SCRF Industrialization
Public Report Akira Yamamoto, Marc Ross, and Nick Walker
ILC-GDE Project Managers
Prepared for ILC-PAC Review, Prague, Nov. 14-15, 2011
Preparation forSCRF Industrialization
GDE-PMs, 14th Nov. 2011 1
SCRF Industrialization
Outline
• Introduction– Industrialization models
• Progress in Communication with industry
• Plan for further study
GDE-PMs, 14th Nov. 2011 2
SCRF-ML Technology RequiredRDR Parameters Value
C.M. Energy 500 GeV
Peak luminosity 2x1034 cm-2s-1
Beam Rep. rate 5 Hz
Pulse time duration 1 ms
Average current 9 mA (in pulse)
Av. field gradient 31.5 MV/m
# 9-cell cavity ~ 18,000(14,560 + a ) x 1.11
# cryomodule (8+4Q4+8, in study)
~ 2,000 (1,680+ b) x 1.08
# RF units ~ (560+g) x 1.08
3GDE-PMs, 14th Nov. 2011
RDR SB2009
SCRF Industrialization
Cavity Fabrication Process
He Tank
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 4
Material/Sub-component
Cavity Fabrication
Surface Process
LHe-Tank Assembly
Vertical Test =Cavity RF Test
CryomoduleAssembly and RF Test
SCRF Industrialization
SCRF Procurement/Manufacturing Model
Regional hub-laboratories responsible to regional procurements to be open for any world-wide industry participation
Regional Hub-Lab:E, & …
Regional Hub-Lab:
A
Regional Hub-Lab:
B
Regional Hub-Lab:
D
World-wideIndustry responsible to
‘Build-to-Print’ manufacturing
ILC Host-Lab
Regional Hub-Lab:C: responsible to Hosting System
Test and Gradient Performance
Technical Coordinationfor Lab-Consortium
: Technical coordination link : Procurement link
GDE-PMs, 14th Nov. 2011 5
Production Process/Responsibility Step hosted Industry Industry/
LaboratoryHub-laboratory
ILC Host-laboratory
Regional constraint no yes yes yes
Accelerator - Integration, Commissioning
Accelerator sys. Integ.
SCRF Cryomodule - Perofrmance Test
Cold, gradient test
As partly as hub-lab
Cryomodule/Cavity- Assembly
Coupler, tuner, cav-string/cryomoduleassmbly work
As partly as hub-lab
Cryomodule component- Manufacturing
V. vessel, cold-mass ...
9-cell Cavity- Performance Test
Cold, gradient test
As partly as hub-lab
9-cell Cavity - Manufacturing
9-cell-cavity assembly, Chem-process, He-Jacketing
Sub-comp/material- Production/Procurement
Nb, Ti, specific comp. …
Procurement
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 6
Reference for Cavity Specification • Technical guideline for ILC-GDE TDR and the cost estimate:
– referring Specifications for E-XFEL SCRF 1.3 GHz Cavity, issued by DESY• EXFEL/001 and associated documents :Rev.B, June 2009, by courtesy of W. Singer (DESY-XFEL)),• The reference specification is available with ILC-GDE PMs, under permission of W. Singer (DESY-XFEL) • URL: http://ilcagenda.linearcollider.org/event/ILC-SCRF-TR
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 7
scrf-treq
Courtesy:W. Singer
Technical Specification Example for Nb Sheet
• Electrical Properties– RRR: > 300
• Chemical contents– see table
• Microstructure– Re-crystalized 100 %– Grain-size: ASTM 6 or finer– Local grain size: ASTM 4-5
• Mechanical Properties– Ultimate strength: > 140 N/mm2, RT– Yield strength: TBD (> xx N/mm2, RT)– Elogation; > 30 %– Hardness: ≤ 60
• Shape/size: TBD – Rect. Sheet : ~ 300 mm sq. or – Circular sheet: ~280 mm dia. with a center-hole
• Possibility of Blanking (in consortium: to be discussed) – Thickness : 2.8 mm +/- 0.1 mm– Flatness: 2 % or better– Surface roughness: < 15 mm (RF side)
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 8
Cavity Deliverable assuming EXFEL cavity specification
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 9
• From EXFEL specification: 02L BQM-Cavity in He Tank
Courtesy:W. Singer
10
Cavity with plug-compatibility Important for Global Cooperation
Plug-compatible interface need to be establishedGDE-PMs, 14th Nov. 2011 SCRF Industrialization
Blade and Slide-Jack Tuners
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 11
SCRF Industrialization
Outline
• Introduction
• Progress in Communication with industry– Progress since May 2011 and status
• Plan for further study
GDE-PMs, 14th Nov. 2011 12
SCRF Industrialization
SCRF Industrialization Study • Our efforts:
– Understand status of industry, and discuss technology and the cost saving effort for the ILC scale production
– Study the ILC SCRF industrialization models • Two approaches in 2011~:
– Visiting and communication with potential industry • visit industry and discuss ‘request for information’ for cost-study,
with currently available industrial technology– Study on specific subjects with small-contracts
• Possible Factory layout for cavity production (in AS; KEK centered)• System engineering for mass production (in EU; CERN centered)
– The coordination meeting held at CERN, in May, July, Sept., 2011• Mass production technology study prepared (in AMs; Fermilab centered)
GDE-PMs, 14th Nov. 2011 13
SCRF Industrialization
Communication with Industry in 2011
• Visit factories, and Request for information– Based on currently available manufacturing technology and available
information with worldwide industry• Assume the EXFEL ‘build-to-print’ specifications as a common reference,
and • Allow alternate designs with ‘plug-compativility’ and with the equivalent or
lestt cost and/or with better performance
• Requests for information to companies1. Cost comparisons: 20/50/100 % in 3 / 6 year after 2-year preparation ?
2. Factory-site location: company or laboratory ?
3. Sharing responsibilities for the cost-effective production ?
4. Deliverables with ‘build-to-print’ fabrication?
5. Consortium to be considered or not
GDE-PMs, 14th Nov. 2011 14
Communication with CompaniesNb, NbTi Material Venders
Date Company Place Technical sbject1 2/8 Hitachi Tokyo (JP) Cavity/Cryomodule
2 2/8 Toshiba Yokohana (JP) Cavity/Cryomodule, SCM
3 2/9 MHI Kobe (JP) Cavity / Cryomodule
4 2/9 Tokyo Denkai Tokyo (JP) Material (Nb) 5 2/18 OTIC NingXia (CN) Material (Nb, NbTi, Ti)
6 (3/3), 9/14 Zanon Via Vicenza (IT) Cavity/Cryomodule
7 3/4, RI Koeln (DE) Cavity
8 (3/14), 4/8 AES Medford, NY (US) Cavity
9 (3/15), 4/7 Niowave Lansing, MI (US) Cavity/Cryomodule
10 4/6 PAVAC Vancouver (CA) Cavity
11 4/25 ATI Wah-Chang Albany, OR (US) Material (Nb, Nb-Ti, Ti)12 4/27 Plansee Ruette (AS) Material (Nb, Nb-Ti, Ti)13 5/24 SDMS Sr. Romans (FR) Cavity14 7/6 Heraeus Hanau (DE) Material (Nb, Nb-Ti, Ti)15 10/18 Babcock-Noell Wurzburg (DE) CM assembly study16 11/11 SST Maisach (DE) Electron Beam Welder
15
Material Cost-study compared with RDR & EXFEL (updated: Nov., 2011)
ILC:RDR
EXFEL ILC:TD OT AW PL
Prep.+Prod. Yrs. 2+3 ~1.5 2+6-1 2+6-1 2+6-1 2+6-1
Fraction 100% 100% 20%(max.)
20% 20% 20%
# Cavity(Nb sheet weight)
17,000 600 3,200, (98 tons)
3,200 3,200 3,200
SC Material
Currentcy unit
GDE-PMs, 14th Nov. 2011 16SCRF Industrialization
Note: The aboveILC material cost is 9-cell cavity’s central part only, Total SC material cost including end-group need to be ~ 10 % higherWe assume the material cost : 20 x (1+0.1) = 22 K ILCU Including the QA/QC cost of “ 2 ”, the total material cost : >>> 22+2 = 24 k-ILCU
Communication with CompaniesSC Cavity Manufacturers
Date Company Place Technical sbject1 2/8 Hitachi Tokyo (JP) Cavity/Cryomodule
2 2/8 Toshiba Yokohana (JP) Cavity/Cryomodule, SCM
3 2/9 MHI Kobe (JP) Cavity / Cryomodule
4 2/9 Tokyo Denkai Tokyo (JP) Material (Nb) 5 2/18 OTIC NingXia (CN) Material (Nb, NbTi, Ti)
6 (3/3), 9/14 Zanon Via Vicenza (IT) Cavity/Cryomodule
7 3/4, RI Koeln (DE) Cavity
8 (3/14), 4/8 AES Medford, NY (US) Cavity
9 (3/15), 4/7 Niowave Lansing, MI (US) Cavity/Cryomodule
10 4/6 PAVAC Vancouver (CA) Cavity
11 4/25 ATI Wah-Chang Albany, OR (US) Material (Nb, Nb-Ti, Ti)12 4/27 Plansee Ruette (AS) Material (Nb, Nb-Ti, Ti)13 5/24 SDMS Sr. Romans (FR) Cavity14 7/6 Heraeus Hanau (DE) Material (Nb, Nb-Ti, Ti)15 10/18 Babcock-Noell Wurzburg (DE) CM assembly study16 11/11 SST Maisach (DE) Electron Beam Welder
17
Cavity Cost-study compared w/ RDR and EXFEL (updated, Nov., 2011)
ILC:RDR
EXFEL:Original 300
Courtesy, H.W.
EXFEL:+ 80
Courtesy, H.W.
ILC:RI AES MHI
Prep.+Prod. Yrs. 2+3 1+2.5 ? 2+6 2+6 2+6
Fraction 100% 2 x 50% ~ same 20% 20% 20%
# cavity 17,000 300 +80 3,200 3,200, 3,200
SC Material (supplied)
Mech. Fabrication including EBW
Chemistry
Ti He-Vessel
Others
Factory investment
Fab. Cost/cavity(+ SC-mat.= Sum)
Unit
Cost Comparison in ILCU
18
Updated Cavity Cost-study compared with RDR and E-FXEL (as of Oct., 2011)
ILC:RDR
EXFEL:Original 300
Courtesy, H.W.
EXFEL:+ 80
Courtesy, H.W.
ILC:RI AES MHI
Prep.+Prod. Yrs. 2+3 1+2.5 ? 2+6 2+6 2+6
Fraction 100% 2 x 50% ~ same 20% 20% 20%
# cavity 17,000 300 +80 3,200 3,200, 3,200
SC Material (supplied)
Mech. Fabrication including EBW
Chemistry
Ti He-Vessel
Accept. Test (RT)
Factory investment
Fab. Cost/cavity(+ SC-mat.= Sum)
Unit
Cost Comparison in ILCU
19
Confidential
Further mass production cost study with contracts in progress: - RI-DESY: 50, 100 % production cost including
facility cost- AES-FNAL: 20 % (& more as option) facility investment
cost- MHI-KEK: 50, 100 % production cost w/ facility
cost
To be completed by spring, 2012.
SCRF Industrialization
Outline
• Introduction
• Progress in Communication with industry
• Plan for further study– Evaluation of technical input– Further detail cost studies with regional efforts
through key laboratories,
GDE-PMs, 14th Nov. 2011 20
SCRF Industrialization
Plan for Further Work
• Evaluation of the industrial response – Frame and common format suggested for smooth
comparisons. • Cost estimate process and conditions:
– Technical survey and investigation for cost-effective production
– Model dependent cost comparison (20~100%) to be further quantitatively evaluated
– Hub laboratory’s input inevitable specially for cryomodule assembly and cold test
– Project management scope how global cooperation and sharing the production to be taken into account
– More mutual work with cost-engineers inevitable
GDE-PMs, 14th Nov. 2011 21
SCRF Industrialization
Technical Information Received
GDE-PMs, 14th Nov. 2011 22
- To be carefully evaluated, in cooperation of PMs and Cost-engineers
SCRF Industrialization
Further Plans to prepare TDR• Cost-estimate work for TDR (by April, 2012)
– Communication with industry under contract• Cavity: RI (w/ DESY), AES (w/ Fermilab), MHI (w/ KEK), • Cryomodule Assembly: BN (w/ CERN), Hitachi (w/ KEK), • Quadrupole: Toshiba (Q, w/KEK)• HLRF (SLAC, KEK)
– Communication with laboratories • Fermilab, JLab, CERN, DESY, Saclay, INFN, KEK, …
• Technical specification to be fixed for TDR cost – SCRF meeting at IHEP, Dec. 8-9, 2011– SCRF-TBR, Jan. 19-20, 2011– GDE meeting, 23-26, April
• GDE-PMs, 14th Nov. 2011 23
SCRF Industrialization
Technical Issues toward TDR• Cavity gradient :
– Update and fix the cavity production and process recipe. – Update and fix the successful production yield definition in production stage,
• including new parameters such as radiation, and the process w/ tumbling
– Gradient spread of 31.5 MV/m +/-20 %, with sorting method, – Gradient degradation after assembly into the cryomodule (see: HLRF/DRFS w/ circulator)
• Cavity Integration– A baseline design chosen for the TDR cost-estimate base,
• Including selection of tuner, coupler, beam-flange, magnetic shield, and LHe tank
– Plug-compatible design to be allowed in case of cost equivalent or more cost effective. – Cavity delivery condition with LHe-tank, and cold-test sequence/monitor,
• Cryomodule and Cavity-string Assembly– Cryomodule string configuration with 8 + (4+Q+4) + 8 cavity-string assembly– Simplification of 5K radiation-shield: simplification of bottom, and removal at inter-connect. – Split-yoke, conduction-cooled quadrupoles– Efficient alignment
• Cavity and Cryomodule Test – Warm conditioning of Input Coupler: before or after installation into the tunnel– Cold performance test: How much fraction to be cold tested? Subjects to be tested?
GDE-PMs, 14th Nov. 2011 24
SCRF Industrialization
Demonstrations and Evaluation of Various Couplers and Tuners in S1-Global
• Every coupler and tuner demonstrated, as expected, and be applicable for ILC cavities
• Finding various subjects to be further investigated and settledGDE-PMs, 14th Nov. 2011 25
Continued• Cryogenics
– Location and the options (reducing the number of station) of cryogenic systems,
– Capacity optimization and heat balance with cryomodule heat-load • HLRF
– KCS/DRFS/RDR-unit HLRF system configuration including backup power supply and utilities with the single tunnel design
– Marx generator to be a baseline modulator, – AC power capacity optimization with gradient spreads, – Adaptability against cavity degradation after installation into cryomodule, by
using circulator and power distribution system, – Optimizations for low-power and high-power option. – Tunable power distbribution system
• ML Integration – Beam dynamics
• Quadrupole/BPM periodicity, locations, alignment, and beam tunability, • Bunch spacing limit specially on KCS (requirement of DR beam dynamics)
– Availability, reliability, and backup of cryomodules to be required GDE-PMs, 14th Nov. 2011 SCRF Industrialization 26
How to prepare for TDR?
• Discussion during LCWS
• Further technical discussion in TTC, Dec. 5 - 8• ILC Specific discussion in post-TTC, Dec. 8-9,
• Consensus for TDR writing, BTR at KEK, Jan. 19 – 20, 2012
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 27
SCRF Industrialization
Summary• Cost-study in Communication with industry
– Major companies responded to our ‘request for information’, and we have received costing information.
– More effort required to reduce the mass production cost, – We are in progress to communicate with industry ,
• to figure out production scale and cost-effective facility (recent reports attached), • to prepare for the information on the model dependent cost estimates (20 ~ 100 %).
– Further study required on risk-mitigation in the various models. • Cost study in Communication with Laboratories
– Communication with potential regional hub-laboratories will be important to establish a whole scope of the cryomodule assembly/test.• DESY, Fermilab, and KEK are working to understand more mass production with
globally distributed production and/or single facility prodcution, • CERN’s involvement is very important to figure out a lab-hosting cryomodule
assembly and test models, in contract with industry
GDE-PMs, 14th Nov. 2011 28
SCRF Industrialization
Backup Slides
• Reference information to establish baseline design for the TDR cost estimates
GDE-PMs, 14th Nov. 2011 29
SCRF Industrialization 30
9-cell cavities: ~ 18,000 (17,325) production
Required Production in ILC
Cryomodule: ~2,000 (1,824) production
Pre-production 2 years +Full production 6 years
GDE-PMs, 14th Nov. 2011
Standard Procedure Establishedfor ILC-SCRF Cavity evaluation, in guidance of TTC
Standard Fabrication/ProcessFabrication Nb-sheet purchasing
Component Fabrication
Cavity assembly with EBW
Process EP-1 (~150um)
Ultrasonic degreasing with detergent, or ethanol rinse
High-pressure pure-water rinsing
Hydrogen degassing at > 600 C
Field flatness tuning
EP-2 (~20um)
Ultrasonic degreasing or ethanol (or EP 5 um with fresh acid)
High-pressure pure-water rinsing
Antenna Assembly
Baking at 120 C
Cold Test (vertical test)
Performance Test with temperature and mode measurement
31GDE-PMs, 14th Nov. 2011 SCRF Industrialization
Key ProcessFabrication• Material • EBW• Shape
Process • Electro-Polishing
• Ethanol Rinsing or • Ultra sonic. + Detergent
Rins.
• High Pr. Pure Water cleaning
allow twice
Cryomodule Gradient Spread and Degradation Observed at DESY and KEK, as of Nov. 2010
• FLASH: – 3 PXFEL cryomodules
• ILC R&D:– S1-Global cryomodule– CM1 (S1-Local @ Fermilab)
• Current status: – 12/40 degraded with ~ 20 %
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 32
1 - AC129 2 - AC123 3 - AC125 4 - Z143 5 - Z103 6 - Z93 7 - Z100 8 - AC1130
510
15
202530
35
40
FLASH 30MV/m XFEL goal
13.07.2009
EA
CC [M
V/m
]
cavity
Cavity tests: Vertical ( CW ) Horizontal (10Hz) CMTB M8 (10Hz) CMTB (10Hz)
very
long
CW
cond
ition
ing
Cavities gradient limits
1 - Z141 2 - AC150 3 - Z133 4 - Z139 5 - AC122 6 - AC121 7 - AC128 8 - AC1150
5
10
15
20
25
30
35
Cavities gradient limits
XFEL goal
04.05.2010
EA
CC [M
V/m
]
cavity
Cavity tests: Vertical ( CW ) Horizontal(10Hz) CMTB (10Hz)
MP
1 - Z135 2 - AC124 3 - Z88 4 - Z134 5 - Z101 6 - AC127 7 - Z140 8 - Z970
5
10
15
20
25
30
35
Cavities gradient limits
XFEL goal
13.09.2010E
AC
C [M
V/m
]cavity
Cavity tests: Vertical ( CW ) Horizontal(10Hz) CMTB (10Hz)
MP
FE
FE
PXFEL-1 PXFEL-2 PFEL-3
S1-Global
D. Kostin & E. Kako
Current statistics on cavity gradient degradation
Institute Project Fraction of Degradation
DESY/FLASH PXFEL Prototype-1 2/8 PXFEL Prototype-2 2/8 PXFEL Prototype-3 1/8 Fermi Lab CM-1 4/8 KEK S1-Global 3/8 Total 12/40
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 33
•Statistics, available now (see right table)
•Rate of degradation with > ~ 20 % ~12/40, which leads to ~30%. This is too high, and efforts of improving is required. How improved? Maybe up to ~10%. (acceptable?) •Sorting after vertical test is planed in DRFS. Furthermore 10% decrease of gradient is likely occurred and this reality should included at the construction plan. This effect also results in cost-up.
a. Numbers of cavities and rf units must be increased if total acceleration is short and it is not compensated by the overhead.
b. Since DRFS employs one rf unit feeds powers to 2 or 4 cavities without using circulator, and therefore cavity gradient sorting is inevitable, effect of unexpected cavity gradient degradation is larger than other scheme such as RDR and KCS.
Operational experiences
SCRF Industrialization 34
Estimate assuming 1/10 cavities degraded with 20 %
• Simple Calculation – 80 % pairs with full performance and 20 % pairs with 0.8
x full performance • 0.8 x 1 + 0.2 x 0.8 = 0.96 without circulators, • 0.8 x 1 + 0.2 x {(1 +0.8)/2} = 0.98 with circulators, • Difference to be 0.02 = 2 % of {Cavity+HLRF} cost required to
add/compensate this degradation, – Necessary study
• Full circulator + distributors cost to be evaluated in comparison with the additional cryomodule backup cost (additional extension of linac).
• Operational flexibility and better efficiency by circulators and power distributors to be evaluated
GDE-PMs, 14th Nov. 2011
Cavity Deliverable assuming EXFEL cavity specification
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 35
• From EXFEL specification: 02L BQM-Cavity in He Tank
Courtesy:W. Singer
EXFEL Cavity and Tuner
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 36
S1-Global Assembly/Test with Global Effort
GDE-PMs, 14th Nov. 2011 SCRF Industrialization
DESY, FNAL, Jan., 2010
INFNand FNALFeb. 2010
FNAL & INFN, July, 2010
DESY, May, 2010March, 2010 June, 2010 ~
DESY, Sept. 2010
37
38
MHI-09MHI-07
MHI-06MHI-05AES004 ACC011 Z108 Z109
FNAL DESY KEK
Comparison of cavity performance ave. Eacc,max VT : 30 MV/m1 cav : 27 MV/m7 cav : 26 MV/m
D
C
D : DetuneC : Coupler
D
Performance reduction in two cavities and one couplerTuner mechanics trouble in two cavities
GDE-PMs, 14th Nov. 2011 SCRF Industrialization
Stability in 6300 sec.LLRF stability study with 7 cavities operation at 25MV/m
Field Waveform of each cavity
- Vector-sum stability: 24.995MV/m ~ 24.988MV/m (~0.03%)- Amplitude stability in pulse flat-top: < 60ppm=0.006%rms- Phase stability in pulse flat-top: < 0.0017 degree.rms
vector-sum gradient
amplitude stability in pulse flat-top
phase stability in pulse flat-top
7-cavity operation by digital LLRF
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 39
SCRF Industrialization
A Proposal Revised
• Keep the concept of 8 cavity sting unit, to be simplified• Accept two typs of Cryomodules (from Cryomodule
manufacturing)
9 4 + Q +4 9
8 8Q 8
8 4 + Q +4 8
GDE-PMs, 14th Nov. 2011 40
SCRF Industrialization 41
Quadrupole Cross-Section
LHe tank for current leads connections
Beam pipe Iron yoke
V. Kashikhin, FNAL Review, March 2, 2010GDE-PMs, 14th Nov. 2011
SCRF Industrialization
R&D/Demonstration Required
• Rapid response to beam handling – Study by K. Kubo and K. Yokoya
• R&D cooperation under discussion between Fermilab and KEK– Magnet by Fermilab and Conduction cooling by KEK
Peak field Response required
Quadrupole 30 T/m*m 0.01 T/m*m/sec (0.03% /sec)
Dipole 0.05 T*m 3E-4 Tm/sec (0.6 % /sec)
GDE-PMs, 14th Nov. 2011 42
Access Routes with Mountain-site
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 43
Layout of 2K Cryoplants
ML BDS IP
2K Cryoplants
RDR-based
How about this?
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 44
High-Level RF SolutionsKlystron Cluster Scheme, KCS (SLAC)
Distributed RF Sources, DRFS (KEK)
2×35 10MW MB klystrons
GDE-PMs, 14th Nov. 2011 SCRF Industrialization 45
~4000×800kW klystrons