1 P. Bosland - Audit WP5 10 th of December 2015 Lund Annual audit for WP5 Elliptical cryomodules Prototype cryomodule M-ECCTD Prototype cryomodule H-ECCTD 9 medium beta serial CM - 36 cavities 21 high beta serial CM - 84 cavities P. Bosland WP5 leader C. Darve Deputy WP5 leader

2 P. Bosland - Audit WP5 10 th of December 2015 Lund Two prototype cryomodules M-ECCTD with medium beta cavities - tested in December 2016  FR-SW agreement  Collaboration IPNO and IRFU H-ECCTD with high beta cavities - tested in October 2017  French In-kind contribution IPNO in charge of the cryostat – design and fabrication Vacuum vessel Space frame – cavity supports Thermal screen Superinsulation Internal cryogenic pipes Instrumentation IRFU in charge of the “cavity package”, the cryomodule assembly and RF power tests: Cavities + helium tank Power couplerdesign, manufacturing, RF tests Piezo tuner Magnetic shield Tooling: field flatness, cavity preparation, cryomodule assembling, … Cryomodule assembly Tests stand for cryogenic and RF power tests Tests of the ECCTD cryomodule FR – SW agreement

3 P. Bosland - Audit WP5 10 th of December 2015 Lund Framework of the cryomodules development and production 2.Two prototype cryomodules: 1.medium beta: M-ECCTD<= FR-SW agreement 2.High beta:H-ECCTD<= CEA FR In Kind Contribution 2.Production of cavities of the series with RF tests: 1.medium beta cavities<= LASA - IT In Kind Contribution 2.High beta cavities<= STFC - UK In Kind Contribution 3.Production of all other components:<= CEA FR In Kind Contribution (including coupler production with RF power processing) 4.Cryomodule assembling :<= CEA FR In Kind Contribution 5.RF power tests of the cryomodules <= ESS Lund 1.Facilitate the collaboration with LASA and STFC for the cavities production 2.Keep the link with IPNO for the cryostat components

4 P. Bosland - Audit WP5 10 th of December 2015 Lund Status of the prototypes M&H-ECCTD Engineering studies completed Fabrication of the components in progress Assembly infrastructure and procedures Preparation of the 2 test stands for coupler processing & cryomodule tests

5 P. Bosland - Audit WP5 10 th of December 2015 Lund Cryomodule & main components  Similar to CEBAF/SNS cryomodule concept with 4 cavities per cryomodule  Common cryomodule design for medium and high beta cavities 5 cells high beta (0,86) cavity 6-cells medium beta (0,67) cavity MediumHigh Geometrical beta Frequency (MHz) Maximum surface field in operation (MV/m) 45 Nominal Accelerating gradient (MV/m) Nominal Accelerating Voltage (MV)14,318,2 Q 0 at nominal gradient> 5e9 Cavity dynamic heat load (W)4,96,5 Power Coupler (HIPPI type coupler) Diameter 100 mm 1.1 MW peak power Antenna & window water cooling Outer conductor cooled with SHe Doorknob transition equipped with a bias system Cold Tuning System (Saclay V5 type modified for ESS cavities) stepper motor + gear box at cold Max tuner stroke: ± 3 mm Max tuning range: ~ 600 kHz Tuning resolution: ~1 Hz 2 piezo stacks Cavities without HOM coupler

6 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

7 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

8 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

9 P. Bosland - Audit WP5 10 th of December 2015 Lund Last vertical test of cavity P01 after correction of the magnetic shielding coils current  Résultats des tests faits ce jeudi si présentables !

10 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

11 P. Bosland - Audit WP5 10 th of December 2015 Lund Production of components for the M-ECCTD Focus on the medium beta cavities and power couplers

12 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

13 P. Bosland - Audit WP5 10 th of December 2015 Lund 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%

14 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

15 P. Bosland - Audit WP5 10 th of December 2015 Lund 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)

16 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

17 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

18 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

19 P. Bosland - Audit WP5 10 th of December 2015 Lund 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)

20 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

21 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

22 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

23 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

24 P. Bosland - Audit WP5 10 th of December 2015 Lund Power test stand for RF power processing of coupler pairs Procurement of the frame in progress

25 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

26 P. Bosland - Audit WP5 10 th of December 2015 Lund (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 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

27 P. Bosland - Audit WP5 10 th of December 2015 Lund 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).

28 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

29 P. Bosland - Audit WP5 10 th of December 2015 Lund Assembly process inside the clean room

30 P. Bosland - Audit WP5 10 th of December 2015 Lund Assembly process outside the clean room The bôth for the cryomodule assembly is almost ready

31 P. Bosland - Audit WP5 10 th of December 2015 Lund Assembly process outside the clean room

32 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

33 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

34 P. Bosland - Audit WP5 10 th of December 2015 Lund Assembly of the series cryomodules inside the XFEL infrastructure See first analysis of the installation of the equipments for assembly in the XFEL clean room for the ESS cryomodules

35 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

36 P. Bosland - Audit WP5 10 th of December 2015 Lund | PAGE 36 CEA Saclay/Irfu projet ESS | DATE CEA ESSI Organisation Project Management office

37 P. Bosland - Audit WP5 10 th of December 2015 Lund The team for the cryomodules activities at Saclay A total of ~150 FTE (CEA staff) estimated for all the CM activities at Saclay + Industry team for the assembly Total team for the CM assembly ~15 persons (CEA + industry)

38 P. Bosland - Audit WP5 10 th of December 2015 Lund 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

39 P. Bosland - Audit WP5 10 th of December 2015 Lund 1 st April 2015TAC1139 M-ECCTD CDR review decision H-ECCTD CDR review decision 2) Power couplers contract awarded RF power source ready for coupler processing Cryomodule components contract awarded Planning Ready For Installation OK with ESS schedule: 03/09/18 => 02/05/19 1CM/month Planning Ready For Installation OK with ESS schedule: Q1 + Q2 2021: installation of HBL n° 1 to 11 Q1 + Q2 2022: Installation of HBL n° 12 to 21 Overall WP5 planning 1) Mb cavities contract awarded 1) Hb cavities contract awarded

40 P. Bosland - Audit WP5 10 th of December 2015 Lund 1 st April 2015TAC1140

41 P. Bosland - Audit WP5 10 th of December 2015 Lund 41 Future work Finalize and test the medium beta prototype cryomodule  cavities & couplers reception & test  assembly with new toolings in a new clean room  RF power test stand to complete at Saclay Realize and test of a high beta prototype cryomodule Prepare the production of the 30 series cryomodules  Production of the cavities INFN Milano: 36 medium beta cavities STFC Daresbury: 84 high beta cavities  Production of the cryostat components  Prepare the assembly infrastructure at Saclay after the XFEL cryomodules assembly

42 P. Bosland - Audit WP5 10 th of December 2015 Lund Thank you for your attention