1. 1 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund P. Bosland (on behalf of the CEA/Irfu and CNRS/IPNO teams) ESS elliptical cryomodules Two families of elliptical cavities: Medium beta:  =0,67 High beta:  =0,86 (geometrical beta values) Same cryostat for both types of cavities

2. 2 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Cryomodule sub-system  Segmented LINAC:  Independent cryogenic cooling and control  Warm-up of a individual cryostat is possible  Individually removable cryostats for repair is possible  Focusing elements at warm temperature

3. 3 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund IPN ORSAY: cryostat design and fabrication  Vacuum vessel  Space frame – cavity supports  Thermal screen  Superinsulation  Internal cryogenic pipes  Instrumentation CEA SACLAY: “cavity package”, the cryomodule assembly and RF power tests  Cavities + helium tank  Power coupler design, manufacturing, RF tests  Piezo tuner  Magnetic shield  Tooling: field flatness, cavity preparation, cryomodule assembling, …  Cryomodule assembly  Tests stand for cryogenic and RF power tests  Tests of the ECCTD cryomodule Two prototype cryomodules  M-ECCTD with medium beta cavities - 2012 – 2016  FR-SW agreement  Collaboration IPNO and IRFU  H-ECCTD with high beta cavities - 2014 – 2017  French In-kind contribution The IRFU - IPNO collaboration

4. 4 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Cryomodule Design total length: 6.6 m Beam height: 1.5 m  Similar to CEBAF/SNS cryomodule with 4 cavities per cryomodule  Common design for medium (6 cells) and high beta (5 cells) cavity cryomodules  Accelerating gradient: for b=0.67 (Medium Beta): Eacc=16.7 MV/m Qo> 5E9 at 2 K for b=0.86 (High Beta): Eacc=19.9 MV/m Qo> 5E9 at 2 K  Maximum operating helium pressure: 1.431 bar

5. 5 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund 57,5 mm Medium / High beta cavity High beta (0,86): -5 cells -Length 1316,91mm High beta (0,86): -5 cells -Length 1316,91mm Medium beta (0,67): -6 cells -Length 1259,40mm Medium beta (0,67): -6 cells -Length 1259,40mm MediumHigh Geometrical beta0.670.86 Frequency (MHz)704.42 Operating temperature (K)2 Maximum surface field in operation (MV/m) 44 Nominal Accelerating gradient (MV/m) 16.719.9 Nominal Accelerating Voltage (MV) 14,318,2 Q 0 at nominal gradient> 5e9 Cavity dynamic heat load (W)4,96,5 Q ext 7.5 10 5 7.6 10 5 MediumHigh Iris diameter (mm) 94120 Cell to cell coupling k (%) 1.221.8  and 5  /6 (or 4  /5) mode separation (MHz) 0.541.2 E pk /E acc 2.362.2 B pk /E acc (mT/(MV/m)) 4.794.3 Maximum. r/Q (  ) 394477 Optimum  0.7050.92 G (  ) 196.63241 No HOM couplers HOM frequencies must be carefully controlled No HOM couplers HOM frequencies must be carefully controlled Tank (Ti) Magnetic shielding Cold tuning system

6. 6 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Fundamental power coupler Coupler conditioning set-up P max = 1.2 MW peak at 4 % duty cycle → critical component  RF ceramic window  Inner conductor Conical tip for stronger coupling Water cooling  Outer conductor Cooled with Liquid He in the vac. Vessel  Coax to rectangular RF transition (Door Knob) HV bias with RF trap  CM integration Large diameter flange with below on vacuum vessel Diagnostic ports distribution

7. 7 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Rods (TA6V, Diam. 6mm) Magnetic shield Half rings linked to the tank (under the magnetic shield) Supports of the different cold components Cross rods fixed on 2 titanium half rings fastened to the helium tank on one side and on the spaceframe on the other side 3000N pre-stress applied on the rods, maximum force 8500N per rod after cooling down Special boxes allowing the axial moving and the thermalization of the thermal shield Thermal shield Supporting rods 2 wheels fixed to the spaceframe at each extremity Guiding ensured by two rails welded to the vacuum vessel 3 jacks at 120° supporting the spaceframe after insertion Rod Pre-stress nut Blocking nut

8. 8 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Inter-cavities bellows HIGH BETA Number of corrugations: 6 Overall length 183mm (at rest) Axial stiffness for 6 corrugations 35N/mm Radial stroke for 6 corrugations +/-0.48mm Radial stiffness for 6 corrugations 7417N/mm MEDIUM BETA Number of corrugations: 10 Overall length 240,5mm Axial stiffness for 10 corrugations 21N/mm Radial stroke for 10 corrugations +/-0.80mm Radial stiffness for 10 corrugations 4450N/mm Cold to warm transition Mechanical cavity misalignment on the cavity strings Longitudinal shrinkage of the cavities Thermal isolation at the two extremities of the cryomodule Distribution of the RF HOM modes

9. 9 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Depl. Total (mm) Depl. Struct. (mm) Depl. Blocs (mm) Contrainte max (Mpa) 1,32 1,24 (Z: -1,21 à +0,50) 0,12 à 1,08 (Z: -0,89 à +0,18) 30 Spaceframe Forces on Rods: 3000 to 9000N Mass spaceframe: 400 - 430 Kg Total mass of cavities + thermal shielding: 1200Kg Blocking by 3 jacks on two levels Tuning (3 positions) Spaceframe: Aluminium alloy Lower part can be disassembled to insert the couplers

10. 10 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Access traps  blocking of the cavities and spaceframe during transport  Access in the tunnel  Maintenance of cold tuning system (change motor and piezo)  Access in the tunnel  Maintenance of cold tuning system (change motor and piezo)

11. 11 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Reflector brackets (coupler flange) Reflector brackets (cavity flange) Alignment made by laser tracker Alignment of the cryomodule in the tunnel (source ESS) 1,5" Corner cube reflector Additional fiducials will be set up inside the ECCTD cryomodule to check the alignment after cooling down. Alignement of the cavities Reflector brackets (vessel alignment) Alignment of the cavity string within 1,5 mm of the beam axis 1 2 3 4 Beam axis reported to reflector bracket on beam flanges Vessel alignment with respect to cavity string

12. 12 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Heat loads Values in Watts

13. 13 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Helium cooling PID Special boxes allowing the axial moving and the thermalization of the thermal shield

14. 14 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Compliance with the PED 97/23/EC Vessels Pipes PS<0,5bar: The equipment is not on the scope of the 97/23/CE directive Article 3.3 The equipment must be designed and manufactured according to workmanlike way Category I The manufacturing must be more documented, especially with internal production control  Objective: stay within « Article 3.3 » area 50 L Elliptical cavity 1 bar Relative pressure

15. 15 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund SAFETY DEVICES European rules compliance Article 3.3 ESS Helium factory, circuits and operating modes Helium Pressure relief devices Working pressure = nominal pressure WP P SET Set Pressure PS Maximum allowable overpressure PS + 10% BURSTING DISK SAFETY DEVICES P SET P OPENING = + 5 % P SET (overpressure when opening) P MAX APERTURE = + 10 % P OPENING P CLOSING = - 5 % P SET P MIN CLOSING = - 10 % P CLOSING (hysteresis before closing) P SET + 10% P SET – 10% RELIEF VALVE Bursting area Opening area WP upper limit Max. allowable press. Safety margin 1,9 bar 1,431 bar (1,3 +10%) 1,729 bar 1,301 bar MAWP 1,58bar 1,670 bar 1,496 bar 1,891 bar 59mbar 65mbar 1,81 bar Bursting disks +/- 10% 2,09 bar Cavity pressure test 1,43 PS 2,72 bar 1,609 bar 1,551 bar Absolute pressure

16. 16 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Helium low pressure circuit 2 bursting disk at each tip + upstream safety relief valve (with he guard) 36° Heat exchanger The circuit is designed to reduce as low as possible the overpressure in case of beam vacuum failure by using a continuous DN100 diameter for the diphasic pipe, large curvatures and 2 DN100 bursting disks at each extremity. A 36° angle is set up for the tank nozzle in order to allow the insertion of the cavity string and the cooling circuit inside the spaceframe To valve box Worst scenario: beam vacuum failure 38KW/m 2 heat load on the cavity wall Accidental overpressure: 230mbar after rupture of the disks

17. 17 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Status of the M-ECCTD  Cavities:  Design finished  Medium beta: fabrication started (KO meeting 03/09/2014)  Couplers:  RF window and antenna ordered  Call for tender for outer conductor (double wall) and door-knob to be launched in the following weeks  Tuners, magnetic shielding:  Design 95% finalized  Fabrication to be launched  Spaceframe, vacuum vessel:  Design finalized. Preparation of the procurement procedures in progress (goal: launch the procurement before the end of January 2015)  Test stand: modification of the cryogenic line and HV modulator in progress  Clean room assembly toolings: studies started - still in progress  Cavities:  Design finished  Medium beta: fabrication started (KO meeting 03/09/2014)  Couplers:  RF window and antenna ordered  Call for tender for outer conductor (double wall) and door-knob to be launched in the following weeks  Tuners, magnetic shielding:  Design 95% finalized  Fabrication to be launched  Spaceframe, vacuum vessel:  Design finalized. Preparation of the procurement procedures in progress (goal: launch the procurement before the end of January 2015)  Test stand: modification of the cryogenic line and HV modulator in progress  Clean room assembly toolings: studies started - still in progress

18. 18 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund 2 prototype high beta cavities haut béta have been tested: The 2 cavités ZANON et RI are within the ESS specifications. 18

19. 19 ESS cryomodules Workshop 15-16 October 2014 Lund Cryomodule assembly

20. 20 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund M-ECCTD Two objectives: 1.To qualify the technology 2.To prepare the assembly procedures, the tools and the documentation for the serial elliptical cavity cryomodules Assembly procedure Integration tools Documentation Others Items manufacturing ECCTD integration Assembly procedure Integration tools Documentation Others Ready for the serial cryomodules Preliminary Version Final Version

21. 21 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund  Study of the assembling sequence and needs of toolings  Pre-study of the toolings: compatible with both types of cavities medium and high beta Assembling in clean roomAssembling outside clean room Student: Amaury Martin 09/2013 – 01/2014 Analyse of the assembling sequence

22. 22 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Coupler / cavity assembly  State of the art: interface coupler / cavity parallel to the laminar air flow  Horizontal coupler  Rotation needed after assembly to get to the final vertical position of the coupler in the cryomodule  Complex tooling  First rough analysis of the air flow around the flange: the air flow may be pertubated because of the reinforcement sheets of the helium tank Air speedWhirlwind Coupler vertical Coupler horizontal  Choice: vertical assembly  Tooling compatible for both types types of cavities  Adjustment of the coupler position relative to the cavity flange

23. 23 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Frame and supports for the assembly in clean room

24. 24 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Cavity string assembly in clean room  Design still in progress  Beam axis height: 1150 mm from the clean room ground  Individual position adjustment system of each cavity and bellow  Supports of the cold to warm transition bellows to be designed

25. 25 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Assembly outside clean room Thermal screen installed but not shown Wheels on the spaceframe Guiding rail on the vacuum tank

26. 26 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Conclusion. The implementation of the assembling process at Saclay will be based on the SPIRAL2 and XFEL experience Courtesy of Spiral 2 CEA team Courtesy of Catherine MADEC - XFEL

27. 27 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund

28. 28 Requirements Conformance for SRF cryomodules 15-16 October 2014 Lund Thank you for your attention