SRF_BizPlan_31Oct2010_Rev_14 Production Preparations at JLAB JLab SRF Team EDMS – PLM DESY TeamCenter Meeting at SLAC 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Outline Strategy Preparations for LCLS-II Cavity Production at Vendors Preparations for Cryomodule Production at JLab Vertical Test Area (VTA) Horizontal Test Bed (HTB) Cavity String Assembly Cold Mass Assembly CMTF (Cryomodule Test Facility) Prototype, Acceptance and Commissioning Tests Issues / Challenges Summary EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Strategy – One Design, Two Production Lines Designs for Prototype and Production CMs Identical Prototypes - utilize as much existing hardware as possible to reduce schedule risk and reduce overall cost while achieving the same performance as the production CMs Identical Production Designs - utilize as much of the DESY/XFEL design as practically possible to reduce schedule risk and reduce overall cost Identical Parts Received at Partner Labs Well-developed drawing packages, clear requirements and specifications Concurrent reviews within LCLS-II project Procurement activities – lead technical contacts at Jlab/FNAL work together during all phases (SOTRs) Identical Tooling Interfaces Interfaces between CM hardware and tooling are identical Avoid adding custom features to CM Adapt non-CM hardware interfaces to Jlab-specific tooling Equivalent Processes yielding Equivalent Performance Recognize that some tools are different at each lab (e.g. HPR, vertical testing systems, vacuum leak checking equipment, etc.) Monitor key process variables in consistent fashion (e.g. samples to verify etch rates) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Preparations for Cavity Procurement Approach – procure dressed cavities processed with high-Qo recipe from multiple vendors Niobium to be purchased and provided to cavity vendors FNAL leads niobium procurement activities and is developing spec Capture best-available high-Qo process to be included as part of cavity specification Three-lab collaboration proceeding with development Cavity procurement activities led by JLab Need well-developed drawing packages, clear requirements and specifications XFEL specification is considered point-of-departure Need to define level of oversight at cavity and component suppliers to ensure performance Reviewing acceptance criteria, processing steps and hold points (where necessary) Lead technical contacts at Jlab/FNAL work together during all phases (SOTRs) JLab/FNAL/SLAC involved during evaluation of offers EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Cavity Procurement – High Level Comparison SNS – 81 bare cavities, 2 types, 1 supplier Niobium supplied to vendor Reactor-grade end groups required post-purification by JLab No performance guarantee; Vendor needed to demonstrate that proscribed manufacturing process was followed Visits to vendor to monitor progress C100 – 85 bare cavities, 1 supplier Niobium procured by vendor Received with bulk BCP and initial tuning No performance guarantee; Vendor needed to demonstrate that proscribed manufacturing process was followed Visits to vendor to monitor progress XFEL – 800 dressed cavities, 2 suppliers Multiple niobium procurements Receive ready for vertical testing Performance guarantee? Availability and use of in-process data? Support at vendor’s facility? EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 CM Production Preparations Adapt existing infrastructure to accommodate LCLS-II components, sub-assemblies, final assembly and testing Define processes required for component handling, assembly and testing Develop test plans – key activities are cavity qualification from vendors and cryomodule acceptance testing Employ SRF QA Tools used for 12 GeV 100 MV CW cryomodules (aka C100) production and SNS production EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Vertical Test Area / Horizontal Test Bench VTA Up to four test stands available for production acceptance testing capable of testing one cavity at a time Utilize same cavity hardware (test flanges, feedthroughs, etc.) provided by project to cavity suppliers Small modifications required to existing supports Ensure low magnetic field environment (“magnetic hygiene”) HTB Plan to conduct five tests during production effort to provide feedback on cavity assembly process or for production development activities Modifications to top hat for XFEL-style FPC and small modifications to existing supports EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Cavity String Assembly in Clean Room “Lollipop” supports for each cavity TBD for SC magnet and bpm Use mobile rail system rather than rail-in-floor used at DESY, CEA/Saclay and FNAL Transfer to CM assembly rails for cold mass assembly EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Cold Mass / VV Assembly “Lollipop” supports for each cavity TBD for SC magnet and bpm Use two-rail system to transfer cavity string onto Return Pipe Use two-rail system to transfer cold mass into vacuum vessel Crane access in high-bay for shipping EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 CMTF HPRF system suitable for individual cavity testing or 8 cavities in short duration steady state TBD system for testing SC magnet Magnetic shielding encloses testing volume reducing external fields to ~50 mG Cryogenic capacity for testing individual cavities in CW mode End Caps – specific for LCLS-II CM testing Interface to CM piping and existing junction box using u-tubes EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 CM Testing Three types of CM testing should be considered: Prototype Testing that may include additional (non-routine) activities for system verification Acceptance Testing in CMTF includes some CMTF-specific checks CMTF procedures may vary from in-tunnel procedures HP RF equipment may not be identical Commissioning Tests in-situ may include tests that Require additional equipment (Network Analyzer) Verify RF zone operations (EPICs controls, Klystrons, etc.) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Comments on Prototype Testing Testing Facility (CMTF) Checks Electrical, water, cryo, controls, LLRF, HPRF, Data acquisition Includes collection of tests envisioned for production CMs Both Low Power and High Power Includes specific tests that may verify CM performance, but might not be conducted on all CMs FPC Qext range vs. CM heat load Detailed microphonics studies LLRF development activities EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 C100 CM Production : LP RF Tests* *Major Steps taken from C100 Low Power RF Test Traveler Cavity ID's Warm Frequencies Mechanical Tuners: Tuner Range and Hysteresis Cold Frequencies including pass-bands and loaded Q’s Mechanical Tuner Resolution Piezo Tuner Range and Hysteresis Piezo Tuner Resolution Piezo Tuner Impulse Response Microphonics Mechanical Mode Measurements HOM Coupler Qext's and HOM Survey Cavity Detuning for Warm up EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 C100 CM Production : HP RF* *Major Steps taken from C100 HP RF Traveler Checklist Qext's, FPC's and HOM's Maximum Gradient Determination (Emax) Extended (One Hour) Run (Emaxop) Field Emission Measurements Qo Measurements / Static Heat Load - Primary Circuit Pressure Sensitivity Measurements Static Lorentz Measurement Swept AM Lorentz Transfer Function EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 C100 CM Production : HP RF Checklist Record Cavity ID #’s Calibrate RF Cables Verify Interlocks Arc Detectors / IR Sensors Beamline / Waveguide Vacuum G-M Tubes Inspect waveguide connections Inspect Heliax cable connections Verify Personnel Safety System (PSS) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 C100 CM Production : Testing in Tunnel* *Major Steps taken from C100 Commissioning Traveler Low Power RF Initial Cold Frequencies Cavity Tuning Final Cold Frequencies and Passbands HOM Measurements Interlock Checkout High Power RF Emax Determination: Qexts and Probe Calibrations Emax Determination: Emax Emaxop Determination (One Hour Run) Field Emission Survey Qo vs. Eacc Measurements Static Heat Load Microphonics Eight Cavity Run (at low duty cycle) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 LCLS-II CMs will be shipped from partner labs to SLAC using shipping fixture on flat-bed trailer with cover Plan to use identical shipping fixtures and covers as for XFEL Design verification can be accomplished with the first article LCLS-II cryomodule. Instrument cavity string, quadrupole, piping and vacuum vessel with triaxial accelerometers to measure shock attenuation and vibration isolation during transport Evaluate performance before / after simulation of loading and shipping environment RF performance Static heat loads Alignment Shipping Method Shipping Covers - provide hermetic seal and piping support XFEL CM Shipping Fixture Aeroflex Isolator - wire rope spring provides triaxial shock attenuation and vibration isolation EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Issues / Challenges Defining level of oversight at cavity and component suppliers Defining acceptance criteria and hold points where necessary at cavity and component suppliers Defining requirements for niobium inspection – e.g. correlating eddy current scanning to cavity performance Goal for production of CMs at Jlab/FNAL is “identical design, identical parts, equivalent processes to yield equivalent performance” Developing coherent QA plan with appropriate QC systems across project partner labs Developing travelers for CM production lines at two labs that utilize equivalent processes “local customization” Availability of XFEL design information and production QA tools as point of departure for LCLS-II design Success-oriented schedule Others? EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014
SRF_BizPlan_31Oct2010_Rev_14 Summary Goal for production of cavities at vendors is “identical design, identical parts, equivalent processes to yield equivalent performance” Goal for production of CMs at Jlab/FNAL is “identical design, identical parts, equivalent processes to yield equivalent performance” Need to identify appropriate QA tools to use during vendor production and lab CM production EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014