1. Full cryogenic operation of AMTF – the first year
6th International Workshop on Cryogenic Operations
Bernd Petersen DESY MKS
presenting the work of many colleagues:
IFJ-PAN (Poland)
WUT(Poland),BINP(Russia),
Linde/Cofely and several DESY groups
How to edit the title slide
Upper area: Title of your talk, max. 2 rows of the defined size (55 pt)
Lower area (subtitle): Conference/meeting/workshop, location, date, your name and affiliation, max. 4 rows of the defined size (32 pt)
Change the partner logos or add others in the last row.
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

2. 6th International Workshop on Cryogenics Operations
Outline
AMTF - purpose & objectives (TDR)
AMTF – layout
AMTF- main cryogenic components
Refrigerator availability
Main cryo operation problems
General safety requirements
Cryogenic safety
Safety of work organisation
Some preliminary test results for XFEL cavities & modules
(Preliminary) conclusions
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

3. AMTF: purpose & objectives (TDR)
- Complete cold performance test of all XFEL cryomodules before tunnel installation (RF, vacuum,cryo-losses)
103 cryomodules, rate: 1/week
- Cold RF test of all XFEL superconducting cavities before cryomodule assembly
824 cavities, rate 6/week
- Cold test of all superconducting magnet packages before cryomodule assembly
103 magnets, 1/week
- ( Assembly and tests of RF Waveguides (WP1)
at Waveguide Assembly and Test Facility WATF)
Before you start editing the slides of your talk change to the Master Slide view: Menu button “View”, Master, Slide Master:
Edit the following 2 items in the 1st slide: 1) 1st row in the violet header: Delete the existent text and write the title of your talk into this text field 2) The 2 rows in the footer area: Delete the text and write the information regarding your talk (same as on the Title Slide) into this text field.
If you want to use more partner logos position them left beside the DESY logo in the footer area Close Master View
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

4. 6th International Workshop on Cryogenics Operations
AMTF layout (TDR)
84m x 48m
Before you start editing the slides of your talk change to the Master Slide view: Menu button “View”, Master, Slide Master:
Edit the following 2 items in the 1st slide: 1) 1st row in the violet header: Delete the existent text and write the title of your talk into this text field 2) The 2 rows in the footer area: Delete the text and write the information regarding your talk (same as on the Title Slide) into this text field.
If you want to use more partner logos position them left beside the DESY logo in the footer area Close Master View
Three test benches (XATB1, XATB2 and XATB3) for testing assembled modules and for high power tests of assembled cavities
Two test cryostats (XATC1 and XATC2) for RF performance tests of the cavities
(One magnet test stand XMTS (located in the Magnet Test Hall Building 55) for testing magnets)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

5. 6th International Workshop on Cryogenics Operations
AMTF Hall - Cavity
Vertical Cryostat
Radiation protection shielding
Cavity preparation area
Cavity storage area
Cavity incoming check area
Clean room
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

6. 6th International Workshop on Cryogenics Operations
AMTF Hall - Cryomodule
Unloading of the cryomodule after transport
Cryomodule preparation area
Cryomodule test stand
Cryomodule test stand – module inside
Cryomodule test stand – front view
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

7. XMTS: Test stand for sc XFEL Quadrupoles
Formal part of AMTF but installed and in operation since July 2008
Status November 2014:
96 (of 103) Quadrupols tested
For the development and series tests of superconducting magnet packages & current leads (in MTH-bldg 55)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

8. Cryogenic operation of AMTF
AMTF is supplied by the FLASH-Helium-Refrigerator (former refrigerator 42 of the HERA plant)
For the operation of the AMTF 3 KW at 40/80K, 0.5 KW at 4.5K and a peak liquifaction rate of 33 g/s
have to be delivered. The peak liquifaction is buffered by means of a 1oooo ltr liquid helium
storage dewar (XAST.)
Capacity limit:
return gas peak
screw compressor capacity during cool down/warm-up
2 dynamic procedures in parallel
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

9. AMTF – cryogenics contributions
Red = WUT
Wroclaw University of Technology -> Kriosystem
Blue = DESY MKS
Acting for XFEL company
(no in-kind !) -> DEMACO
Green= BINP
Budker Institute Novosibirsk
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

10. AMTF components (utilities etc./DESY in-kind)
Pump station – completed in September 2010
Compressor station – completed in August 2010
Control building – completed in October 2010
Test Hall – erected in May 2010
Piping bridge – completed in October 2010
Before you start editing the slides of your talk change to the Master Slide view: Menu button “View”, Master, Slide Master:
Edit the following 2 items in the 1st slide: 1) 1st row in the violet header: Delete the existent text and write the title of your talk into this text field 2) The 2 rows in the footer area: Delete the text and write the information regarding your talk (same as on the Title Slide) into this text field.
If you want to use more partner logos position them left beside the DESY logo in the footer area Close Master View
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

11. 6th International Workshop on Cryogenics Operations
Transfer line XATL1
The ~170m long DN400 transfer line XATL1 supplies the test stands with cryogenic power from HERA refrigerator. WUT/Poland in-kind.
Spec DESY:
Short specification in August 2008
Full specification in August 2009
Commissioning August 2012
– in continuous operation since December 2012
Before you start editing the slides of your talk change to the Master Slide view: Menu button “View”, Master, Slide Master:
Edit the following 2 items in the 1st slide: 1) 1st row in the violet header: Delete the existent text and write the title of your talk into this text field 2) The 2 rows in the footer area: Delete the text and write the information regarding your talk (same as on the Title Slide) into this text field.
If you want to use more partner logos position them left beside the DESY logo in the footer area Close Master View
DESY (in-kind):
Valve box for XATL1 at refrigerator
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

12. Helium compressors (DESY in-kind)
2 sets of compressors for 2K operation at AMTF ( 2 x 20 g/s helium at 20 mbar)
1 set = 13 x parallel (WS 2001 RUVAC roots blower + SOGEVAC SV750B )
– simple, (robust), modular, redundant
Manifacturer: Oerlikon Leybold
SOGEVAC:
4 unscheduled repairs,
complete replacement of bearings & packing rings (all SOGEVAC)
RUVAC: 4 repairs,
complete exchange of bearings ongoing (all RUVAC)
RUVAC
No impact for AMTF operation
Very reliable service & support from manufacturer
SOGEVAC
In average: about 5000 h operation (status November 2014)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

13. AMTF Vertical Cryostats
SPEC DESY
April 2009
Design & Construction
WUT&Kriosystem
Poland in-kind
Delivery & installation:
July 2012 – April 2013
Cavity Frame Design:
DESY FLA
6 inserts for AMTF
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

14. AMTF: 3 cryomodule test stands & cryostat adapters
Spec DESY (February 2010)
Design, Construction, Installation: BINP in-kind
First test stand delivered & installed May 2013 (cold commissioning July 2013)
Cold commissioning of 3rd test stand December 2013
2 cryostat adapters for the test of single dressed cavities at AMTF
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

15. 6th International Workshop on Cryogenics Operations
XAST,XAVB, XAVB
DESY is acting for the XFEL company
Manufacturer: DEMACO NL
Wessington Cryogenics Ltd UK
L Helium Dewar XAST
Sub Cooler Box XASB
Valve Box XAVB
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

16. Cool down and Warm up XATC1, XATC2 XATB1, XATB2, XATB3
Pump and purge manual
Cool-down to 4K, liquid helium transfer and warm-up process automatized by use of SNL scripts
Pump-down to 2K manual
XATB1, XATB2, XATB3
Pump and purge manual
Complete cool-down and warm-up process performed manually by cryo-operators
Pump and purge
Pump and purge
Cool-down to 4K, helium liquefaction
Cool-down to 100K
Liquid helium transfer to the cryostat
Pump-down to 2K
Cool-down to 70K
Pump-down to 2K
Measurement at 2K
Measurement at 2K
Warm-up to 300K
Liquid helium transfer from the cryostat
Pressure rise to 1 Bar
Warm-up to 300K
Liquid helium evaporation
Pressure rise to 1 Bar
Cryogenics operation sequence for vertical cryostat
Cryogenics operation sequence for cryomodule test stand
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

17. Vertical Cryostats Operation Cycles
Example: July > September 2014
About 180 cycles since start of AMTF operation in 2013
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

18. XFEL Cryomodule tests operation Cycles
About 20 cycles since September 2013 (now 13th XFEL cryomodule under test)
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

19. Refrigerator Avialability 2013
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

20. Refrigerator Avialability 2014
Courtesy of
J.Zajac Linde/Cofely
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

21. Main Cryo Operation Problems in AMTF
Mixing of serial tests with installation work and commissioning
Problems with warm 2K helium compressors (see transparency)
Mixing of warm&cold gas for controlled cool-down/warm up
LHe level measurements affected by electrical heaters
2K supply JT-valve in module test stand 3 (XATB3) out of shape
Misalignment of process tube flanges (feed-caps) -> adapters
‚Digital‘ operation of valve positioners -> change type of positioners
Thermal contact of electrical heaters -> use of ‚CMTB-type‘ heaters
Liquid level measurements -> increase current
Mix-up of thermometers (calibration) -> try to sort, some re-
calibration
-> Several problems with well known and ‚mature‘ components !
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

22. Cryogenic safety
no general risk of oxygen deficiency within the AMTF hall (about m3 volume)
oxygen deficiency monitors in each module test stand radiation protection cave
design of helium safety valves and venting systems according to our cryomodule ‚crash-tests‘ on CMTB
or – on default- according to ‚Lehmann-Zahn‘ values
5K and 40/80K helium release systems separated from 2K release systems (20 bar vs. 4 bar)
all safety valves vent into helium volumes – venting to atmosphere outside the hall
Oxygen monitor
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

23. AMTF: general design & safety requirements
EU/German law ‚Betriebssicherheitsverordnung‘
DESY safety rules
Rules&procedures for buildings & utilities
General safety & radiation safety rules
Pressure vessels: PED (AD2000,EU harmonized code)
This means in advance of technical commissioning:
Third party interlock approvals
PVI(=appoval before operation) by third party
(the complete procedure took several months for AMTF)
… (list is not complete)
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

24. AMTF safety at work - organisation
Safety officers for different working areas
Electronic access control for AMTF (‚DACHS‘)
Safety instructions checked by electronic access control (general safety, cryogenic safety, radiation safety)
‚DACHS‘
electronic access control
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

25. Vertical acceptance tests25
Vertical acceptance tests
Analysis of vertical acceptance tests includes
Series Cavities + “ILC HiGrade”-Cavities
NO infrastructure commissioning tests
So far delivered: 488 cavities (status November 2014)
Total RF tested: 450 cavities
Manufacturer 1
Manufacturer 2
Average: > 9 tests per week since Oct (full operation of AMTF)
Status of plot: July 2014
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

26. Yield of gradients: “As received”26
Yield of gradients: “As received”
Yield of usable and maximum gradient of 339 cavities “as received” M1 M1 M2 M2
Average maximum gradient:
(30.4 ± 7.6) MV/m M1: (28.4 ± 7.1) MV/m M2: (32.4 ± 7.6) MV/m
Average usable gradient:
(26.6 ± 7.6) MV/m M1: (24.8 ± 7.0) MV/m M2: (28.6 ± 7.9) MV/m
given errors are standard deviation
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

27. Summary of preliminary module results27
Summary of preliminary module results
Status November 2014: XM13 is under test, 18 modules at DESY
average max. gradient module [MV/m]
average max. gradient vertical [MV/m]
Average operational gradient module [MV/m]
Average usable gradient vertical [MV/m]
XM-2
27.2
28.1
24.5
26.5
XM-1
28.2
30.8
25.1
29.4
XM1
30.3
32.5
27.6 29
XM2
27.7
32.7
25.5
28.6
XM3
30.4
32.0
28.8
29.3
XM4
33.3
23.8
30.5
XM5
27.8
28.9
24.9
26.9
Courtesy of
J.Swierblewski IFJ-PAN details see LINAC 2014
All results above XFEL specs MV/m
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY

28. Some (preliminary) conclusions
Deliveries & installation of XATCs,XATB,XAVB,XATL
were ‚just-in-time‘ for start-up of cavity production
Deliveries & installation of XATBs
were ‚just-in-time‘ for start-up of cryomodule production
No dedicated de-bugging of cryo-supply (and other systems)
XATCs design capacities demonstrated
Complexity of XATBs commissioning underestimated
General effort for installation & commissioning underestimated
To be demonstrated: 1 cryomodule test/week
So far: in budget and almost ‚in time‘ (not ‚on schedule‘)
Thank you for your attention !
6th International Workshop on Cryogenics Operations
Bernd Petersen DESY