1 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Status of the prototype M-ECCTD and high beta prototypes M-ECCTD: Engineering studies completed Fabrication of the components in progress First bare Mbeta cavity delivered – 5 last ones to be completed Assembly infrastructure and procedures Preparation of the 2 test stands for coupler processing & cryomodule tests Hbeta cavities prototypes: Good performances of cavities during first tests Q0 decrease during the last tests in VC is still to be understood HOM issues understood. Close follow-up of the cell shape applied for the next Mbeta prototypes manufacturing

2 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Volumes of the helium circuits and vessels < 48 l bara < Working pressure Ps = 1.04 barg TUV Nord analysis report: The elliptical and Spoke cryomodules are classified according to PED article 3.3 Cryo pipes designed to reduce the overpressure in case of beam vacuum failure continuous diphasic pipe Ø=100 with large curvatures 2 Ø=100 bursting disks at each extremity Compliance with European Pressure Equipment Directive (PED) 97/23/EC

3 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Layout of the cryogenic circuits SV relief valve P<1,1bara Scale of pressures of the cavities vessels the SV relief line is at 1.1bara (worst case) A PLC controlled valve at 0,5bar is needed Maximum operating pressure 0.43barg

4 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Vertical Tests of two β0.86 prototype cavities Both prototype cavities met the ESS requirements after the first test. Slight degradation (pollution) of performances after 600°C heat treatment for hydrogen removing : => Tests performed in a second vertical cryostat with problems of magnetic shielding that could explain this degradation. Analysis in progress P01 - E. ZANON P02 - RI LHe tank welding: no frequency shift measured and no field flatness modification P01 with LHe tank welded after heat treatment

5 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Dangerous HOM close to MHz 704 MHz 1421,32 MHz Both high beta prototype cavities are not conform with the ESS HOM Requirement Reminder: “All higher order modes (HOMs) shall be at least 5 MHz away from integer multiples of the beam-bunching frequency ( MHz) for any HOMs whose resonant frequencies are below the cut-off frequency of the beam-pipe” Design (at 300K) Measured on ESS086-P01 Calculated with measured shape (HFSS) Measured on ESS086-P02 Calculated with measured shape (HFSS)  3D measurements of the cavity shape have been performed  Shape reconstructed in the simulation software HFSS The strong internal shape deviation close to the equator > 1 mm explains very well the frequency decrease of the two dangerous HOMs. Special care on the cavity cells shape has to be taken for the next cavities Slater coefficient analysis which represents frequency sensitivity to volume changes

6 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Production of components for the M-ECCTD Focus on the medium beta cavities and power couplers

7 P. Bosland - SRF Collaboration 15 December 2015 Daresbury First medium beta cavity delivered After weldingExpectedMeasured Length [mm] Frequency ( π -mode) [MHz] ModeFrequency [MHz] π π/ π/ π/ π/ π/ Visual inspection of the welds inside the cells at the equator: no significant defect

8 P. Bosland - SRF Collaboration 15 December 2015 Daresbury HOM and field flatness Most dangerous HOM identified At delta F >17MHz from the 5 th beam line (The cavity is as received before field flatness correction) Bead pull measurements of the field flatness: 56%

9 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Planning of the activities on the Mb cavity: Week 48: magnetic field map measurements of the vertical cryostat and correction of the magnetic shielding of the cryostat (adjusting the current of the coils and adding a magnetic shield around the cavity) Week 49: Cavity tuning and field flatness Weeks 50 and week 1 (2016): BCP Weeks 2 & 3: tests in vertical cryostat

10 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Production of six beta0.67 prototype cavities All Dumbbells and end groups are completed and frequency measurements performed Helium tank prepared for welding Once the 1st cavity is approved by CEA, Zanon can deliver one bare cavity every 2-3 weeks. Release of the production of the cavities of the series: after tests in VC (end of January)

11 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Production of the power couplers 8 ceramic windows and antennas: Toshiba 6 external conductors: Sominex 8 doorknobs: Sominex (4) and PMB (4) 3 coupling boxes: Sominex RF conditionning stand (frame, pumps and toolings) Electron pick-ups

12 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Frequency: MHz Peak power: 1.1MW Pulse length: 3,1 ms F=14Hz Cooling systems:  external conductor: SHe at 3bars & 4,5K  Ceramic window: air or water  Antenna: water Bias voltage can be applied to the antenna (10kV max) Diagnostics  Electron pickup (RF measurements can be made)  2 arc detectors (air side + vacuum side)  Vacuum gauge Coupler characteristics SHe cooling Antenna bias voltage Vacuum gauge Window for arc Detectors Ceramic cooling Antenna water cooling Electron Pick-up SHe cooling

13 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Ceramic windows at Toshiba Difficulties for brazing the ceramic windows (chockes not within the tolerances) brazing of 8 ceramic windows failed (2 brazing operations with 4 ceramics) 2 last ceramic windows brazed – small deviations of the chockes dimensions slightly out of tolerances – analysis of the consequences before acceptance (beginning of January 2016 TBC) Vacuum gauge Cooling of the ceramic, Pipe connector, Arc detector window

14 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Ceramic windows at Toshiba Analysis of the S 11 parameters for different chocke defects Design of the coupler +/- 0.05mm Measurement of the chocke-ceramic gaps The effect on the S 11 parameter of the gaps is acceptable. Vacuum side (external/internal choke) Air side (external/internal choke) Nominal3.15/3.15 (mm) Proto 13.01/2.98 (mm)3.31/3.38 (mm) Proto 23.13/3.11 (mm)3.24/3.33 (mm)

15 P. Bosland - SRF Collaboration 15 December 2015 Daresbury External conductors Next main step: the copper coating = main issue for the fabrication of the tube first samples coated for tests were rejected Next samples should be received this week … The 6 tubes should have been delivered before the end of A new planning should be given on the 10th of December (visit at Sominex for the follow-up) He circuit in the double wall with a chicane

16 P. Bosland - SRF Collaboration 15 December 2015 Daresbury RF trap Arc detector at the air side of the ceramic window kapton electrical insulator Doorknobs 2 factories in charge of the fabrication of a total of 8 doorknobs: Sominex (4 delivered mid of January 2016) and PMB (4 delivered mid of February) The main “difficulties”: Fabrication: tight tolerances on the geometry Kapton insulator to be fitted between the inner conductor and the knob. Discussion with one of the manufacturer to use another insulator (PEEK) – an analysis of this alternative is in progress at Saclay RF contacts of the RF seals Inner conductor Knob

17 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Tested part RF seal spring Doorknobs A mockup of the RF trap was manufactured with the 5 RF seals: Check of the mounting procedure Definition of the sealing grooves Behavior of the RF seal during the mounting and dismounting operations

18 P. Bosland - SRF Collaboration 15 December 2015 Daresbury 3 coupling boxes for RF processing Arc detectors Fans 8 weeks delay of the delivery of the raw material (error in the dimensions of the first delivery !) Should have been delivered in January Discussion to get a first box mid of February

19 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Production of the main components and the toolings is in progress M-ECCTD cryostat components - Spaceframe: July Vacuum chamber: December -MLI of the thermal shield: November - MLI of the cold mass: Beginning of February Bellows of the couplers:November - Thermal screen:Delayed in January Diphasic tube:May Cryo pipes:Procurement started in November - Tubes for rupture discs:procurement to be launched - Helium heat exchanger:Delivered - Helium valves:Delivered - Instrumentation: part is delivered

20 P. Bosland - SRF Collaboration 15 December 2015 Daresbury (N 2 ) Assembling of the cavity string with a N2 flow for protection against dust particles The detailed study of the assembling procedures is in progress. XFEL cryomodules assembly lessons learn applied, QA process Preparation of the assembly of the cryomodules of the series (QA) Welding the titanium diphasic tubes The cavity string is inserted in the spaceframe already eaquipped with the thermal shield Closing the vacuum Assembly of the M-ECCTD

21 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Moving to the post clean room assembly site Clean room Bôth assembly area  The clean room and the post clean room assembly area are not in the same building  Few hundred meters between the two buildings  The cavity string installed on the previously described post clean room support shall be transfered from one place to an other using the XFEL automotive carrier No shock absorbers on the automotive carrier Design of a frame with damping system Is the maximum allowable acceleration a sufficient requirement to design the frame? Need of a spectrum (frequency, amplitude)? It is planned to perform a test transfer with a representative mass of the string assembly to get information (acceleration, frequency, amplitude).

22 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Leaving the clean room  40 cm step between the floor of the clean room and the floor of the hall  Transfer the cavity string from the clean room cart to another support for the post-clean room assembly Alignment constraints between the rails of the clean room cart and the rails of the post clean room support: 0.1 mm  The loaded post clean room support shall be manipulated with a crane -> mechanical constraints on the design

23 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Assembly process inside the clean room

24 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Assembly process outside the clean room The bôth for the cryomodule assembly is almost ready

25 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Assembly process outside the clean room

26 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Example of assembling procedures in preparation See the example of the coupler preparation in clean room for the RF processing: t raining with real components of geometry close to the final one

27 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Tests station at Saclay

28 P. Bosland - SRF Collaboration 15 December 2015 Daresbury

29 P. Bosland - SRF Collaboration 15 December 2015 Daresbury RF power test stations at CEA Saclay 704 MHz RF Plateform Pilot Switch RF Security box water C/C Water vacuum Safety RF Fast acquisition (RF signals, electron pick-up, arc detector by photomultipliers) + slow acquisitions (vacuum…) Signals for fast interlock Coupler Conditioning Security box C/C Water Vacuum Cryo safety RF ESS Cryomodule (ECCTD+ pre-series) Security box C/C Klystron: 704 MHz 1 MW Modulator HT 110 kV Circulator + load waveguides Supratech Cryogenic system Manual switch

30 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Assembly of the series cryomodules inside the XFEL infrastructure Preparation of the industrial assembly in 3 steps: 1.First draft of the analysis (present analysis) 2.Contract for the industrialisation process analysis 3.Contract for the assembly of the cryomodules of the series Clean room Bôth assembly area XFEL Village

31 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Production of the components of the series (except cavities) CEA in charge of all the procurement of the cryomodules except the cavities Most challenging = power couplers with RF processing at Saclay Urgent: procurement of the RF power source at 704MHz 1.5 MW. 3 call for tenders: 1.KlystronCall for tender already launched 2.ModulatorCall for tender already launched 3.Complete RF power source Call for tender launched end December Offers opened on the first week of February Spares for all components production?

32 P. Bosland - SRF Collaboration 15 December 2015 Daresbury The collaboration with LASA and STFC started KO meeting at Saxclay: 23 June rst meeting at LASA: 2 nd November nd meeting at STFC: 15 th of December (With Sebastien) Weekly visio meeting on Friday morning (10H30) The 1 rst objective is to freeze the cavities design and interfaces: first requests from LASA for modifications were sent to Saclay. CEA needs to analyse the impact on the cryomodule design and on the toolings before approval. See presentation of the interfaces of cavities - KO meeting at Saclay

33 P. Bosland - SRF Collaboration 15 December 2015 Daresbury First meeting at LASA about the medium beta cavity 2 nd of November 2015 Main proposal for changes of the prototype drawings by LASA:  Change on the cavity axis referenced to the equator and not to the irises <= accepted  Relax some tolerances of the cavity beam flanges referenced to the cavity axis <= OK for some, not for others – to be discussed  Tolerances on overall length: +/- 3mm after tuning  sliding system for an easier adjustment of the helium tank length  SS/Ti bimetallic joint for Lhe filling line  2 phases pipe: temporary tooling to avoid the two phases pipe bending Analyze in progress

34 P. Bosland - SRF Collaboration 15 December 2015 Daresbury Thank you for your attention