ILCTA_IB1 Infrastructure Analysis for multiple VTS (Preliminary – Work in Progress) Presented by: Ruben Carcagno Analysis team: Ruben Carcagno, Camille Ginsburg, Yuenian Huang, Arkadiy Klebaner, Joe Ozelis, Tom Peterson, Clark Reid, Cosmore Sylvester September 28, 2006

IB1 Infrastructure Analysis for Multiple VTS Motivation Cavity yield increase identified as a top ILC R&D priority (S0 goal) during 2007-2009 Requires large quantity of vertical test cycles (hundreds per year) to be performed in all three regions How many vertical test cycles can be supported in ILCTA_IB1? At what cost? Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS Single VTS Throughput The VTS under construction at ILCTA_IB1 can accommodate up to two ILC cavities per test cycle Expected to start operation in mid-2007 Throughput Assumptions: Single shift operation Cavity arrives hermetically sealed 120 °C bakeout done prior to IB1 delivery “Production” Q vs. E test only (e.g., no 8-hr pause at 100K during cooldown to determine degree of H contamination (Q-disease)) Two cavities in a VTS cryostat Only one RF ON cavity test at any given time Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

Unconstrained Test Cycle Schedule (Nearly) Unattended Operation ~ 28 hours Attended Operation ~ 11 hours TOTAL (unconstrained) ~ 39 hours Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS Adding Constraints Shift Operations 11 hours of attended operations require a minimum of 23 hours because of 12-hour pause between 8-hour shifts Inefficiencies (idle time due to shared resources, equipment availability, troubleshooting) Add ~ 24 hours Total Test Cycle ~ 75 hours or ~ 3.12 work days for two cavities. Assuming 8 work weeks of maintenance and other facility down time per year: Single VTS throughput ~ 70 Test Cycles per year, with up to two cavities per cycle (140 cavity tests) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

How to (quickly) increase throughput? Two additional VTS stands can be added to the IB1 facility by relocating the ILCTA_IB1 Horizontal Test Stand (HTS) planned for FY07 to ILCTA_MDB. Throughput can increase to ~ 3x140 = 420 cavities per year by mid-2008 Some throughput increase might be possible by adding shifts and removing inefficiencies Substantial additional throughput increase only possible by building modifications and/or a building addition. Cryogenic capacity becomes a limiting factor (tie-in to CHL after Tevatron shutdown?) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

Phased Approach for a Vertical Cavity Test Facility (VCTF) Phase I Complete VTS under construction by mid-2007 Phase II Add two more (nearly) identical VTS stands by mid-2008 Phase III Add one or more high-throughput VTS stands in a modified or new building addition with tie-in to the Central Helium Liquefier (after 2009 and the Tevatron Shutdown) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS IB1 SRF Test Area Layout Vertical Test Area (FY06) (Bare Cavities) Existing Cryo Piping Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS IB1 Layout for Phase II Trench for cryo piping Door Radiation Lid “park” area Stairs Additional VTS Vertical Magnet Test Facility (VMTF) Staging Area VTS under construction Tie-in to test stands cryo distribution box Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Considerations The IB1 Test Facility shares cryogenics and people with a very active Magnet Test Facility (MTF) It is essential to decouple cryogenic operations between MTF and the Vertical Cavity Test Facility (VCTF) There should be adequate cryogenic resources available to sustain both MTF and VCTF test programs. This includes both LHe inventory and pumping capacity for superfluid operation Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

Infrastructure Requirements Add a third vacuum pump to increase pumping capacity from 6 g/s at 20 Torr to at least 10 g/s Add a compressor/purifier at the outlet of the vacuum pump system to mitigate contamination risk Add more GHe storage capacity to store the entire LHe inventory as gas Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

Current Plan for single VTS integration to IB1 Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

Multiple VTS Integration to IB1 Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS How much pumping? For baseline E = 35 MV/m, Q0 = 1010 the power dissipation is: Substantial margin is needed to continuously operate at higher gradients and/or lower Q. Constraints: JT Heat Exchanger and Pumping Capacity (6 g/s at 2 K) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

JT Heat Exchanger Pumping Limit With the current VTS JT Heat Exchanger design, practical limit for 2K operation is around 8 to 10 g/s due to excessive shellside pressure drop Taking into account flashing losses at the JT valve, up to 200 Watts can be removed with a continuous supply and pumping of 10 g/s To remove more than 200 Watts (10 g/s pumping) continuously, a redesigned JT Heat Exchanger must be used in future VTS. This may require an adjustment to the cryostat (and pit) diameters. We recommend using 160 Watts (8 g/s pumping) as the practical limit for continuous 2K operation of the current VTS design. Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS IB1 Pumping Capacity Installed: 6 g/s at 20 Torr Kinney Pump I: 4 g/s Kinney Pump II: 2 g/s Need more pumping: Margin for higher gradients and/or lower Q continuous operation Simultaneous operation of superfluid magnet test and cavity test Preferred option: a new, dedicated, large (13 g/s) vacuum pump for VTS stands. Use existing pumps for magnet testing. Alternative option: add a third pump (4 g/s or larger) and share all three pumps for both magnet and cavity testing (requires a valve manifold to easily allocate and share pumping capacity to different test stands) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS Compressor/Purifier Contamination is already one of the largest reason for IB1 cryo system unscheduled downtime and loss of efficiency Addition of sub atmospheric test stands will make this problem worse Need a high pressure compressor and purifier skid to remove all contamination at the outlet of vacuum pumping system (like the one recently installed at ILCTA_MDB). This is a high-priority item, even for only one VTS stand. Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS LHe Inventory IB1 cryo system LHe make rate: ~ 250 l/hr (9 g/s) VTS LHe consumption per test cycle: ~ 2,000 l (equivalent to 27 l/hr for a 75-hr test cycle) For three VTS stands operating continuously: 3x27 = 81 l/hr On average, there is still ~ 170 l/hr LHe make rate available to support magnet testing. Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS IB1 LHe and GHe storage A 10,000 liter He dewar stores up to 7,000 liter of LHe Three 30,000 Gallon GHe tanks store up to 3,900 LHe equivalent He gas (only 55% of LHe inventory capacity) Need two more 30,000 Gallon tanks to store the majority of LHe inventory as gas Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS IB1 FY07 Test Schedule and Civil Construction (Window during Feeder 47 and Cryo Maintenance Upgrade April-May 07) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS : Magnet Dept. Support : SRF Dept. Support : IB1 Maintenance : New development needed for test

Preliminary M&S Cost Estimate Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS

IB1 Infrastructure Analysis for Multiple VTS Project Challenges Aggressive schedule (Phase I ready by mid-2007, Phase II by mid-2008) Must minimize disruption to the Magnet Test Program Requires experienced resources outside of T&I department (e.g., AD-Cryo, FESS) Must be a Laboratory High Priority Project Requires adequate funding Schedule-driven nature of project dictates need to procure turn-key skids from industry as much as possible (e.g., Compressor/Purifier, Kinney Pump) Ruben Carcagno IB1 Infrastructure Analysis for Multiple VTS