1. i XFEL Module Assembly AWLC’14, 14/05/2014 O. Napoly, CEA

2. i Cryomodule Assembly at CEA-Saclay Commitment of CEA to the E-XFEL Accelerator Consortium: assembly of 103 accelerator modules (101 in the tunnel) with 1 per week throughput ! operated by an industrial contractor on the Saclay site and with CEA infrastructures AWLC’14, 14/05/2014 O. Napoly, CEA

3. i Overview of the Assembly Buildings AWLC’14, 14/05/2014 O. Napoly, CEA XFel Village 3232 4 6 5 Bldg 124 North 25x15 m² Bldg 126 North 40x11 m² 7 Bldg 126 South 30x17 m² 8 1 Court Yard 6b ©GoogleMap Clean rooms Assembly halls Offices Warehouse

4. i the XFEL Village Coupler Area CO-WS1 & 2 Alignment Area AL-WS1 & 2 Shipment Area SH-WS1 & 2 Roll-out Area RO-WS1 & 2 Warehouse Clean room Area CO-WS1 & 2 SA-WS1 & 2 Reception Area REC-WS1 Cantilever Area CA-WS1 Assembly Hall : Workstations AWLC’14, 14/05/2014 O. Napoly, CEA

5. i Organisation of Work Stations 1. Clean Room Cold Coupler Area (IS04-CC-WS1) Cold coupler assembly (x8), leak check of cavity-coupler connection (+RGA) 2. Clean Room String Assembly Area (ISO4-SA-WS1, ISO4-SA-WS2) String connections (1 gate valve + 8 cavities + 1 Qpole unit) Leak check of string and N 2 venting (+RGA) 3. Roll-out Area (RO-WS1, RO-WS2) HOM adjustment, magnetic shielding, T-sensors (x6) Tuner assembly (x8), coupler 4K and 80 K shields 2 Ph-tube welding, NCT (LT, PT, RT) Cold-mass/string connection 4. Alignment Area (AL-WS1, AL-WS2) Cavity and quadrupole fine alignment (~100 µm) Welding of 8 mm LHe filling line (x9) Tuner and piezo electric tests 5. Cantilever Area (CA-WS1) Welding of 4K and 70 K shields, 4K and 79 K super insulation Cable routing and insulation, Quad current lead Insertion into vacuum vessel and cold mass alignment 6. Coupler Area (CO-WS1, CO-WS2) Warm couplers + coupler pumping line + leak checks (8 connections + coupler vacuum) Cabling of flanges A (x8) and flange D Quadrupole current lead connections and welding Final leak check of cavity vacuum + final pumping 7. Shipment Area (SH-WS1, SH-WS2) Control operations (RF frequency), End-caps closing, N2-insulation, CEA-Alsyom “acceptance test”, Loading 6 May 2014 O. Napoly, XFEL MAC5

6. i Cold Coupler Assembly AWLC’14, 14/05/2014 O. Napoly, CEA

7. i String Assembly AWLC’14, 14/05/2014 O. Napoly, CEA XM4 (String assembly) on 14/02/2014

8. i Roll-out and Alignmemt XM2 (Alignment) and XM3 (Roll-out) on 14/02/2014 AWLC’14, 14/05/2014 O. Napoly, CEA

9. i Cantilever AWLC’14, 14/05/2014 O. Napoly, CEA XM1 (Cantilever) on 14/02/2014

10. i Warm Coupler AWLC’14, 14/05/2014 O. Napoly, CEA XM-1 (Warm couplers) on 14/02/2014

11. i Cantilever and Warm Coupler AWLC’14, 14/05/2014 O. Napoly, CEA XM1 (Cantilever) and XM-1 (Warm couplers) on 14/02/2014

12. i Shipment AWLC’14, 14/05/2014 O. Napoly, CEA

13. i Status of Assembly: 6 cryomodules delivered to DESY AWLC’14, 14/05/2014 O. Napoly, CEA

14. i XM-3 RF Test Results AWLC’14, 14/05/2014 O. Napoly, CEA cryomodule test cavity tests

15. i XM-3 : ILC Cryomodule !! AWLC’14, 14/05/2014 O. Napoly, CEA A success for SRF Technology Average individual cavity gradient: 32 MV/m Average cavity pair gradient: 29 MV/m Three cavities reach gradients above 38 MV/m Cryogenics losses are low: Q0 ~ 3e10 A success for String and Module Assembly: Seven cavities are reproducing VT gradient The cryomodule reproduces gap of 230 MV Cavity 1 is degraded from 31 down to 23 MV/m useable gradient: gate valve/cav1 connection was fautly, not for training ! A success for the industrialization process: XM-3 is the assembly demonstration cryomodule of CEA w.r.t. ALSYOM contract.

16. i XM-2 RF Test Results at AMTF (Dec. 2013) AWLC’14, 14/05/2014 O. Napoly, CEA

17. i XM-2 RF Test Results Successful RF test for XM-2 Vert. Test average: 25,8 MV/m Module test Average: 24,5 MV/m XFEL specification: 23,6 MV/m AWLC’14, 14/05/2014 O. Napoly, CEA

18. i XM-1 RF Test Results at AMTF ? AWLC’14, 14/05/2014 O. Napoly, CEA not too good 

19. i Status of Assembly AWLC’14, 14/05/2014 O. Napoly, CEA 2 phase-line welding crisis

20. i Status of Assembly (future) Eu-XFEL goal is to deliver XM100 in March 2016 to close the tunnel in June 2016. The remaining three main challenges: 1.Alsyom staffing, training and coordination 2.2-phase line welding issues 3.Non-conformities on components and needed evolutions With the current schedule, acceleration of production to 1.5 module/week delivery rate sometime in 2015, is needed to meet the goal; AWLC’14, 14/05/2014 O. Napoly, CEA

21. i Industrial Contract : ALSYOM Management Plan and Staffing O. Napoly, XFEL MAC 6 May 2014 21 Off site On site: 29 persons 1* 2 (1**) 20 (4**) 1** 1* 1 Core Team (11 persons) * arrived Sept. 2012 ** arrived Feb. 2013 + 1 @@

22. i Project Weeks 2012 20132014 Start of training phase Start of production phase Start of observation phase 01/04/2914, 24 persons 14/04/2014, 26 persons (+3 —1 ) Alsyom Staffing (SEIV not included) AWLC’14, 14/05/2014 O. Napoly, CEA

23. i Status on 2-phase line welding Four Welding Issues mentioned at the last ACB: 1 – Qualifications of Alsyom (EN3834-2) and of Alsyom welders Problem is moslty solved 2 - NDT by Radiography TÜV-Nord requested systematic Non-Destructive Testing by X-Ray radiography (RT) for all the welds (17 welds) of the Helium 2K two-phase line along cavity string, for all the cryomodules, to the systematic Visual Test (VT) and Leak Test (LT), and Paint Test (PT) for a 2 lip-welds. Organizing and bringing NDT at Saclay is challenging: 1)Contract: a call for tender organized for about 92 campaigns (> 200 k€) and bids are received on 22 April 2)Safety: CEA-Saclay has very strict safety regulations for implementing X-Ray radiography : < 0.5 µSv/h in public zone 3 – Execution of NDT and TÜV Module assembly at two different workstations will need to be synchronized (in the best case) or delayed (in the worst case) with the external action of NDT operators and of TÜV-Nord inspector, on a weekly basis ! TÜV-Nord inspector takes vacations. 4 - Non-conform Welds (pores, or blow-holes) AWLC’14, 14/05/2014 O. Napoly, CEA

24. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

25. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

26. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

27. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

28. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

29. i Example of Pores AWLC’14, 14/05/2014 O. Napoly, CEA

30. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

31. i Status on 2-phase line welding Courtesy Kay Jensch AWLC’14, 14/05/2014 O. Napoly, CEA

32. i Status on 2-phase line welding XM3 : under DESY EN3834-2 coordination by certified DESY welder 14 welds at level 1 1 weld at level 2 1 weld at level 3 XM4 : under DESY EN3834-2 coordination by certified DESY welder 14 welds OK at level 1 3 welds OK at level 2 1 longitudinal weld beyond level 3: 2 repair welds at Level 1 XM5 : under DESY EN3834-2 coordination by certified ALSYOM/SEIV welder 5 welds at level 1 7 welds at level 2 4 welds at level 3 – exchange decided: 6 repair welds performed by DESY welder at Level 1 AWLC’14, 14/05/2014 O. Napoly, CEA

33. i Status on 2-phase line welding AWLC’14, 14/05/2014 O. Napoly, CEA XM6 : under ALSYOM EN3834-2 coordination by certified ALSYOM welder 9 welds OK at level 1 3 welds OK at level 2 4 welds OK at level 3 XM7 (May 12-13) : under ALSYOM EN3834-2 coordination by certified ALSYOM welder 12 welds OK at level 1 3 welds OK at level 2 1 welds OK at level 3

34. ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 34 O. Napoly, XFEL MAC Nombre de non-conformités détectées par mois (FAQ) – Situation à fin Avril 2014 34

35. 35 O. Napoly, XFEL MAC Nombre de non-conformités détectées par mois et par origine (FAQ) ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 35

36. 36 O. Napoly, XFEL MAC NC par origine (de Mars 2013 à Avril 2014) NC par origine (01/04/14 au 30/04/14) ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 36

37. 37 O. Napoly, XFEL MAC NC par WS (de Mars 2013 à Avril 2014)NC par WS (Avril 2014) ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 37

38. 38 O. Napoly, XFEL MAC REPARTITION DES NON CONFORMITES PAR CRYOMODULE ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 38

39. 39 O. Napoly, XFEL MAC REPARTITION DES NON CONFORMITES (FAQ) PAR COMPOSANTS (cumul de Mars 2013 à Avril 2014) ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 39

40. i Problems of Non-conformities AWLC’14, 14/05/2014 O. Napoly, CEA

41. i Conclusions 6 May 2014 41O. Napoly, XFEL MAC XM-2 successful RF test qualifies the remainder of CEA equipment (pumping system) XM-1 revealed the challenges and difficulties of the Helium tank welding: qualification, radiography, conformity  these problems are now under control Ramp-up is in progress and 1-week assembly rate is around the corner o CEA assembly ‘tool’ is operational o Alsyom just finished staffing, slight overstaffing is needed o 1-week assembly depends on  training of Alsyom staff on each workstation  fewer Non-conformities on components Documenting the module assembly (BOM, NCR, AR, ADP, etc…) in EDMS has been an outstanding effort from DESY-CEA-Alsyom over the past 2 years. However the QA resources put on ‘virtual modules’ are badly missing for the ‘real module’ (QA controls).

42. i Back-up slides O. Napoly, XFEL MAC 6 May 2014 42

43. i 43 O. Napoly, XFEL MAC NC Cavités (de Mars 2013 à Avril 2014) – REC WS 1/2 ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 43

44. i 44 O. Napoly, XFEL MAC NC Cavités (de Mars 2013 à Avril 2014) – REC WS 2/2 ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 44

45. i 45 O. Napoly, XFEL MAC NC Cavités (de Mars 2013 à Avril 2014) – CC WS ETAT DES NON-CONFORMITES - XFEL CRYOMODULE NC Cavités (de Mars 2013 à Avril 2014) – SA WS 45

46. i 46 O. Napoly, XFEL MAC NC Cavités (de Mars 2013 à Avril 2014) – RO WS ETAT DES NON-CONFORMITES - XFEL CRYOMODULE NC Cavités (de Mars 2013 à Avril 2014) – AL WS 46

47. i 47 O. Napoly, XFEL MAC NC Coupler Cold Part (de Mars 2013 à Avril 2014) – REC WS ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 47

48. i 48 O. Napoly, XFEL MAC NC Coupler Cold Part (de Mars 2013 à Avril 2014) – CC WS ETAT DES NON-CONFORMITES - XFEL CRYOMODULE NC Coupler Cold Part (de Mars 2013 à Avril 2014) – SA WS NC Coupler Cold Part (de Mars 2013 à Avril 2014) – CO WS 48

49. i 49 O. Napoly, XFEL MAC NC Cold Mass (de Mars 2013 à Avril 2014) – REC WS ETAT DES NON-CONFORMITES - XFEL CRYOMODULE NC Cold Mass (de Mars 2013 à Avril 2014) – AL WS NC Cold Mass (de Mars 2013 à Avril 2014) – RO WS 49

50. i 50 O. Napoly, XFEL MAC NC Cavity Bellows (de Mars 2013 à Avril 2014) ETAT DES NON-CONFORMITES - XFEL CRYOMODULE 50

51. i 51 O. Napoly, XFEL MAC NC Vacuum Vessel (de Mars 2013 à Avril 2014) – REC WS ETAT DES NON-CONFORMITES - XFEL CRYOMODULE NC Vacuum Vessel (de Mars 2013 à Avril 2014) – REC WS 51