1. FPC & HPRF status Couplers mounting (FPC, HOMS & FA)
on behalf of many colleagues involved in the project
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

2. Glossary
FPC Fundamental Power Coupler, Main Power Coupler HOMS High Order Mode Suppressor FA Field Antenna SSPA Solid State Power Amplifier IOT RF tube amplifier HVPS High Voltage Power Supply Cubicle RF transmitter including IOT, HVPS, SSPA and controls HPRF High Power Radio Frequency system including Cubicle, transmission lines, circulator and loads
SPS Super Proton Synchrotron, the second-largest machine in CERN's accelerator complex, in service since 1976, measuring nearly 7 kilometres in circumference BA Batiment Auxiliaire, Surface building of the SPS LSS Long Straight Section, underground sector of the SPS LS Long Shutdown YETS End of the Year Technical Stop EYETS Extended End of the Year Technical Stop
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

3. Mandate (from a quick email guideline from WP4 leader)
A quick recap of the design choices for the FPC and HPRF, and why this is a good choice for the LHC The test results for the FPC and for the IOT Status of the HPRF procurement & installation in BA6 and in LSS6 Assembly of the FPC, HOMS & FA in the near future Any critical items and challenges as you see today both for SPS and LHC I was reminded by Lucio that this review is a "management" review with technical contents, so not too many technical details
HPRF
FPC
Cryo
module
Controls
LLRF
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

4. Outline
Schedule and design choices for the HPRF & for the FPC LHC Summary Conclusion
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

5. Preamble – purchasing rules
We always try to contact a minimum of one company per member state
Minimum ONE year from announcement to Contract Start Date
Once we decide on technical parameters, very difficult to modify the choices whilst keeping the schedule constrains
For small series
One year to place the order
One year to build the device (a minimum with high power RF systems)
Half a year to commission the device
Two and a half years from technical decision to operation
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

6. High Power RF & Fundamental Power Coupler
Successful story of a moving target planning
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SPS prototype beam tests
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Thanks to the always moving planning we have been able to propose very good technical choices
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

7. High Power RF & Fundamental Power Coupler
LHC Crab Cavity Engineering Meeting, FNAL, Dec 2012
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Inner cooling tube
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40 kW 400 MHz
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Three possible designs
Inner line outer Ø = 27 mm
Outer line inner Ø = 62 mm
SPS tests to start in 2016 in LSS4
RF power amplifier
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

8. High Power RF & Fundamental Power Coupler
Crab Cavity Workshop, CERN, Dec 2013
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SPS prototype beam tests CM
HPRF
Re-use the Tetrode amplifiers that have been in operation in the SPS from 1996 to 2000
Four units MHz
One unit MHz
For the Crab programme, we intended to build
Two systems for the BA4 (SPS test)
Two systems for the SM18 (qualification)
The HVPS of the SPS SUPRA project from 1996 to 2000
On the left, the 352 MHz 50 kW CERN Tetrode amplifier
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

9. High Power RF & Fundamental Power Coupler
Crab Cavity Workshop, CERN, Dec 2013
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SPS prototype beam tests CM
HPRF
As we will have to operate full reflection, we also need a circulator to protect the IOT
We decided to purchase LHC circulators and loads
Will be LHC spares after the SPS test
Rated 330 kW for almost the same cost as a new development for 50 kW unit
The SPS table, seen from the HPRF side
Two flexible coaxial lines connected to the circulators, the loads (reduced length compare to LHC for integration reasons), and the WG to the FPC on top of the cryomodule
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

10. High Power RF & Fundamental Power Coupler
Crab Cavity Workshop, CERN, Dec 2013
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SPS prototype beam tests CM
FPC
To our experience a FPC project from design to tests, takes minimum from three to five years
Due to the very tight schedule, we decided to build FPC based on the recent successful SPL design
The SPL test bench at CEA
We successfully tested FPC up to 1 MW full reflection at all phases
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

11. High Power RF & Fundamental Power Coupler
Crab Cavity Workshop, CERN, Dec 2013
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SPS prototype beam tests CM
FPC
The FPC design is with
Titanium flange
AL2O % disk ceramic
(increased ceramic diameter from 100 to 125 mm)
3D forged OFE Copper outer line
Coaxial to Wave Guide transition without doorknob
Inner line inner with water cooling (exception to CERN’s rule) as hook is in the high B-field region
The FPC design had to be compatible with three different possible options
DQW (Double Quarter Wave Resonator)
RFD (RF dipole)
4Rods
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

12. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests CM
HPRF
June 2014, one SPS SUPRA unit successfully tested up to 45 kW 400 MHz
Launch the order of six tetrodes
Old HVPS have shown to be out of age, started the purchasing process of a new HVPS
The old complete SPS SUPRA system restarted in in our test bench
On the front, the CERN amplifier based on a TH571B tube
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

13. High Power RF & Fundamental Power Coupler
Cost & Schedule review, CERN, Mar 2015
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SPS prototype beam tests CM
HPRF
In parallel to the Tetrode option (base line)
we started to look for an IOT option (80 kW)
In function of the SPS test results, LHC power requirements could then be
Less than 20 kW by SSPA
Up to 80 kW by Tetrode (LHC baseline)
Higher than 80 kW by IOT
The SPS 800 MHz IOT systems in operation since 2015
Two RF power plants of four 60 kW IOT each
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

14. High Power RF & Fundamental Power Coupler
Cost & Schedule review CERN, Mar 2015
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SPS prototype beam tests CM
FPC
Down selection has been done to two FPC
DQW and RFD
Coupling element defined November 2014
Starting date for test box calculation
Common side fully designed, construction launched
The FPC with the common part (top side) including several specificities, such as conical vacuum line to allow very high power levels ( above 1 MW), a conical air line from the ceramic to the waveguide and a ‘cyclotronic’ air inlet to cool down the ceramic
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

15. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests CM
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HPRF
Instead of ordering new HVPS for the Tetrode amplifiers, we worked hard to modify the IOT amplifier in order to operate it at 400 MHz
In May 2016 we succeeded to obtain 60 kW and IOT became the new baseline for SPS and LHC
We launched the order of two ‘SPS’ cubicles that are to be delivered in June 2017
The Spare SPS IOT cubicle modified from 800 MHz to 400 MHz performed up to 60 kW CW
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

16. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
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HPRF
BA4 was not available anymore, we had to move to BA6
Amplifiers were expected to be 5 meters close to the FPC, here they will be 150 meters away
Flexible lines were not available or impossible to integrate, so rigid lines must be used
Integration study of the power lines showed a much less easier task than expected as the SPS in an old machine with a really crowded underground
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

17. High Power RF & Fundamental Power Coupler
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Power capability versus Frequency plot (courtesy of MEGA), The lines crossing the left axis indicate the peak power capability
The average power is given at the desired frequency for a straight line
We also have to take in consideration losses due to the length (150 meters) and the elbows (30 per line)
At the for 60 kW CW, we need a 6-1/8’’ coaxial line
SPS prototype beam tests
CM1
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HPRF
Handling 60 kW CW of RF power along the line is never so simple
𝑃𝑝𝑒𝑎𝑘𝑚𝑎𝑥= 𝐸 2 𝑑 2 𝜀𝑟 𝑙𝑛 𝐷 𝑑
With
E = breakdown strength of air (‘dry air’ E = 3 kV/mm, commonly used value is E = 1 kV/mm for ambient air)
D = inside electrical diameter of outer conductor in mm
d = outside electrical diameter of inner conductor in mm
Zc= characteristic impedance in Ω
εr = relative permittivity of dielectric
f = frequency in MHz
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

18. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
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HPRF
The system will be operated in full reflection
To get away from standing wave difficulties (2 * Vpeak), we have to protect the lines with a circulator close to the FPC
Integration of the ‘moving table’ has been updated
The table with all the HPRF devices : Rigid coaxial lines, LHC circulators and Loads, WG elbows, Straight WG, Flexible WG and FPC. Water cooling distribution system and HOMS power loads are also shown
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

19. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
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FPC
All components have been produced for four DQW and four RFD FPC
By August 2016, three DQW and three RFD FPC were available for RF processing
Despite difficulties with the ceramic brazing, all six FPC were delivered on due time (thanks to delays of others)
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

20. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
CM1
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CERN
Eric Montesinos
KEK
Eiji Kako
DESY
Wolf-Dietrich Möller
Yasuchika Yamamoto
RIKEN
Kazutaka Ozeki
IHEP
Tong ming Huang
LAL
Walid Kaabi
IPNO
Emmanuel Rampnoux
BNL
Wencan Xu
IBS
Ilkyoung Shin
CAS
Yongming Li
CEA
Guillaume Devanz
Cornell
Vadim Veshcherevich
JLAB
Robert Rimmer
ORNL
Mark Champion
ANL
Mike Kelly
FNAL
Sergey Kazakov
SLAC
Chris Adolphsen
FPC
Following recommendation of the November 2015 review, FPC design was presented to WWFPC meeting members
Even if not a formal Crab FPC review, the proposed design has been agreed by experts present
Yearly WWFPC meeting between FPC colleagues coming form laboratories all over the world
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

21. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
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FPC
The Test box has been designed, simulations done by HL-LHC-UK
The same test box has been made compatible with DQW FPC & RFD FPC, only the outer line length of the antenna being adapted
The test box in the centre, with the vacuum system under it, and with two couplers face to face on both sides
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

22. High Power RF & Fundamental Power Coupler
Clean room review
CERN, Oct 2016
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SPS prototype beam tests
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Clean Room assembly
We had a clean room review to present the assembly processes of FPC and HOMS & FA
Example of the proposed tooling, some modifications were suggested by the reviewers, that we implemented
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

23. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
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Clean Room assembly
We integrated the comments, and did a first assembly of the FPC and the Test Box in December 2016
From design and power point, to true life
all was quite as expected
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

24. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
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Clean Room assembly
We have better defined our needs and prepared all the tooling for the cavity assembly, we even built a lot of mock-ups to test the processes
We are now ready for FPC, HOMS and FA assembly in clean room that will take place in the coming weeks
On the right and on the left, Frida testing the HOMS & FA tooling, in the centre, the 1:1 cavity mock-up on the trolley that we will use in the clean room
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

25. High Power RF & Fundamental Power Coupler
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SPS prototype beam tests
see SLHIPP-6 meeting
23-24 May 2016 at Cockcroft Institute
CM1
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HPRF & FPC
The First two DQW FPC have been processed up to
30 kW CW (limited by test box)
75 kW full reflection all phases (limited by IOT)
We applied the RF process we developed in 1998 and that has been deployed in many places over the world (ESRF, SOLEIL, BNL, KEK, …)
Some members of the team who built and assembled the FPC
On the right bottom, the automated RF processing HMI
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

26. Why all these choices are also good for the LHC ?
2015 baseline was 32 * 80 kW CW
Due to budgetary reasons, we had to reduce to 16 * 40 kW CW (+ 80 kW 1ms)
From 2015 to 2016, HPRF galleries have strongly been reduced, however we kept them large enough to host eight ‘compact’ HPRF systems (thanks to management & integration team)
The present SPS proposal with IOT can do the job in the new LHC galleries, we did the SPS work in order to ensure it will be the case
This will be very crowded, but feasible even with 32 systems
HPRF Galleries showing eight ‘compact’ power stations
On the left, WG, circulators and loads
On the right, eight ‘compact’ systems
There will be four galleries in total around the LHC
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

27. Lessons learnt for the LHC
With the SPS phase, we were able to use contract that were already granted
Cubicle One year and a half (identical as the SPS one)
FPC Three years (based on a known design)
Lines Two years (long qualification process, very few qualified companies)
This will not be the case for the LHC as we will have larger series
We have to be very careful to launch each contract early enough to stick to the LHC planning as all expensive items will take five years+ to be operational
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HPRF
Demonstrator
SAT
Series SAT and commissioning
Tender
Demonstrator
Production & FAT
Series production & FAT
FPC
Assembly in clean room
Construction
Tender
RF processing
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

28. Summary
Equipment Systems
Upcoming milestones
HPRF
* 60 kW IOT for the SPS BA6
2018 Operation of the two systems in the SPS
2018 Compact SSPA R&D for SM18
2019 Technical Specification for the LHC system
FPC
2017 Assembly in clean room
2018 FPC 2.0 design
2018 Technical Specification for the LHC system
Still a lot to do, however, looking at the projects we achieved the recent previous years,
such as Linac4 FPC, SPS 800, Medical RFQ, and having learnt a lot with the SPS phase,
we are confident that the LHC RF power crab project is correctly on track
and will be feasible within the given boundaries
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

29. Conclusion, HPRF & FPC
All the HPRF and FPC devices needed for the SPS are on track, and within the schedule
All the delays that occurred helped us to better define the systems needed for the LHC
A lot has been learnt in order to prepare the LHC design and its procurement phase
The SPS tests will help to consolidate the choices
Permanent staff (mid-age) have been on board since the beginning, in order to secure the project
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017

30. Thanks to the management for the indefectible support
Even if we know that a lot still has to be done,
we are ready for the challenges offered to us,
and we are eager to participate with a lot of enthusiasm
International Review of the Crab Cavity Performance for HiLumi, CERN, Geneva, April 2017