materials to support the discussion: - recall of tac11 (1-2 april 2015) recommendations -hom and ped...
Post on 30-Dec-2015
213 Views
Preview:
TRANSCRIPT
Materials to support the discussion:
- Recall of TAC11 (1-2 April 2015) recommendations- HOM and PED- Possible QA applicable to SRF collaboration projects
Elliptical Cavity Cryomodules
• Recommendations– The success oriented schedule presented leaves almost(?) no room for
iteration of any of the sub-components or the module itself. Thus an extremely careful self-assessment of technical risks is to be made.
– Qualification of sub-components and finally of the completed cryo modules requires smoothly running infrastructure. A complete list of all related infrastructure with commissioning and training plans should be established.
– The IKC concept for the cryo module and its‘ components requires precisely defined interfaces. Include in all IK negotiations aspects for technical, logistical and contractual issues.
– At the time of the cryo module CDR the final design has to be absolutely stable. Series production of components requires precise specifications for all components and procedures. A clear timeline for all related project decisions should be established.
1-2 April 2015 ; ESS TAC11
Elliptical Cavity Cryomodules (con‘
– CEA Saclay / Irfu is strongly contributing to ESS and XFEL cryo module assembly. Lessons learned should be discussed and documented / presented.
– The cryo module QC at ESS Lund will lead into some repair actions. The planned coordination meetings between ESS/CEA/INFN/STFC should address this issue.
– Identify cryo module tooling to be made available to ESS for long term. Either at ESS or through long-term binding contracts at the IKC labs.
1-2 April 2015 ; ESS TAC11
Elliptical Cavities (high beta)
• Comments• Cavity vendors need to modify existing infrastructure and tooling for
surface treatment. Since STFC has no prototypes to be simply copied by industry, good coordination between STFC, INFN and industry is required. What can one learn from other lab infrastructures? Knowledge exchange / transfer is of utmost importance.
• Recommendations– The presented STFC schedule includes time for infrastructure
modification, commissioning and training. But self-assessment of technical risks should be made. Comparison with other similar infrastructures already used for series production should be done as much as possible.
– Industrial infrastructure needs to be developed and supervised. Identify what can be learned from others.
– If STFC is building to print clarify responsibilities.
1-2 April 2015 ; ESS TAC11
Medium beta cryomodules
• Comments– degradation after heat-treatment : possible explanation is an
insufficient chemical etching, – there will be no feedback from first cryomodule power testing
on the assembly of the following cryomodules, and this is a serious concern
• Recommendations– Degradation cause should be confirmed as soon as possible In
order to secure the global process– Regarding manufacturing geometry accuracy, analysis should
be performed to determine the geometric tolerance to escape the HOMs from the harmonics with a minimum spacing of 5 MHz
1-2 April 2015 ; ESS TAC11
Elliptical Cavities (medium & high beta)
• Comments– Using large grain niobium for producing cavities at INFN adds
some risk to the project schedule. Should a problem occur with this R&D, definite milestones should be established that would trigger a decision to revert to known fabrication techniques with small grain niobium.
– It has been decided to not scan sheets of niobium for acceptable RRR. Experience at DESY in the construction of X-FEL have shown a 3% failure rate of niobium sheets. This presents a risk to cavity construction, especially since production did not include the fabrication of spare cavities. This decision needs to be reassessed.
1-2 April 2015 ; ESS TAC11
Elliptical Cavities (medium & high beta) -
• Recommendations– There are many common issues between medium and high
beta elliptical cavities. • try to avoid double work; • profit from each other;• develop common strategies for industry supervision• Check common Nb procurement across work-packages• use identical clean room and vacuum specs
– Work to understand the source of cavity performance degradation following the additional treatment. Contact SRF community experts.
– In case the currently used elliptical cavity design is questioned, establish schedule decision point milestones for elliptical cavity redesign efforts (e.g. geometry optimization and material selection).
– Identify cavity tooling to be made available to ESS for long term. Either at ESS or through long-term binding contracts.
9
Dangerous Higher Order Mode close to 1408.8 MHz
704 MHz
1421,32 MHz
Slater coefficient analysis which represents frequency sensitivity to
volume changes:
Both high beta prototype cavities are not conform with the ESS HOM Requirement
Reminder: « All higher order modes (HOMs) shall be at least 5 MHz away from integer multiples of the beam-bunching frequency (352.21 MHz) for any HOMs whose resonant frequencies are below the cut-off frequency of the beam-pipe.”
Design (at 300K)
Measured on ESS086-P01
Calculated with measured
shape (HFSS)Measured on ESS086-P02
Calculated with measured
shape (HFSS)
1418.178 1402.254 1403.8 1407.848
1418.674 1404.666 1406.8 1408.258
3D measurements of the cavity shape have been performed Shape reconstructed in the simulation software HFSS
Þ On P01 cavity (from ZANON), a strong internal shape deviation in this dome region (more than 1 mm instead of 0.3 mm) explains very well the frequency decrease of the two dangerous HOM
Þ Study under progress on P02 cavity (from RI)
Cells reshaping has to be implemented in the fabrication process of future cavities
Annual Review 23rd April 2015
10
• Volumes of the helium circuits and vessels < 50 l• 1,431 bars< Working pressure• Ps = 1,9 bars
TUV Nord analysis report:The elliptical cryomodules are
classified according to PED article 3.3
Compliance with European PED 97/23/EC
Cryo pipes designed to reduce the overpressure in case of beam vacuum failure
continuous diphasic pipe F=100 with large
curvatures
2 F=100 bursting disks at each extremity
Annual Review 23rd April 2015
• Recall: October 15-16, 20Requirements Conformance for SRF Cryomodules Workshop Home
• Indico link: https://indico.esss.lu.se/indico/event/185/timetable/#all.detailed
• Preliminary approach - CNRS
Possible QA applicable to SRF collaboration projects
- 12 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
QA / QC Plans for the ESS spoke production
Main goal and path:• Develop all the necessary tools and documentation to
insure a high quality/traceability of the fabrication and assembly of the ESS spoke cryomodule parts.
• Take benefit of the ongoing prototyping phase to draft and later on modify/correct these tools
• Once ready, transfer and/or adapt to the overall ESS QA system that will be developed.
We started to set our QA/QC plans only a few months ago, the basis is here, but it’s only a start…
Based on our past contributions to LHC, SPIRAL-2…
- 13 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
QA / QC Plans for the ESS spoke production
HOW ? Based on the following pillars:
• A Product Breakdown Structure to list all components, equipments, tooling to be used for the spoke production
• A detailed life cycle of the components that could also serve as a Work Breakdown Structure to list in details all the production/preparation/assembly/test of the components and associate the required input/output
• A component identification/naming convention to be able to identify all basic component / assembly
- 14 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
QA / QC Plans for the ESS spoke production
HOW ? Based on the following pillars:
• A set-up of documentation (procedure, travelers, reports, legal/purchase documents, publications…) to properly insure a reliable, stable, not company or people-dependent quality of production
• A document management system to insure access, ordering, sorting, traceability of all documentation produced.
• A configuration table to trace which sub-system is installed in each cryomodule.
- 16 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
Spoke cryomodule overall life cycle
Appro Niobium
FabricationCavité
Traitement surfaceCavité
Assemblagecavité
Salle blanche
Test en CV
COMPONENT
PHAS
EEx
port
/de
liver
yTe
st /
valid
ation
Prép
arati
on/
asse
mbl
ySU
pply
/Pr
oduc
tion
Niobium Cavities Couplers vesselVacuum
Cryomod.Full.
compon..Cryomod.
stringCavityCTS …
Transport -> site
assemblage
Transport -> Fabriquant
cavités
…
…
…
…
FabricationEnceinte
Cryomodule
Transport -> site
assemblage
Appro Compos.
cryomodule
Transport -> site
assemblage
Assemblagetrain
cavités
Transport -> site
assemblage
FabricationSAF
AssemblageSAF
Test à chaud SAF
Transport -> site
assemblage
Assemblagecryomodule
Test àchaud
Transport -> Uppsala
FabricationCoupleur
Préparation salle blanche
coupleurs
Conditionn-ement
coupleurs
Transport -> site
assemblage
- 17 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
Spoke cryomodule detailed life cycle
Phase_Name
Validation stage -> Go /
No Go
Stage name (number
Phase and stages
Names, shapes and colors
- 18 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
Spoke cryomodule detailed life cycle
Names, shapes and colors
Requirement
Administrative / Contractual
Milestone
Technical
Report
Minutes
Contractual/legal document
Input /Output documents
Document type Color convention
- 19 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
Spoke cryomodule detailed life cycle
1st example: Niobium production
Production Niobium
Spécifications Techniquesdu Niobium
SpécificationsNiobium (CCTP)
Appel d’offre Niobium CCAP, RC, AE
Analyse offres et choix fournisseur Nb
Rapport d’analyse
Commande Niobium
Suivi de fabrication Nb
Rapports d’avancement
Livraison Niobium P.V. Livraison
Contrôle et
Réception Niobium
Rapport de phase Prod Nb
Procédure de contrôle
Niobium
Notification et bon de commande
Choix et marquage des faces RF
- 20 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
Spoke cryomodule detailed life cycle
2nd example: Cavity production
Fabrication Cavités
Spécifications Techniques
cavités
Spécificationscavités (CCTP)
Appel d’offre cavités
Analyse offres et choix fournisseur
cavités
Rapport d’analyse
Commande Cavités
Suivi de fabrication cavités
Rapports d’avancement
Transport Cavités vers IPNO P.V. Livraison cavités
Acceptation Cavités
Rapport de phase Prod
cavités
Notification et bon de commande
Recette usine
Accord en fréquence
P.V. Recette usine
P.V. accord en fréq.
CCAP, RC, AE
Procédure de tuning cavités
Procédure contrôle
visuel cavitéP.V. Contrôle visuel
Procédure contrôle
dimensionnelP.V. Contrôle dim.
Procédure test de fuite
P.V. Contrôle étanchéité
Contrôle visuel
Contrôle dimensionnel
Contrôle étanchéité
Fabrication Cavités
Spécifications Techniques
cavités
Spécificationscavités (CCTP)
Appel d’offre cavités
Analyse offres et choix fournisseur
cavités
Rapport d’analyse
Commande Cavités
Suivi de fabrication cavités
Rapports d’avancement
Transport Cavités vers IPNO P.V. Livraison cavités
Acceptation Cavités
Rapport de phase Prod
cavités
Notification et bon de commande
Recette usine
Accord en fréquence
P.V. Recette usine
P.V. accord en fréq.
CCAP, RC, AE
Procédure de tuning cavités
Procédure contrôle
visuel cavitéP.V. Contrôle visuel
Procédure contrôle
dimensionnelP.V. Contrôle dim.
Procédure test de fuite
P.V. Contrôle étanchéité
Contrôle visuel
Contrôle dimensionnel
Contrôle étanchéité
- 21 -S. Bousson, Workshop on Requirements Conformance for SRF Cryomodules, Lund, 15th Oct. 2014
Spoke cryomodule detailed life cycle
3rd example: Cavity preparationPréparation Cavités (1/2)
Nettoyage U.S. cavité
Pesée #1 cavité
Chimie #1 cavité
Validation chimie cavité
Rapport de phase chimie
cavités
O.K
.
Procédure nettoyage US cavité
P.V. nettoyage US
P.V. pesée #1Procédure
pesée cavité
P.V. chimie #1Procédure
chimie cavité
Pesée #2 cavité P.V. pesée #2Procédure
pesée cavité
Chimie #2 cavité P.V. chimie #2Procédure
chimie cavité
Mesure fréquence cavité P.V. mesure f #1
Procédure mesure f
cavité
Pesée #2 cavité P.V. pesée #2Procédure
pesée cavité
Mesure fréquence cavité P.V. mesure f #2
Procédure mesure f
cavité
Transport vers salle blanche
Procédure transport chim/SB
Mesure fréquence cavité P.V. mesure f #2
Procédure mesure f
cavité
Préparation cavités (2/2)
HPR cavité
Assemblage cavité pour test CV
Validation Prépa cavité
Rapport phase préparation
cavités
O.K
.
Procédure HPR cavité P.V. HPR cavités
P.V. assemblageProcédure
pesée cavité
Traitement thermique
Procédure traitement thermique
cavité
P.V. Traitement thermique cavités
Flash BCPProcédure chimie flash P.V chimie flash
Test de fuite en SB P.V. Test de fuite SBProcédure
test de fuite SB
Etuvage SB P.V. Étuvage SBProcédure étuvage SB
top related