1. Infrastructure and Test Facilities in the U.S.
Robert Kephart
Fermilab

2. Work packages in this talk support:
ILCTA test FNAL
Vertical and Horizontal test of Cavities:
Determine the maximum operating gradient of each cavity
Evaluate gradient spread, Q0 and their operational implications.
Measure dark currents, cryogenic loads, and radiation levels.
Test of Cryomodules:
Measure gradient of cavities in cryomodules
Measure vibration of components, system trip rates & recovery times
Beam Based Measurements:
Beam energy, stability, & energy spread
Wakefield measurements, HOM based alignment & LLRF issues
Goal: Are the cryomodules “good enough” for the ILC ?
RF SLAC & FNAL:
Develop high power RF components for Main Linac
Development of LLRF and multi-cavity control systems
RF systems in support of FNAL
Fermilab Apr 4-6, 2006
ILC ART Review

3. ILCTA: ILC RF unit at Fermilab08 09 07
Plan is to build one RF unit to be tested with Beam by 2009. 06
07-08
Fermilab Apr 4-6, 2006
ILC ART Review

4. Work Packages for this talk
5.8
GHz RF Power Source SLAC Adolphsen
ILCTA support SLAC Cassel
HA Modulator IGBT Switch array
ILCTA Cryo design
RF Power FNAL Nagaitsev
LLRF Controls FNAL Carcagno
5.9
Cavity Horizontal Test Stand FNAL Hocker
Cavity Vertical Test Stand FNAL Ginsburg
Cryogenics for test stands FNAL Theilacker
Fermilab Apr 4-6, 2006
ILC ART Review

5. 1.3 GHz RF Power Source Description (WBS 5.8.1) SLAC
Build a 1.3 GHz RF 5 MW power source to test ILC RF components
HV modulator that is on loan from SNS, 1.5 ms pulses at 5 Hz
A 5 MW klystron
High power RF distribution system (3 ATM N2 Gas)
Epics based LLRF system
Goal:
Process developmental couplers
and perhaps process production couplers for FNAL
Test normal conducting positron capture cavity at NLCTA, including accelerating beam with them.
Longer Range Goal:
In the next few years, build and test ILC prototype klystrons and modulators, and by FY10, have six industry-built ILC prototype rf sources (modulator, klystron and controls) in operation (one unit to be used at FNAL to drive three cryomodules).
Fermilab Apr 4-6, 2006
ILC ART Review

6. Status & Plans Status Plans
Drove a Thales 2104U klystron with the SNS modulator
120 kV, 80 A, 5 Hz with 1 msec pulses
In an initial rf test, produced 3 MW, 0.7 msec rf pulses at 5Hz
Will receive a Thales 2104C tube in a few weeks for 5 MW operation
Received parts from LANL to upgrade SNS modulator to drive the TH2104C and ILC prototype 10 MW klystrons
Plans
Complete system checkout with the Thales 2104U klystron
Upgrade SNS modulator (test at 95 A and 130 A with a resistor load)
Install the TH2104C klystron, complete waveguide runs to test areas, and process system with high power RF
On track to finish 1.3 GHz Source in FY06
Fermilab Apr 4-6, 2006
ILC ART Review

7. 1.3 GHz Source @ SLAC SNS Modulator Current RF source with isolator
and load
Thales 2104U
Klystron
Fermilab Apr 4-6, 2006
ILC ART Review

8. Modulator IGBT Switch Motivation Scope *
Description: (WBS 5.8.2) SLAC
Design, build, test and deliver two solid state switches for the Bouncer modulator operating at 10 kV and ~1800A peak.
Project is SLAC contribution to ILCTA program.
Motivation
Improve reliability through solid state n/N redundant switch structure and redundant serial switches to protect klystron in case of switch failure.
Scope
WBS 5.8.1
WBS 5.8.2 *
* Note that actual cost of IGBT is more like $ 172 K… see next slide
Fermilab Apr 4-6, 2006
ILC ART Review

9. 5.8.2.1 Progress FY06 Status Budgets
Design 100% complete; fabrication and testing 75% complete.
Awaiting delayed IGBTs delivery from vendor
Delivery ~ 1 month after all parts received.
Budgets
SLAC funded one switch ($75K) in FY05
Later design requirements changed to two switches for redundancy, increasing engineering, fabrication cost estimate to $172K.
Project on track to complete within re-estimate.
Fermilab Apr 4-6, 2006
ILC ART Review

10. IGBT Switch Array Design Complete First Assembled Unit IGBT’s
Gate Drive Board
IGBT Stack
6” Plastic Stand-Off
Diode Stack
Aluminum Plate
Fermilab Apr 4-6, 2006
ILC ART Review

11. RF Power (WBS 5.8.3) WBS 5.8.3: RF For ILCTA @ FNAL
Purpose: RF Power (Modulator, Klystron, distribution system) for Horizontal & Vertical Test Stand and ILC cryomodule.
Small RF System #1 for HTS/Capture Cavity II:
Klystron = Phillips YK1240 ( 300 KW)
Modulator = 600 KW
LLRF = Simcon 2.1 ( More on this later)
Status:
System installed and operational in MDB
RF has been applied to Capture cavity II
System will move to HTS when this is ready
Fermilab Apr 4-6, 2006
ILC ART Review

12. MDB: Small RF System # 1 Charging supply and Series Tube Modulator
Klystron
300 KW
RF Controls
Fermilab Apr 4-6, 2006
ILC ART Review

13. RF Power (WBS 5.8.3) Large 10 MW Modulators (2 being built, ILC & PD):
Klystrons = 1.3 GHz: Thales, CPI, or Toshiba
Modulator = FNAL Bouncer type
Status:
Both modulators are being assembled
1:12 HV Pulse transformers have arrived
Plans
PD modulator in FY06 in MDB (325 MHz klystron)
On track to install 1st large ILC modulator in ILCTA_NM (New Muon lab) in FY07
Modulator will be used to supply RF power for the test of the first U.S. built cryomodule (TTF type III)
Fermilab Apr 4-6, 2006
ILC ART Review

14. Large Modulator Capacitor Frame 1:12 HV Pulse transformer
For PD = 4.5 mS
Capacitor Frame, Main Capacitors and Bouncer Capacitors: On site
Bouncer Choke, High Voltage Stripline, and Bus: On Site
High Voltage Resistors and Undershoot / Snubber Capacitors: On site
Cabinets and First IGBT Switch from SLAC scheduled to arrive: April
Fermilab Apr 4-6, 2006
ILC ART Review

15. Scope and Schedule FY06 Scope Status & Schedule
Small RF system for HTS/Cap Cav II: done
Big Modulators: PD in May 06, ILC in FY07
VTS RF system (small CW) in late FY06
Fermilab Apr 4-6, 2006
ILC ART Review

16. Low Level RF (WBS 5.8.4) Purpose:
Develop LLRF for ILCTA test areas, work towards ILC LLRF system
Stand alone RF systems for ILCTA: VTS, HTS, New Muon
LLRF Capture Cavity II/HTS:
FPGA based Simcon 2.1 LLRF system from DESY
Master Oscillator & 8 channel timer designed at FNAL
Status:
System installed and operational in MDB
RF has been applied to Capture cavity II
System will move to HTS when this is ready
Plans
Develop multi-cavity control system for New Muon FNPL + cryomodule
Evaluating Simcon 3.1 boards from DESY + alternatives
Fermilab Apr 4-6, 2006
ILC ART Review

17. Stand-alone LLRF System
The CC2 LLRF Portable Rack was commissioned at A0 and is ready to support CC2 operations
VME Modules:
Sparc CPU-56 running DOOCS and Matlab
8-Ch Timer Module (FNAL design)
8-Ch, 10 MHz fast digitizer (DESY design)
8-Ch Function Generator board (DESY design)
Simcon 2.1 FPGA board (DESY design + commercial FPGA board)
Drive Vector Modulator and Downconverter Vector Modulator/Mixer (New FNAL design, upgradeable to 3.9 GHz operation)
Fermilab Apr 4-6, 2006
ILC ART Review

18. New DESY Simcon 3.1 Board
3 prototypes received from DESY Jan 06. This can control 8 Cavities from one Klystrons.
Fermilab (AD, TD, CD) in collaboration with DESY and Poland are working on developing and debugging this new board.
Expanding the collaboration on LLRF to include: UPenn, SLAC and INFN.
Fermilab Apr 4-6, 2006
ILC ART Review

19. Scope and Schedule FY06 Scope Status & Schedule
LLRF system for HTS/Cap Cav II: done
LLRF for VTS: FY07
LLRF system for New Muon: FY07
Fermilab Apr 4-6, 2006
ILC ART Review

20. Vertical Test Stand (WBS 5.9.2)
Our goal is to rapidly advance the intellectual understanding of SCRF surface physics and establish process controls to reliably achieve high gradient ( 35 MV/M) SCRF cavity operation
Approach: Establish a “tight loop” processing and test infrastructure in the U.S.
Tight loop elements:
Cavity fabrication improvements ( e.g. single crystal)
BCP & Electro-polish facilities
High purity water and High pressure rinse
Vertical test facilities
SCRF experts & materials program to interpret results
Vertical test facilities exist at Cornell and TJNL (bare cavities)
These are being modified for near-term use by ILC R&D
On a longer term ( 2007) new Vertical Test Stand (designed for 35 MV/M) cavity testing is being built at FNAL
Fermilab Apr 4-6, 2006
ILC ART Review

21. ILCTA_VTS
A Vertical Test Stand VTS is sited in IB1 because this building currently houses the Magnet Test Facility  large refrigerator capable of 60 W at 1.8 K
Bare 1.3 GHz 9-cell Tesla-style cavities
Measure Q vs. T and Q vs. Eacc
250 W (CW) RF power required at maximum gradient (Q=5x109, Eacc=35 MV/m)
Installed in a vertical pit in the Floor
Shielding against X-rays and Neutrons is an important issue for 35 MV/M cavities
Maintain “Controlled Area” status in IB1
<5 mrem/hr immediately outside shielding
<0.25 mrem/hr in normal working areas
LHe & vacuum
lines
Industrial Building 1
Cornell
Fermilab Apr 4-6, 2006
ILC ART Review

22. One or two 9 cell cavities
VTS Status & Plans
Cryostat Design
Added phase separator to DESY design to improve He Quality
Estimated RF duty factor possible based on IB1 cryogenic capacity
Started cryogenics controls modifications
Cryostat design in progress
Radiation Shielding
Estimated x-ray flux from DESY data
Finalizing shielding design; prerequiste for finalized civil construction design
Secure OK from Safety, then proceed with Civil work ~ 2 months
RF & instrumentation
Instrumentation design has begun
Rack layout, etc
Input coupler design will start soon
VTS Civil Design
One or two cell cavities
Fermilab Apr 4-6, 2006
ILC ART Review

23. VTS Scope & Schedule FY06 Scope: Schedule:
Some costs will spill over to FY07. On track to have a Vertical Test System to test high gradient cavities at Fermilab in 2007
Fermilab Apr 4-6, 2006
ILC ART Review

24. Horizontal Test Facility
Purpose: Verify dressed cavity performance (Eacc vs. Q0) to qualify cavities for assembly into a cryomodule
Bare cavities that pass vertical test are “dressed” with LHe cryostat, coupler, & tuner then tested with RF pulsed power
Usually referred to as “Horizontal Test” since this test is performed in this orientation at DESY in the Chechia facility
Horizontal Test Systems (HTS) are under design for ILCTA_MDB (Meson Detector Building) and ILCTA_IB1 (Industrial Bldg 1)
Bare 1.3 Ghz 9 cell Cavity
Horizontal
4 cavities received from ACCEL
4 cavities on order at AES
2 cavities on order at TJNL
4 cavities expected from KEK
Dressed Cavity
Fermilab Apr 4-6, 2006
ILC ART Review

25. HTS (WBS 5.9.1) ILCTA_MDB HTS ILCTA_IB1 HTS Cryostat: Cryogenics:
Accepts single “dressed” cavities, 1.3 GHz or 3.9 GHz
Similar to the DESY HTS but has access at both ends.
Cryogenics:
MDB has an existing K cryogenic system
New distribution system built to supply cavity test areas
Large vacuum pump has been added to achieve 60 W at 1.8 K
Cryogenic costs for this are in WBS 5.9.3
RF System:
300 KW klystron & modulator provides pulsed RF power
Costs associated with RF system are in 5.8.3
ILCTA_IB1 HTS
A second HTS will be built for IB1
Improved throughput (HTS is DESY)
Design improvements
Accepts two 1.3GHz cavities simultaneously.
Fermilab Apr 4-6, 2006
ILC ART Review

26. HTS Status & Plans ILCTA_MDB
Phase I: Qualify six 3.9 GHz cavities for DESY TTF-VUV-FEL
Phase II: Qualification and R&D for 1.3 GHz cavities for ILC
Cryostat being fabricated at PHPK (Columbus, OH)
Delivery date: 14-APR-2006
Cryo lines to cave installed, interface to cryostat (feed can) under construction
Working 1.3 GHz RF system in MDB
Operated daily (A0 Capture Cavity 2 testing)
Gathering components for 3.9 GHz
Fermilab Apr 4-6, 2006
ILC ART Review

27. HTS Scope and Schedule Scope Schedule
Delivery of MDB cryostat in mid-April
Connect to MDB cryo system and commission
RF commissioning in parallel
Ready for 3.9 GHz cavity testing by end June
FY07: Construction of 2nd HTS in IB1
Exploits existing facility to increase cavity throughput
Allows LLRF R&D on driving multiple cavities w/ one klystron
Fermilab Apr 4-6, 2006
ILC ART Review

28. Cryogenics (WBS 5.9.3 & 5.8.2.2) HTS:
WBS 5.9.3: Cryogenics for Test FNAL
Purpose: Develop cryogenic capability to cool cavities in Vertical and Horizontal Test Stands
WBS : ILCTA Cryogenics Designer from SLAC
Funded via SLAC core vs GDE provided funds
HTS:
Upgrade the existing 1800 W (4K) refrigerator system at the Meson Detector building at Fermilab to supply 60 W of 1.8 K refrigeration for the HTS
Transfer lines extended from upstream locations to MDB
Build and install Feed cans
Install New Large Vacuum pump skid and associated plumbing and infrastructure
Modify cryogenic controls
Near-term Goal: Cool 1st 9 cell ILC cavity to 4 K (Cap. Cavity # 2)
Next Goal: Achieve 60 Watt capacity at 2K by May 06.
Fermilab Apr 4-6, 2006
ILC ART Review

29. Cryogenics
VTS:
Connect existing VTS to existing 60 W 1.8 K refrigerator system in IB1 for the HTS
Modify existing IB1 LHe transfer and vacuum lines to connect to VTS top plate
Must wait until LHC quad testing is complete (end of Apr)
Modify cryogenic controls
Goal: Achieve 60 Watt capacity at 2K to VTS by the end of FY06.
Fermilab Apr 4-6, 2006
ILC ART Review

30. Scope and Schedule FY06 Scope Status & Schedule
Current Labor is yyy FTE
Status & Schedule
Transfer line and feed cans: done
Refrigeration connected to capture cavity # 2
Capture Cavity # 2 cooled to 4 K with RF power
Vacuum Pump skid refurbished & installed
Electrical, water, piping, controls in progress
Plan: 2K capability to Cap Cavity # 2 in April
Plan: 2K capability to HTS cryostat by June 06
Fermilab Apr 4-6, 2006
ILC ART Review

31. MDB Transfer Lines & feed cans
This feed can was designed at SLAC
and built at FNAL
WBS
Fermilab Apr 4-6, 2006
ILC ART Review

32. Capture Cavity II Cold & RF power
First 1.3 GHz TESLA Cavity in MDB
Cold and RF power
MDB Cryogenics K
He inlet Temp
He Outlet Temp
Cavity Pressure
25 MV/M
@ 4.5 K
Reasonable
Dark
Current
Fermilab Apr 4-6, 2006
ILC ART Review

33. Vacuum Pump Connected in MDB
Electrical Installation
Mechanically Installed
This is a BIG vacuum pump… 2 motors… total 300 hp!
Fermilab Apr 4-6, 2006
ILC ART Review

34. ILCTA_NM Cryogenics ILCTA_NM:
Installing Cryogenics, vacuum pump, plumbing, electrical infrastructure, laser room, controls, etc
Plan to move FNPL photo-injector to New Muon in 07
Will provide ILC like beam to test cryomodules
Building transfer lines, feed cans, etc.
FY06: Funded from Fermilab “SCRF infrastructure” from “core” program funds at FNAL  ie not via GDE
FY06 progress is limited by available cash
Needs serious funding in FY07
Need to procure a new large refrigerator
Will provide test of 1st U.S. built Cryomodule in 2007
Fermilab Apr 4-6, 2006
ILC ART Review

35. ILCTA_NM @ Fermilab New Muon Lab FNPL Photo-injector
11/05
Building a ILC cryomodule test area in the New Muon Lab (ILCTA_NM)
Cleaning out building (Done) except for CCM
Bid package out remove CCM
Plan to move Photo-injector
Work is in progress to install interim cryogenic solution in FY06
Will build part of the cryogenic distribution system in FY06
Funding  Can not start Cryomodule feed cans until FY07
Fermilab Apr 4-6, 2006
ILC ART Review

36. NML Heat xchanger & LN2 Dewar
Fermilab Apr 4-6, 2006
ILC ART Review

37. Cryomodule end cans Delayed to FY07 ($$)
Cryomodule Test at DESY TTF
End Cans
Fermilab Apr 4-6, 2006
ILC ART Review

38. Current Status New Muon Lab He storage tanks - 60% complete
LN2 storage tank was refurbished
Drawings and specification for Mycom piping contract - done
PS-1 heat exchanger relocation – done
Helium piping and purifiers bid package - 70% complete
Designing test cave distribution system
Cryogenic controls - 30% complete
Budgetary estimate for the ILC CM feed and end caps – done
PLANS
Long Term goal is one ILC RF unit (3 cryomodules, modulator, 10 MW klystron, LLRF, etc by 2009
Fermilab Apr 4-6, 2006
ILC ART Review

39. Conclusions
Our prime objective is to build and evaluate the components of the ILC main Linac
Also we need to acquire experience & expertise in the U.S. on SCRF technology
We are building extensive infrastructure at Fermilab and SLAC in support of these goals
Cavity test facilities ( horizontal and vertical)
High Power RF test systems
LLRF test systems
Cryomodule Test facilities ( including beam tests )
Significant Technical Progress in FY0506
Progress is limited by the available funding
Fermilab Apr 4-6, 2006
ILC ART Review