenics (WBS 5.9.3 & 5.8.2.2) HTS: WBS 5.9.3: Cryogenics for Test Stands @ FNAL Purpose: Develop cryogenic capability to cool cavities in Vertical and Horizontal Test Stands WBS 5.8.2.2: ILCTA Cryogenics Designer from SLAC Funded via SLAC core vs GDE provided funds HTS: Upgrade the existing 1800 W (4K) refrigerator system at the Meson Detector building at Fermilab to supply 60 W of 1.8 K refrigeration for the HTS Transfer lines extended from upstream locations to MDB Build and install Feed cans Install New Large Vacuum pump skid and associated plumbing and infrastructure Modify cryogenic controls Near-term Goal: Cool 1st 9 cell ILC cavity to 4 K (Cap. Cavity # 2) Next Goal: Achieve 60 Watt capacity at 2K by May 06. Fermilab Apr 4-6, 2006 ILC ART Review

Cryogenics VTS: Connect existing VTS to existing 60 W 1.8 K refrigerator system in IB1 for the HTS Modify existing IB1 LHe transfer and vacuum lines to connect to VTS top plate Must wait until LHC quad testing is complete (end of Apr) Modify cryogenic controls Goal: Achieve 60 Watt capacity at 2K to VTS by the end of FY06. Fermilab Apr 4-6, 2006 ILC ART Review

Scope and Schedule FY06 Scope Status & Schedule Current Labor is yyy FTE Status & Schedule Transfer line and feed cans: done Refrigeration connected to capture cavity # 2 Capture Cavity # 2 cooled to 4 K with RF power Vacuum Pump skid refurbished & installed Electrical, water, piping, controls in progress Plan: 2K capability to Cap Cavity # 2 in April Plan: 2K capability to HTS cryostat by June 06 Fermilab Apr 4-6, 2006 ILC ART Review

MDB Transfer Lines & feed cans This feed can was designed at SLAC and built at FNAL WBS 5.8.2.2 Fermilab Apr 4-6, 2006 ILC ART Review

Capture Cavity II Cold & RF power First 1.3 GHz TESLA Cavity in MDB Cold and RF power MDB Cryogenics 60 W @ 1.8 K He inlet Temp He Outlet Temp Cavity Pressure 25 MV/M @ 4.5 K Reasonable Dark Current Fermilab Apr 4-6, 2006 ILC ART Review

Vacuum Pump Connected in MDB Electrical Installation Mechanically Installed This is a BIG vacuum pump… 2 motors… total 300 hp! Fermilab Apr 4-6, 2006 ILC ART Review

ILCTA_NM Cryogenics ILCTA_NM: Installing Cryogenics, vacuum pump, plumbing, electrical infrastructure, laser room, controls, etc Plan to move FNPL photo-injector to New Muon in 07 Will provide ILC like beam to test cryomodules Building transfer lines, feed cans, etc. FY06: Funded from Fermilab “SCRF infrastructure” from “core” program funds at FNAL  ie not via GDE FY06 progress is limited by available cash Needs serious funding in FY07 Need to procure a new large refrigerator Will provide test of 1st U.S. built Cryomodule in 2007 Fermilab Apr 4-6, 2006 ILC ART Review

ILCTA_NM @ Fermilab New Muon Lab FNPL Photo-injector 11/05 Building a ILC cryomodule test area in the New Muon Lab (ILCTA_NM) Cleaning out building (Done) except for CCM Bid package out remove CCM Plan to move Photo-injector Work is in progress to install interim cryogenic solution in FY06 Will build part of the cryogenic distribution system in FY06 Funding  Can not start Cryomodule feed cans until FY07 Fermilab Apr 4-6, 2006 ILC ART Review

NML Heat xchanger & LN2 Dewar Fermilab Apr 4-6, 2006 ILC ART Review

Cryomodule end cans Delayed to FY07 ($$) Cryomodule Test at DESY TTF End Cans Fermilab Apr 4-6, 2006 ILC ART Review

Current Status New Muon Lab He storage tanks - 60% complete LN2 storage tank was refurbished Drawings and specification for Mycom piping contract - done PS-1 heat exchanger relocation – done Helium piping and purifiers bid package - 70% complete Designing test cave distribution system Cryogenic controls - 30% complete Budgetary estimate for the ILC CM feed and end caps – done PLANS Long Term goal is one ILC RF unit (3 cryomodules, modulator, 10 MW klystron, LLRF, etc by 2009 Fermilab Apr 4-6, 2006 ILC ART Review

Conclusions Our prime objective is to build and evaluate the components of the ILC main Linac Also we need to acquire experience & expertise in the U.S. on SCRF technology We are building extensive infrastructure at Fermilab and SLAC in support of these goals Cavity test facilities ( horizontal and vertical) High Power RF test systems LLRF test systems Cryomodule Test facilities ( including beam tests ) Significant Technical Progress in FY0506 Progress is limited by the available funding Fermilab Apr 4-6, 2006 ILC ART Review