1. WP 11.5.3: High-Beta Cavity Delivery
A Wheelhouse ASTeC, STFC Daresbury Laboratory
ESS SRF Elliptical Cavities Collaborations Meeting
INFN Milan
20th May 2016

2. Outline Delivery Schedule Infrastructure Quality Assurance Summary
Scope
Delivery Plan
Risk Register
Infrastructure
Cleanroom
Shielding
Cryogenic Plant
Cryogenic System
RF System
Quality Assurance
Summary

3. Outline Delivery Schedule Infrastructure Quality Assurance Summary
Scope
Delivery Plan
Risk Register
Infrastructure
Cleanroom
Shielding
Cryogenic Plant
Cryogenic System
RF System
Quality Assurance
Summary

4. Scope
Niobium procurement: STFC to procure the high RRR Niobium for the high-β elliptical dressed cavities in agreement with the SRF collaboration for the ESS linac.
Cavity fabrication of the 84+4 spare high-β elliptical dressed cavity in industry including:
Cavity fabrication.
Chemical processing.
Heat treatment.
Vacuum processing.
Procedure Qualification and Training:
A qualified test procedure to be developed and implemented.
A QA/QC system for individual tests in accordance with ESS policies.
Trial tests to be performed and performance targets verified.
Staff training in procedures and processes.
High pressure rinsing.
Field flatness and frequency tuning.
Assembly of RF antenna and isolation valve in cleanroom.
Shipment of dressed cavities to STFC.

5. Scope (Cont) Vertical Test (VT) of SRF cavities:
VT stand to be qualified to meet ESS cavity requirements including new cryogenic and RF system, along with a suitable controls system.
A QA/QC system for individual tests in accordance with ESS policies.
Testing of the high-β dressed cavities to 22.9 MV/m at 704 MHz, with a Qo better than 5 x 109.
Documented test results provided to ESS.
Preparation and shipping of cavities to cryomodule integration site:
STFC to design and procure shipping fixtures for SRF dressed cavities for transport from industry.
STFC to transport SRF cavities from STFC to the cryomodule integration site.
STFC to support transport cost in accordance with ESS transportation policy.

6. Project Delivery Majority of the infrastructures is on order
Procedure & Staff Development
Cavity Fabrication and Testing
Majority of the infrastructures is on order
Processes are being mapped out
Training plans have been defined
Specification for Niobium material is being drafted

7. Project Schedule & Key Milestones
Description
Date
CAS
Stage 1 4
Design and procurement of the VTF including RF system, control system, cryogenic system, cryostat, cavity handling tooling.
9/9/2016 5% 5
Installation and commissioning of the full VTF system with suitable prototype/pre-production cavities.
7/7/2017 8
Critical Design Review, reporting, stage 2 starts after approved CDR
Q4 2017
10%
Stage 2 9
Receiving and arrival inspection reporting of first batch of niobium material at STFC
20/6/2017 12
FAT at STFC and shipping of high-β cavities for CM 1 to CEA
25/10/2018 18
FAT at STFC and shipping of high-β cavities for CM 2-3 to CEA
3/2/2019 19
FAT at STFC and shipping of high-β cavities for CM 4-6 to CEA
6/6/2019 20
FAT at STFC and shipping of high-β cavities for CM 7-9 to CEA
3/10/2019 21
FAT at STFC and shipping of high-β cavities for CM to CEA
3/3/2020 22
FAT at STFC and shipping of high-β cavities for CM to CEA
3/6/2020 23
FAT at STFC and shipping of high-β cavities for CM to CEA
3/9/2020 24
FAT at STFC and shipping of high-β cavities for CM to CEA*
4/12/2020 28
Preparation of the data package for SAR 2 regarding cavities to CM 2-21 after assembly and SAT at ESS in Lund
Q1 2021
*Note for 84 cavities only (excl spares)
Factory Acceptance Tests (FAT)
Site Acceptance Tests (SAT)
System Acceptance Review (SAR)

8. Risk Register 8

9. Risk Register Nb Defects Procurement Management
Agreed during the TAC that eddy current scanning is the best way forward
No capability of Nb scanning at the Nb vendors
Discussions held with DESY
Scanner can be modified: Larger bed required and a program update
Scanning times longer but acceptable
Need to assess how this can be included within the schedule  Early procurement of Nb material
Procurement Management
Suffering long delays in procurement due to changes in the process
Mitigation strategy:-
Elevated within SBS (Procurement provider)
Identified SBS resource and regular communication on progress
Procurement plan has been developed with John Webber (IKC Program Office)
Documentation for major procurement to be started as early
Nb material and cavity procurement will need finalised specifications from ESS as soon as possible
STFC needs to define latest dates when the specifications are required
Specification for Niobium material is being drafted 9

10. Risk Register HOM Management
Special care on the cavity cells shape needs to be taken for the production cavities
Rigorous validation of fabrication procedure to be performed by CEA Saclay prior to STFC purchase of fabricated cavities
Understanding of the effects of tuning to be gained from the work under taken on the prototypes by CEA Saclay
On going evaluation being undertaken at CEA Saclay in conjunction with work being performed by Roger Jones group at Manchester University 10

11. High-Beta Project Team
High-Beta Cavity Delivery Team
Management
Project Sponsor – P McIntosh (ASTeC)
RF & Cryogenic Group Leader – A Wheelhouse (ASTeC)
Interim Project Manager – P Atkinson (Technology)
New Project Manager – M Ellis (ASTeC) (Started 1st April)
QA Manager – M Pendleton (Technology)
Operations – Andy Goulden (ASTeC) RF
Senior RF Engineer – P Smith (ASTeC) (Started 18th April)
RF Engineer – P Goudket (ASTeC)
RF Engineer – K Dumbell (ASTeC)
Cryogenics
Senior Cryogenic Engineer – S Pattalwar (ASTeC)
Senior Cryogenic Engineer – R Buckley (ASTeC)
Cryogenic Engineer – L Bizel-Bizzellot (ASTeC)
Mechanical
Senior Mechanical Technician – P Davies (Technology)
Mechanical Technician – W Roberts (Technology)
Mechanical Technician – R Corcoran (Technology)
Cavity Qualification Team
Project Manager
Michael Ellis
Quality Manager
Mark Pendelton
Mechanical Technician
Phil Davies
Wyn Roberts
Ryan Corcoran
RF Engineer
Paul Smith
Cryogeninc Engineer
Louis Bizel-Bizellot
Training plan identified

12. Outline Delivery Schedule Infrastructure Quality Assurance Summary
Scope
Delivery Plan
Risk Register
Infrastructure
Cleanroom
Shielding
Cryogenic Plant
Cryogenic System
RF System
Quality Assurance
Summary

13. SRF Hall VTF Cleanroom Full crane coverage Cryo-plant Offices upstairs
He Compressor House
Offices upstairs
Cavity Goods-In & Out downstairs
Thin Film Lab
Crab
Lab
20m
VTF
Cleanroom
Cryo-plant
55m

14. SRF Hall – Cleanroom Layout
Discussions held with a specialist cleanroom firm
Cleanroom performance specification defined
HPR requirements defined
Specification being prepared
Mobile cleanroom requirements being defined after DESY visit
Tenders need to be progressed urgently
He Compressor House
Offices upstairs
Cavity Goods-In & Out downstairs
Thin Film Lab
Crab
Lab
VTF
Cleanroom
Cryo-plant

15. Shielding Outlined radiation assessment initially performed
More detailed assessment completed by Nuclear Technology

16. Shielding ADD PICTURES FROM SHIELDING REPORT
Concrete thickness is defined – 1.85 m
Approval from RPA gained
Mechanical shielding design is still being finalised
Procurement through central services
Digging of hole to commence shortly
ADD PICTURES FROM SHIELDING REPORT

17. Cryogenic System
He-Liquefier 8
Procurement Schedule

18. Cryogenic Plant Air Liquide Advance Technologies
Cryogenics plant will consist of:
He Liquefier (100 l/h)
3000 l LHe Dewar
Helium Recovery System (10g/s)
Gas Storage
Order has been placed with Air Liquide Advance Technologies
Project kick-off meeting held 17th March 2017
Preliminary design review was held 9th May 2016
Final design review to held July 2016
Delivery by February 2017
Commissioning of system July 2017 (after cryostat delivery)
Air Liquide
Advance
Technologies
PFD & Process description

19. Horizontal Tests in a Cryostat
Aim to test 3 cavities horizontal in the cryostat
Diameter sufficient to test 3 vertically if required
Helium vessel will be used to cool the cavities:
Reduced LHe requirements  75% saving on LHe and gas storage
Automatic leak checks on He vessel
Higher confidence in performance
Quicker cool-down/warm up periods
Cryostat order placed with Criotec
Schedule discussions held
Kick-off meeting 1st June 2016
Requirements to be fully defined and agreed
Delivery May 2017 (Improvement from the original date of July 2017)
Cryostat Proposed Design

20. Cryostat P&ID Layout To GHe Recovery LHe From Cryo-Plant 40 K GHe JT
FM2230
2K pumps
To GHe
Recovery
TI2005
PI2157
FM2232
HT2040
PRV2181
HTR
TI2009
HT2044
LHe
PI2156
HTR
From
Cryo-Plant
FM2231
BD2170
HT2041
PRV2180
TI2000
40 K GHe
HTR
PI2150
TI2011
LI2090
BD1170
PI2155
PRV1180
TI2004
HT2042
TI2008
PRV1181
PI2154
TI2001
PI1151
TI2003
HT2043
PI1150 JT
PRV3180
Turbo x 3
PI2151
PI3150
RF Port
I-Port
WARM GHe
TI2002
PI2152
TI2010
OVC
TI2006
PI2153
Radiation shield
TI2007
IVC
TI1011
TI3004
LI1090
TI3006
TI3001
TI1010
TI3003
TI1009
HT1043
TI1001
TI1002
TI1000 T1
HT1040
HT3041 V1
HT3040
TI1003 T2
TI3005 V2
TI3007
TI1004
TI1006 T3
TI1005
TI1007 V3
HT1041
TI1008
TI3000
TI3002
HT1042

21. Upstream Circuit of 2K System
Ambient Temperature
Transfer Line
Helium
Recovery
Heater
LHe
HTR
Helium
Liquefier
40 K GHe
2K Heat
Exchanger
HTR
4.2K Helium
Bath JT
WARM GHe
2K box
2K Superfluid
Helium Bath
And Cavities T1 V1 T2 V2 T3
Upstream Circuit of 2K System V3
Cryostat

22. RF System Microwave Amplifier
Existing VTF test facility configured for an operational frequency of 1.3 GHz.
Modifications required to enable testing at 704 MHz.
System has been defined
Robust and versatile system
Low risk as it is an already operational system at JLab
RF amplifiers (500W) on order:
RF power level allows for F/E and m/p conditions
Delivery early July 2016
Majority of the components are on order or have arrived
System integration and commissioning to be completed Dec 2016
Microwave Amplifier
Low level block diagram
Courtesy of Tom Powers (JLab)

23. Outline Delivery Schedule Infrastructure Quality Assurance Summary
Scope
Delivery Plan
Risk Register
Infrastructure
Cleanroom
Shielding
Cryogenic Plant
Cryogenic System
RF System
Quality Assurance
Summary

24. Quality Assurance QUALITY MANAGEMENT SYSTEM – ISO 9001:2008
Development of procedures and processes has commenced
Processes are being mapped out
Visit to DESY undertaken to assess the full requirements for the procedures , documentation and data collection
Training plans have been defined
Arrangements with DESY for cleanroom training – September 2016
Need a better understanding of parameters to be recorded
Understand data collected on prototype cavities tested to date
Quality Plan to be defined

25. Cavity Workflow

26. Data Management
Requirements of data management system are being defined
Cavity material
Cavity fabrication
Dressed cavity fabrication
VTF assembly
Cavity performance testing
Discussions on-going with a specialist company
Establishing a system for the high-β cavity data collection to meet ESS requirements
These requirements are still to be finalised

27. Outline Delivery Schedule Infrastructure Quality Assurance Summary
Scope
Delivery Plan
Risk Register
Infrastructure
Cleanroom
Shielding
Cryogenic Plant
Cryogenic System
RF System
Quality Assurance
Summary

28. Next Steps Finalise all orders for the Test Facility
Monitoring of vendors for delivery of Test Facility
Finalise and sign-off the Technical Annex
Specification and procurement documentation for the Nb material
Fixed material requirements and specification will be required as this will be bought ahead of schedule to enable eddy current scanning
Continue on-going discussions with potential suppliers (Nb and cavity fabrication)
Commencement of staff training
Cleanroom training at DESY (Sept 2016)
Commencement of development of procedures
On-going

29. Summary UK IKC signed off by BIS Infrastructure progressing well
Recruitment of ESS Qualification Team complete
Nb defect mitigation in place
Schedule needs reviewing
Technical Annex progressing
Scheduled for the high-β elliptical cavities still meets the timescales for the ESS programme