1. Accelerator Module Test Facility
XFEL
13/09/2018
Accelerator Module Test Facility
The Work Package 10: Module Test Facility
Cryomodule Test Bench (CMTB) or Module Test Stand
Accelerator Module Test Facility (AMTF)
Technical coordinator: Mr. Bernd Petersen, DESY, MKS
Y. Bozhko
20 February 2007

2. AMTF according to XFEL TDR The AMTF Hall (70mx60m) contained also:
Test stands at AMTF:
3 Module Test Stands (MTS)
one CHECHIA like Test Stand
one Test Stand for magnets
two vertical cryostats for testing cavities
one Waveguide Assembly & Test Facility
one Klystron Test Stand
One RF station should be shared between the CHECHIA and one MTS!
The AMTF Hall (70mx60m) contained also:
3 Cryogenic Valve Boxes
two 20t cranes
one 10m³ LHe tank
storage area for modules
two transport areas
Outhouses and the equipment outdoors:
Pump station (28mx10m)
Transformer station
Compressor station (30mx10m)
Office building (25mx12m)
one LN2 tank to produce gaseous N2
one LHe transfer line (~200m long)
Y. Bozhko
20 February 2007

3. How the modules will be tested?
The Modules will be tested at 3 Module Test Stands
incoming inspection
the module is put on a movable support placed on rails
moving the module to inside the shielding by a pusher
fixing the movable support
mounting works, leak tests, etc.
moving the concrete stone to its ”door” position in the shielding
tests
Total testing time including mounting works, pumping, cool-down & warm-up and tests proper amounts to days
Y. Bozhko
20 February 2007

4. How the cavities will be tested?
The bare cavities will be tested at 2 vertical cryostats each roughly 4m high. For the tests each cryostat will be loaded with 4 cavities at once.
Total testing time including mounting works, pumping, cool-down & warm-up and tests proper amounts to 44 hours per set of 4 cavities
Y. Bozhko
20 February 2007

5. Changes since XFEL TDR Cause: savings
one cryogenic valve box is abolished. Its functions are delegated to one of the two remaining valve boxes
Savings: ~400k€
the LN2 tank is abolished. Gaseous nitrogen will be supplied from the vapourizer of the existing HERA LN2 tank
Savings: ~100k€
one redundant vacuum compressor is abolished. The redundancy will be provided by switching between the two remaining compressors depending on test situation
Savings: ~750k€
Y. Bozhko
20 February 2007

6. Changes since XFEL TDR Cause: savings
Sidewise position of the Feedbox
Axial position of the Feedbox
Proposal is to place the Feedbox in line with the module. By this the connecting transfer line and the feed cap are no more necessary
Savings: ~80k€ per MTS or ~240k€ total
Y. Bozhko
20 February 2007

7. Changes since XFEL TDR Cause: savings
13/09/2018
Changes since XFEL TDR
Cause: savings
Proposal is to test the CHECHIA like cavities at Module Test Stands. The cavity is placed inside a vacuum vessel (~1/8 of module) which is connected to the Feedbox instead of a module. By this the CHECHIA-like test stand is abolished
Savings: ~600k€
Y. Bozhko
20 February 2007

8. Changes since XFEL TDR Cause: savings
13/09/2018
Changes since XFEL TDR
Cause: savings
XFEL TDR: 220m of transfer line, 55m of new bridge, 160m of old bridge to be reinforced
Proposal 1: 150m of transfer line, 150m of new bridge. Savings: ~300k€
Proposal 2: 55m of transfer line, 55m of new bridge, valve box. Savings: ~760k€
Connecting transfer lines to the HERA refrigerator means interruption in HERA-FLASH cold supply!
Y. Bozhko
20 February 2007

9. Cause: need to test XFEL magnets earlier
13/09/2018
Changes since XFEL TDR
Cause: need to test XFEL magnets earlier
The Magnet Test Stand moved to Bld.55 and is presently in tendering phase
Cause:
to access modules during tests
Cause:
increased space requirements
each MTS RF station: 4.5mx16m6mx20m
WATF: 14.5mx16m25mx30m+5.5mx15m
Klystron Test Stand: 6.5mx16m9mx16m
clear width of the shielding: 4.8m5.2m
An entry labyrinth is planned on the front side of the shielding
Y. Bozhko
20 February 2007

10. XFEL
13/09/2018
Present view of AMTF
Dimensions of the AMTF Hall increased from 71.2mx58.6m to 75.5mx to 60.5m
D3: The AMTF Hall shall be free of control and restricted access areas!
Y. Bozhko
20 February 2007

11. XFEL
13/09/2018
AMTF office building
Purpose: to provide social and working areas for the AMTF personnel
The AMTF personnel:
5 shifts each of:
The office building shall contain:
RF-Laboratory (~100m²) & workshop (~50m²)
Control room (~60m²), computer room (~40m²) and an electronic laboratory (~30m²)
Break room, seminar room
Social rooms as required
Offices for ~20 people
2 vacuum engineers
2 cryogenic engineers
2 RF engineers
1 engineer supervisor
1 controls engineer
2 technicians (mechanics)
1 safety engineer
1 scientist supervisor
3 engineers (RF test stands)
9 technicians (RF test stands)
Total: 64 persons
Possible layout of the control room
Y. Bozhko
20 February 2007

12. AMTF schedule (counting from today’s ”Go!”)
XFEL
13/09/2018
AMTF schedule (counting from today’s ”Go!”)
AMTF construction:
Middle of March 2007: handing over DESY sketches to WTM
Middle of April 2007:
Establishing building application
July 2007: Call for tenders
September 2007: Awarding of a contract
October 2007: Start of construction
August 2008: Finish of construction
November 2008: Installation of infrastructure inside the AMTF Hall
Cryogenics (vertical tests)
July 2007: Start of preparation of 6 technical specifications
December 2007: Call(s) for tenders
March 2008: Awarding of contracts
April 2008: Start of manufacturing
February 2009: Delivery of the equipment; mounting works
July 2009: Beginning of tests
Cryogenics (MTSs+CHECHIA)
January 2008: Start of preparation of 2 technical specifications
July 2008: Call(s) for tenders
September 2008: Awarding of contracts
October 2008: Start of manufacturing
November 2009: Delivery of the equipment; mounting works
December 2009: Beginning of tests
Y. Bozhko
20 February 2007

13. AMTF Infrastructure The required capacities: Electrical power: ~4.9MVA
XFEL
13/09/2018
AMTF Infrastructure
The required capacities:
Electrical power: ~4.9MVA
Cooling water: ~2.5MW
Waste heat: ~0.5MW
Instrument air: ~330Nm³/h
Y. Bozhko
20 February 2007

14. XFEL
13/09/2018
Open questions
The Hall is too big!: For industrial halls with area > 4500m² an automatic fire fighting system (e.g. sprinkler system) is required. Moreover, driving round the hall shall be ensured.
Presently, area of the AMTF Hall is 4573m²>4500m²
Prove of the principle of
pushing/pulling the modules/stones:
The pusher shall be procured and tested (e.g. on the shielding of vertical cryostats in Hall 3) before the call for tenders for the AMTF.
Carrying out stability calculations and designing the MTS supports:
The proposed concept shall be proven by a draft design and calculations.
Placement the AMTF hall:
To avoid the low loading trucks from backwards movement, the AMTF hall shall not be placed too close to the seepage pool.
Y. Bozhko
20 February 2007

15. XFEL
13/09/2018
Open questions
Clear width of the MTS shielding shall be precisely defined (new design of WG distribution + more place required to move module inside the shielding )
Placing the RF stations at right site of the shielding will approach the MTS valve box to the shielding and shorten the length of each of 3 MTS transfer lines on 6m. Savings: ~90k€
The option shall be carefully studied in the light of testing the CHECHIA-like cavities
Connecting each RF station with each MTS will provide a reliable redundancy for the case if one RF station fails
Shortcomings:
more place is required
floor channels shall be laid under rails
interlock system more complicated
additional costs
Y. Bozhko
20 February 2007