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X-FEL Cryomodule Development. XFEL-WP 10 ‚Module Test‘ Bernd Petersen DESY –MKS- 1st ILC-Workshop, KEK, November 2004. Overview. Industrial Cryomodule Assembly Studies ( Single-) C ryo m odule T est B ench X-FEL Cavity&Cryomodule Test Facility. - PowerPoint PPT Presentation
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1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
X-FELX-FELCryomodule DevelopmentCryomodule Development
XFEL-WP 10 ‚Module Test‘XFEL-WP 10 ‚Module Test‘Bernd Petersen DESY –MKS-
1st ILC-Workshop, KEK, November 2004
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Overview
Industrial Cryomodule Assembly Studies
( Single-) Cryomodule Test Bench
X-FEL Cavity&Cryomodule Test Facility
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
‘In view of the European X-FEL-project and other FEL light sources like the BESSY-FEL-project, which will use the superconducting linear accelerator TESLA technologies, the already existing design and assembly procedures of prototype cryomodules have to be reviewed by industrial studies in respect to series production, reduction of efforts and costs, and increase of performance. This review shall be part of the EUROFEL design study work package DS6 ‘Cryomodule Technology Transfer.’ In addition, for the time being, the TESLA technology represents the most developed approach for a superconducting linear collider, which will be the basis for the design of the future International Linear Collider (ILC). ‘
Scope of the Industrial Module Assembly Studies
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Industrial Studies on assembly ProceduresProcurement of cryomodules – legal restrictions
For the time being DESY can not start the complete cryomodule procurement ( only after final agreement with other XFEL- partners)
On the other hand: in order to adapt the cryomodule design to industrial series production, industry should be involved as soon as possible
-> Industrial assembly studies are separated from the final
procurement procedure for the cryomodules
EU-procurement for industrial studies will be started open to
industry
Results will be published open to public and industry
-> equal information and chances for industry at the start of the final module procurement
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Industrial Studies on assembly Procedures
Specifications for the procurement of the studies :
- Review of present cryomodule design & design changes for XFEL
- Analysis and review of the present assembly procedures ( inside /outside cleanroom)
- Suggestions for design/ assembly changes in respect to performance, cost savings and series production
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
internal modul production number
design type status of planning
earliest date of assembly
comment
6 TTF-III scheduled May 2005 35 MV/m high gradient module
7 TTF-II scheduled December 2005 VUV-FEL linac spare module
8 X-FEL not yet scheduled
end of 2006 X-FEL prototype
9 ? not yet scheduled
? ?
At least 2 competent companies shall analyze the assembly of modules 6 an 8
Procurement of the studies is in Progress: December 2004
(Completely separated from the final cryomodule procurement procedure)
The studies will be published !
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Industrial Studies on assembly procedures
CLR string assembly
assembly outside CLR
Preserve performance of cavities !
Save assembly costs !
-> Assembly procedures can be -> Assembly procedures can be verified only in verified only in module testsmodule tests
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Objectives of the test bench:
• In general: cryomodule tests independent from TTF-linac operation• RF cavity processing / performance • processing of RF couplers • cryogenic performance• tests of vacuum systems• tests after repairs before installation into linac• tests of new design features ( 2K quad ...etc.)• dark current• Wire Position Monitors • thermal cycling• insulation vacuum / beam vacuum venting• ...etc.........
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Types of CryomodulesTable 1: The presently known different cryomodule designs or basic concepts, which have to be tested on the CMTB ( for the (*)-marked types, no final designs exist yet ) Type of cryo module
Vacuum vessel diameter / mm
Number of cavities/ RF main couplers
Magnet package
2K-2-phase tube
Length /m Coupler distance/mm
TTF-type II 1089 8/8 4.5K end cap side
on top of cavity
12.2 1380.5 -1381
TTF-typeIII 965.2 8/8 4.5K end cap side
see fig.2 12.2 1380
TESLA type preliminary compressed 9-cell (*)
965.2 8/8 2K center of module
see fig.2 12.2 1319.2 ???
TESLA type compressed 9-cell (*)
965.2 12/12 2K center of module
see fig.2 17.136 1319.2
TESLA type 9-cell-super structure (*)
965.2 12/6 2K center of module
see fig.2 16.1306 2471.7
NN (*) NN NN NN NN NN NN
XFEL
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
CMTB test hall
TTF
Hall3
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
CMTB test hall (2)Cave cross section
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Status of cryogenic components
feed box
(odered)feed cap
(ordered)
end cap (ordered)
cryomodule
supports
(designed)
feed cap transfer line
(ordered)
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Line of construction
DN250 tranfer line
DN150 30mbar line
DN100 water pipe
RF wave guides
cable traces
______________
DN200 LP
DN80 HP
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
DN25 4.5K forward
DN50 4.5K return
DN25 40K forward
DN25 80K return
80K shield covered
DN250 vacuum tube
CMTB-transfer line (ordered)FEL-subcooler box -> CMTB feed box
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
cryogenic supply of the CMTB
HERA CB
HERA SCREWS
SC&V BOX
MOD TEST SMESVUV-FEL LINAC
TTF CB
TTF SCREWS
VD1 VD2 CHECHIA VD3
VC2 VC1
HEX
11/2005 12/2004
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Cryo Module Test BenchSome details:
Cryogenic equipment:
After EU call for tender now in the process of making contracts
RF-equipment:
Modulator, puls-transformer on DESY site
Klystron ordered, will be delivered in 2005
Call for tender for wave guides etc….
Civil engineering:
Final specifications ready, procedures prepared and will be started now
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Cryo Module Test Bench
ID Vorgangsname Duration Start Finish
1 Cryomodule Test Bench 429 dys Tue 01.06.04 Fri 20.01.06
2 Civil engineering/building 220 dys Mon 06.09.04 Fri 08.07.05
3 test hall 220 dys Mon 06.09.04 Fri 08.07.05
4 building permit 3 mons Mon 20.09.04 Fri 10.12.04
5 demolishing the Nissen hut 2 wks Mon 04.10.04 Fri 15.10.04
6 cutting trees 1 mon Mon 18.10.04 Fri 12.11.04
7 tubing the stream 1 mon Mon 18.10.04 Fri 12.11.04
8 hardening ground 2 wks Mon 15.11.04 Fri 26.11.04
9 specification for test hall 1 mon Mon 06.09.04 Fri 01.10.04
10 call for tenders 2 mons Mon 04.10.04 Fri 26.11.04
11 contract 2 mons Mon 29.11.04 Fri 21.01.05
12 erecting the hall 6 mons Mon 24.01.05 Fri 08.07.05
13 line of construction 80 dys Mon 13.09.04 Fri 31.12.04
14 specification 1 mon Mon 13.09.04 Fri 08.10.04
15 fundaments 30 dys Mon 11.10.04 Fri 19.11.04
16 manufacturing 30 dys Mon 11.10.04 Fri 19.11.04
17 mounting 30 dys Mon 22.11.04 Fri 31.12.04
18 shielding 85 dys Mon 06.09.04 Fri 31.12.04
19 specification 3 wks Mon 06.09.04 Fri 24.09.04
20 call for tenders 6 wks Mon 27.09.04 Fri 05.11.04
21 contract & 1st payment 40 dys Mon 08.11.04 Fri 31.12.04
22 Cryogenics 369 dys Tue 01.06.04 Fri 28.10.05
23 Feed-box,-cap, end-cap 369 dys Tue 01.06.04 Fri 28.10.05
24 call for tenders 79 dys Tue 01.06.04 Fri 17.09.04
25 contract 2 mons Mon 20.09.04 Fri 12.11.04
26 design/construction 250 dys Mon 15.11.04 Fri 28.10.05
27 Transfer line 369 dys Tue 01.06.04 Fri 28.10.05
28 call for tenders 79 dys Tue 01.06.04 Fri 17.09.04
29 contract 2 mons Mon 20.09.04 Fri 12.11.04
30 design/construction 11 mons Mon 15.11.04 Fri 16.09.05
31 installation 1.5 mons Mon 19.09.05 Fri 28.10.05
32 warm valves 265 dys Wed 01.09.04 Tue 06.09.05
33 specification 30 dys Wed 01.09.04 Tue 12.10.04
34 procurement 2 mons Wed 13.10.04 Tue 07.12.04
35 construction,delivery 6 mons Wed 23.03.05 Tue 06.09.05
36 warm gas tubing 120 dys Wed 23.03.05 Tue 06.09.05
37 construction 6 mons Wed 23.03.05 Tue 06.09.05
38 cryo-controls 178 dys Mon 03.01.05 Wed 07.09.05
39 hardware 120 dys Mon 03.01.05 Fri 17.06.05
40 software 143 dys Mon 21.02.05 Wed 07.09.05
41 RF-Euquipment 60 dys Mon 11.07.05 Fri 30.09.05
42 RF and LL-RF 3 mons Mon 11.07.05 Fri 30.09.05
43 commissioning 60 dys Mon 31.10.05 Fri 20.01.06
44 first operation 3 mons Mon 31.10.05 Fri 20.01.06
May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan2004 2005 2006
First operation / commissioning: November 2005
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
X-FEL Cavities: Test Scheme
Fabrication
Preparation
CLR BCP/EP
Tank Welding
Coupler etc
100% Tests
CHECHIA
Optional Tests
?
DESY Site
Out of DESY
about 1000 Cavities production rate: 8 / week
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Test -Schedule for Vertical Tests 4.5 K liquefaction loads Status: 27.1003 B.Petersen DESY -MKS-Time / h 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31AssemblyPump & Purge,leak checksCool down 300K->4.5 K 0 0Cryostat filling 50 50pump down 4.5K->2K 50 50measurement 1 cavity 20 20measurement 1 cavity 8 8 8 8measurement 1 cavity 8 8 8 8measurement 1 cavity 8 8 8 8warm up 2k -> 300K 8 8 8 8Dis-assembly
Single Cavity Test Schedule
4 cavities tested in 31 h -> 2 Cryostats +1
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Horizontal Test (CHECHIA) Test Schedule
Test of one cavity : 8 – 12 d
-> 2 cryostats
optional
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Cryomodule Test Schedule
Test of one cryomodule: 14 d
Production rate: 1/ week
-> 3 (+ 1) Test Benches
100% Test of all cryomodules
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
X-FEL Test Hall Layout
optional
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Test Hall Layout
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Cryogenic Supply
overall design average heat loads
10 KW at 40/80 K ( HERA CB 20 KW) 1 KW at 4.5 K (HERA CB 6.8 KW)
( 0.6 KW at 2K)+ 50 g/s liquefaction at 4.5K ( HERA CB 20.5 g/s)
4.5 K peak loads will be buffered by one 10 m3 storage dewar
no 2K helium distribution system
distributed warm helium pumping units10 g/s ( 20 mbar) at module test benches
20 g/s ( 20 mbar) at vertical dewars
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
RF components
5+1 10MV Klystrons
5+1 Modulators
waveguide distribution / circulators for 3+1 module test benches and 2 horizontal test cryostats
350 KW/ coupler
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
X-FEL Testhall: Staff profile
0
5
10
15
20
25
30
35
40
45
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Quarter of Year
Sta
ff
0
2
4
6
8
10
12
14
Qu
an
tity
of
Ca
v /
Mo
d
scientist
engineers
mechanics
Cavities/w
Mod/w
Engineers / TechniciansVac/ Cry / RF/ Controls
Mechanics
Cavities/ Week
Modules / Week
Scientist
Spec Tender Fabrication Installations Commissioning Full Operation Fade Out
Civil Engineering / Utilities
Training
0peration: 3 years after start of project
1st ILC-Workshop KEK 11/04 Bernd Petersen DESY
Summary
Industrial XFEL-cryomodule assembly studies are started now
A cryomodule test stand will be in operation end of 2005
XFEL-cryomodule test hall will start operation in 2009