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CERN SPL Fundamental Power Coupler Progress report SLHiPP-4 meeting, 2014, CERN, Geneva Eric Montesinos, CERN-RF SLHiPP-4, 15-16 May, CERN, Geneva Eric.

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Presentation on theme: "CERN SPL Fundamental Power Coupler Progress report SLHiPP-4 meeting, 2014, CERN, Geneva Eric Montesinos, CERN-RF SLHiPP-4, 15-16 May, CERN, Geneva Eric."— Presentation transcript:

1 CERN SPL Fundamental Power Coupler Progress report SLHiPP-4 meeting, 2014, CERN, Geneva Eric Montesinos, CERN-RF SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 1

2 Outline SPL Fundamental Power Coupler project (reminder & already a long story) Difficulties along the project Key R&D results & successful new ideas Next steps & conclusion SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 2

3 SPL Fundamental Power Coupler Project SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 3 RF Characteristics f0f0 704.4 MHz Power levels 1000 kW pulsed 0.4 + 1.2 + 0.4 = 2.0 ms 50 Hz (20 ms) 100 kW average Cavity design gradient19-25 MV/m Q ext of input coupler1.2 x 10 6 Input line Ø 100 / 43.5 mm = 50 Ω (from the cavity design) WaveguidesWR 1150

4 SPL Fundamental Power Coupler Project Technical Choices Single window coupler Fixed coupler With a Double Walled Tube Mounted in clean room with its double walled tube Vertically below the cavity and will be a support for the cavity (first time worldwide) With a HV DC biasing capacitor Air cooled SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 4

5 SPL Fundamental Power Coupler Project SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 5 Disk window Coupler Cylindrical window Coupler Both designs will have the same Double walled tube Matching waveguide without doorknob Contacts ring including DC capacitor Interface to cryomodule flange & RF + vacuum gasket

6 Already a long story 2008/2009 First SPL Collaboration meeting Proposal of four possible designs 2010 Design review with world wide coupler experts, Two designs validated ANL-APS: Ali Nassiri DESY: Wolf-dietrich Moeller Fermilab: Mark Champion & Sergey Kazakov Jlab: Mircea Stirbet 2011 3D printing & Construction SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 6

7 Already a long story 2012 First tests & first difficulties Copper peeling on Double walled Tube (DT) 2013 High peak power difficulties in SW tests Arcing regarding some reflected power phases Not found with simulations New test program First pair of Disk couplers ok 2014 Bolts/nuts & vacuum gasket difficulties Still not ok with cylindrical windows Second pair of Disk couplers ok (yesterday 6 pm, May 15, 2014 !) SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 7

8 Acknowledgments to involved teams worldwide SPL coupler review committee Ali Nassiri, Wolf Dietrich Moeller, Mark Champion, Sergey Kazakov, Mircea Stirbet, Amos Dexter, Rama Calaga, Miguel Jimenez, Sergio Calatroni, Ofelia Capatina, Vittorio Parma CEA Antoine Dael, Claude Marchand, Stephane Chel, Guillaume Devanz, Michel Desmond, Abdallah Hamdi, and local team DESY Wolf-dietrich Moeller, Axel Matthaisen, Birte Van der Horst, and local team ESS Anders Sunesson, Morten Jensen, Rutambhara Yogi ESRF Jorn Jacob, Vincent Serriere, Jean-Maurice Mercier, Michel Langlois APS Ali Nassiri, Doug Horan, Gian Tenko, Dave Brubenker SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 8

9 Acknowledgments to involved teams at CERN Mechanical & Material Engineering group Ramon Folch, Francesco Bertinelli, Serge Mathot, Agostino Vacca, Thierry Tardy, Thierry Calamand, Thierry Renaglia, Ofelia Capatina, Marc Polini, Laurent Deparis, Philippe Frichot, Jean-Marie Geisser, Jean-Marc Malzacker, Pierre Moyret, Alain Stadler, and team Vacuum, Surface & Coating group Miguel Jimenez, Sergio Calatroni, Wilhelmus Vollenberg, Marina Malabaila, Nicolas Zelko, and team Magnets, Superconductors & Cryostats Vittorio Parma, Arnaud Van de Craene, and team RF group Charles Julie, Sebastien Calvo, Antoine Boucherie, Nicolas Jurado, all FSU-AB03 members SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 9

10 Difficulties along the project Double walled tubes Arcing along the ceramics, new test program Special screws SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 10

11 Double Walled Tube Double Walled Tube copper coating peeled off during the first cleaning at DESY facilities We fixed the trouble at cern, coating process was modified We had to remove all first coatings and restart from the beginning Today 6 out of 8 DT are now successfully copper coated We are still waiting for the two last one SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 11 Double Walled Tube copper peeling during cleaning before installation at DESY premises

12 Arcing along ceramic on the air side SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 12 Black deposit Gold & Copper from upper collar Copper from lower collar

13 Arcing along ceramic on the air side Distance between rings limits the peak power due to surface flashover rating As these ceramics are part of the matching system, it is not so easy to calculate the RF peak power limit We work on three axis  ‘protection’ to improve peak voltage capability  Air flow to remove ionized air  Increasing the ceramic path length SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 13 Arcing with 44 kVDC applied between copper collars (1 MW SW most of the phases, RF limit 600 kW SW at some phases)

14 Arcing along ceramic on the air side Distance between rings limits the peak power due to surface flashover rating As these ceramics are part of the matching system, it is not so easy to calculate the RF peak power limit We work on three axis  ‘protection’ to improve peak voltage capability  Air flow to remove ionized air  Increasing the ceramic path length SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 14 Arcing with 72 kVDC applied between copper collars with two ‘plastic protection’ added (1 MW SW most of the phases, RF limit improved to 650 kW SW at some phases)

15 Arcing along ceramic on the air side Distance between rings limits the peak power due to surface flashover rating As these ceramics are part of the matching system, it is not so easy to calculate the RF peak power limit We work on three axis  ‘protection’ to improve peak voltage capability  Air flow to remove ionized air  Increasing the ceramic path length SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 15 SPL couplers Air cooling study to improve HV flashing limits

16 Arcing along ceramic on the air side Distance between rings limits the peak power due to surface flashover rating As these ceramics are part of the matching system, it is not so easy to calculate the RF peak power limit We work on three axis  ‘protection’ to improve peak voltage capability  Air flow to remove ionized air  Increasing the ceramic path length SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 16 SPL couplers Air cooling study from EN-CV team to improve HV flashing limits

17 Arcing along ceramic on the air side Distance between rings limits the peak power due to surface flashover rating As these ceramics are part of the matching system, it is not so easy to calculate the RF peak power limit We work on three axis  ‘protection’ to improve peak voltage capability  Air flow to remove ionized air  Increasing the ceramic path length SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 17 SPL couplers Ceramic surface path length study to be launched in order to improve HV flashing limits

18 Arcing along ceramic on the air side SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 18 Our SPL output couplers (Disk or cylindrical) were always ok, input couplers are subject to arcing regarding some phases DESY-PETRA FPC test bench experienced the same kind of troubles only onto their input couplers (TW test) ! No explanation yet… some ideas, but still to be solved

19 Test program We will continue to work on this trouble, however, we must deliver FPC to SPL project NOW Initial test program has been modified taking into account all these difficulties Nevertheless it remains fully compatible with SM18 tests program Yesterday evening (6 pm, May 15, 2014), we completed the second pair of couplers SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 19 Test Repetition rate 50 Hz Initial kW New kW TWC1000 SW 100 µs1000 SW 200 µs1000500 SW 500 µs1000250 SW 1 ms1000250 SW 2 ms1000250

20 Test program We will continue to work on this trouble, however, we must deliver FPC to SPL project NOW Initial test program has been modified taking into account all these difficulties Nevertheless it remains fully compatible with SM18 tests program Yesterday evening (6 pm, May 15, 2014), we completed the second pair of couplers SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 20

21 Special screws During FPC review we were advised to use special nuts and bolts (DESY type CuNi1Si, CuNi2Si, CuNi1.5Si0.5 and CuNi3Si) We lost a lot of time before we understood these items are not strong enough to correctly tighten our all in one RF & vacuum seal Indeed, DESY vacuum seal and CERN one are very different It has cost us a lot of clean room time… SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 21

22 Special screws During FPC review we were advised to use special nuts and bolts (DESY type CuNi1Si, CuNi2Si, CuNi1.5Si0.5 and CuNi3Si) We lost a lot of time before we understood these items are not strong enough to correctly tighten our all in one RF & vacuum seal Indeed, DESY vacuum seal and CERN one are very different It has cost us a lot of clean room time… SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 22

23 Special screws During FPC review we were advised to use special nuts and bolts (DESY type CuNi1Si, CuNi2Si, CuNi1.5Si0.5 and CuNi3Si) We lost a lot of time before we understood these items are not strong enough to correctly tighten our all in one RF & vacuum seal Indeed, DESY vacuum seal and CERN one are very different It has cost us a lot of clean room time… SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 23

24 Special screws During FPC review we were advised to use special nuts and bolts (DESY type CuNi1Si, CuNi2Si, CuNi1.5Si0.5 and CuNi3Si) We lost a lot of time before we understood these items are not strong enough to correctly tighten our all in one RF & vacuum seal Indeed, DESY vacuum seal and CERN one are very different It has cost us a lot of clean room time… SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 24 SPL couplers assembly on test box in clean room, a lot of preparation and manpower are required

25 Key R&D results & successful new ideas 3D printing ‘Plug and Play’ waveguide Inner line special RF contact All in one, only two covers conditioning test box SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 25

26 3D printing Thanks to SPL R&D program we demonstrated that 3D printing can be used with an accuracy of 0.2 mm which allows a cheaper mechanical check compare to machining With the correct paint, it can also be used for LLRF checks at a quite cheaper cost compare to cost of true items SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 26 S21 = 0.01 dB S11 = -40 dB S21 = 0.03 dB S11 = -25 dB @ 400 MHz

27 ‘Plug and Play’ waveguide SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 27 ‘Plug and Play’ waveguide with matching step and DC capacitor included 1-2connect the monbloc waveguide to the body line 3Insert the contacts ring, without stress given to the ceramic 4Final assembly of air cooling system

28 Inner line special RF contact Air cane ensuring 1 MW RF contact Inner ceramic is brazed with a stainless steel nut Air cane is built with a specific bolt Air cane is screwed compressing springs Springs ensure a good RF contact SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 28

29 Inner line special RF contact Air cane ensuring 1 MW RF contact Inner ceramic is brazed with a stainless steel nut Air cane is built with a specific bolt Air cane is screwed compressing springs Springs ensure a good RF contact SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 29

30 All in one test box Easier (not easy) copper sputtering, all vacuum gaskets included, self supporting shape Use of a specially designed for SPL test boxes helicoflex seal In June 2011, the four test boxes were assembled in DESY clean room, since that time they are still perfect ! Thanks to DESY colleagues who have performed a very good job SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 30 SPL test box Upper cover with all flanges machined from a plain 3D forged Stainless Steel block

31 All in one test box Easier (not easy) copper sputtering, all vacuum gaskets included, self supporting shape Use of a specially designed for SPL test boxes helicoflex seal In June 2011, the four test boxes were assembled in DESY clean room, since that time they are still perfect ! Thanks to DESY colleagues who have performed a very good job SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 31

32 All in one test box Easier (not easy) copper sputtering, all vacuum gaskets included, self supporting shape Use of a specially designed for SPL test boxes helicoflex seal In June 2011, the four test boxes were assembled in DESY clean room, since that time they are still perfect ! Thanks to DESY colleagues who have performed a very good job SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 32 SPL test box helicoflex Specially designed to avoid any dust going into the box

33 All in one test box Easier (not easy) copper sputtering, all vacuum gaskets included, self supporting shape Use of a specially designed for SPL test boxes helicoflex seal In June 2011, the four test boxes were assembled in DESY clean room, since that time they are still perfect ! Thanks to DESY colleagues who have performed a very good job SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 33 Four SPL test boxes successfully assembled in DESY clean room facility in June 20011

34 Next steps We now have to EBW the couplers at the DT flange level to the cryomodule ‘flanging system’ Very delicate step in the process as it can destroy 4 years of construction and tests Mock-ups are under construction to train the specialist SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 34 Last critical operation on couplers before assembly onto cryomodule EBW

35 Next steps Integration onto the cryomodule in cern SM18 clean room FPC TD being the support of the cavities SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 35

36 Next steps Thanks to SPL project, we have launched a R&D program on how to perform an ideal conditioning process, safe and swift SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 36

37 Conclusion Not yet at the end of the story However, an important step has been achieved My warmest thanks to all people that have contributed to obtain these important results A special thank to Claude Marchand for solving all the recent paperwork difficulties regarding tests at CEA within the last weeks SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 37

38 Thank you very much for your attention SLHiPP-4, 15-16 May, CERN, Geneva Eric Montesinos, CERN-RF 38 CEA test bench with two SPL couplers, Double Walled Tubes and Test Box

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