1. ILCTA_IB1 Infrastructure Analysis for multiple VTS (Preliminary – Work in Progress)
Presented by:
Ruben Carcagno
Analysis team: Ruben Carcagno, Camille Ginsburg, Yuenian Huang, Arkadiy Klebaner, Joe Ozelis, Tom Peterson, Clark Reid, Cosmore Sylvester
September 28, 2006

2. IB1 Infrastructure Analysis for Multiple VTS
Motivation
Cavity yield increase identified as a top ILC R&D priority (S0 goal) during
Requires large quantity of vertical test cycles (hundreds per year) to be performed in all three regions
How many vertical test cycles can be supported in ILCTA_IB1? At what cost?
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

3. IB1 Infrastructure Analysis for Multiple VTS
Single VTS Throughput
The VTS under construction at ILCTA_IB1 can accommodate up to two ILC cavities per test cycle
Expected to start operation in mid-2007
Throughput Assumptions:
Single shift operation
Cavity arrives hermetically sealed
120 °C bakeout done prior to IB1 delivery
“Production” Q vs. E test only (e.g., no 8-hr pause at 100K during cooldown to determine degree of H contamination (Q-disease))
Two cavities in a VTS cryostat
Only one RF ON cavity test at any given time
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

4. Unconstrained Test Cycle Schedule
(Nearly) Unattended Operation ~ 28 hours Attended Operation ~ 11 hours TOTAL (unconstrained) ~ 39 hours
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

5. IB1 Infrastructure Analysis for Multiple VTS
Adding Constraints
Shift Operations
11 hours of attended operations require a minimum of 23 hours because of 12-hour pause between 8-hour shifts
Inefficiencies (idle time due to shared resources, equipment availability, troubleshooting)
Add ~ 24 hours
Total Test Cycle ~ 75 hours or ~ 3.12 work days for two cavities.
Assuming 8 work weeks of maintenance and other facility down time per year:
Single VTS throughput ~ 70 Test Cycles per year, with up to two cavities per cycle (140 cavity tests)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

6. How to (quickly) increase throughput?
Two additional VTS stands can be added to the IB1 facility by relocating the ILCTA_IB1 Horizontal Test Stand (HTS) planned for FY07 to ILCTA_MDB.
Throughput can increase to ~ 3x140 = 420 cavities per year by mid-2008
Some throughput increase might be possible by adding shifts and removing inefficiencies
Substantial additional throughput increase only possible by building modifications and/or a building addition. Cryogenic capacity becomes a limiting factor (tie-in to CHL after Tevatron shutdown?)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

7. Phased Approach for a Vertical Cavity Test Facility (VCTF)
Phase I
Complete VTS under construction by mid-2007
Phase II
Add two more (nearly) identical VTS stands by mid-2008
Phase III
Add one or more high-throughput VTS stands in a modified or new building addition with tie-in to the Central Helium Liquefier (after 2009 and the Tevatron Shutdown)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

8. IB1 Infrastructure Analysis for Multiple VTS
IB1 SRF Test Area Layout
Vertical
Test Area (FY06)
(Bare Cavities)
Existing
Cryo Piping
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

9. IB1 Infrastructure Analysis for Multiple VTS
IB1 Layout for Phase II
Trench for cryo piping
Door
Radiation Lid “park” area
Stairs
Additional VTS
Vertical Magnet Test Facility (VMTF)
Staging Area
VTS under construction
Tie-in to test stands cryo distribution box
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

10. IB1 Infrastructure Considerations
The IB1 Test Facility shares cryogenics and people with a very active Magnet Test Facility (MTF)
It is essential to decouple cryogenic operations between MTF and the Vertical Cavity Test Facility (VCTF)
There should be adequate cryogenic resources available to sustain both MTF and VCTF test programs. This includes both LHe inventory and pumping capacity for superfluid operation
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

11. Infrastructure Requirements
Add a third vacuum pump to increase pumping capacity from 6 g/s at 20 Torr to at least 10 g/s
Add a compressor/purifier at the outlet of the vacuum pump system to mitigate contamination risk
Add more GHe storage capacity to store the entire LHe inventory as gas
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

12. Current Plan for single VTS integration to IB1
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

13. Multiple VTS Integration to IB1
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

14. IB1 Infrastructure Analysis for Multiple VTS
How much pumping?
For baseline E = 35 MV/m, Q0 = 1010 the power dissipation is:
Substantial margin is needed to continuously operate at higher gradients and/or lower Q.
Constraints: JT Heat Exchanger and Pumping Capacity
(6 g/s at 2 K)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

15. JT Heat Exchanger Pumping Limit
With the current VTS JT Heat Exchanger design, practical limit for 2K operation is around 8 to 10 g/s due to excessive shellside pressure drop
Taking into account flashing losses at the JT valve, up to 200 Watts can be removed with a continuous supply and pumping of 10 g/s
To remove more than 200 Watts (10 g/s pumping) continuously, a redesigned JT Heat Exchanger must be used in future VTS. This may require an adjustment to the cryostat (and pit) diameters.
We recommend using 160 Watts (8 g/s pumping) as the practical limit for continuous 2K operation of the current VTS design.
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

16. IB1 Infrastructure Analysis for Multiple VTS
IB1 Pumping Capacity
Installed: 6 g/s at 20 Torr
Kinney Pump I: 4 g/s
Kinney Pump II: 2 g/s
Need more pumping:
Margin for higher gradients and/or lower Q continuous operation
Simultaneous operation of superfluid magnet test and cavity test
Preferred option: a new, dedicated, large (13 g/s) vacuum pump for VTS stands. Use existing pumps for magnet testing.
Alternative option: add a third pump (4 g/s or larger) and share all three pumps for both magnet and cavity testing (requires a valve manifold to easily allocate and share pumping capacity to different test stands)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

17. IB1 Infrastructure Analysis for Multiple VTS
Compressor/Purifier
Contamination is already one of the largest reason for IB1 cryo system unscheduled downtime and loss of efficiency
Addition of sub atmospheric test stands will make this problem worse
Need a high pressure compressor and purifier skid to remove all contamination at the outlet of vacuum pumping system (like the one recently installed at ILCTA_MDB).
This is a high-priority item, even for only one VTS stand.
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

18. IB1 Infrastructure Analysis for Multiple VTS
LHe Inventory
IB1 cryo system LHe make rate: ~ 250 l/hr (9 g/s)
VTS LHe consumption per test cycle: ~ 2,000 l (equivalent to 27 l/hr for a 75-hr test cycle)
For three VTS stands operating continuously: 3x27 = 81 l/hr
On average, there is still ~ 170 l/hr LHe make rate available to support magnet testing.
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

19. IB1 Infrastructure Analysis for Multiple VTS
IB1 LHe and GHe storage
A 10,000 liter He dewar stores up to 7,000 liter of LHe
Three 30,000 Gallon GHe tanks store up to 3,900 LHe equivalent He gas (only 55% of LHe inventory capacity)
Need two more 30,000 Gallon tanks to store the majority of LHe inventory as gas
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

20. IB1 Infrastructure Analysis for Multiple VTS
IB1 FY07 Test Schedule and Civil Construction (Window during Feeder 47 and Cryo Maintenance Upgrade April-May 07)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS
: Magnet Dept. Support
: SRF Dept. Support
: IB1 Maintenance
: New development needed for test

21. Preliminary M&S Cost Estimate
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS

22. IB1 Infrastructure Analysis for Multiple VTS
Project Challenges
Aggressive schedule (Phase I ready by mid-2007, Phase II by mid-2008)
Must minimize disruption to the Magnet Test Program
Requires experienced resources outside of T&I department (e.g., AD-Cryo, FESS)
Must be a Laboratory High Priority Project
Requires adequate funding
Schedule-driven nature of project dictates need to procure turn-key skids from industry as much as possible (e.g., Compressor/Purifier, Kinney Pump)
Ruben Carcagno
IB1 Infrastructure Analysis for Multiple VTS