spx cryomodules wbs cd2dr-u1.02.01.03.05

SPX CryomodulesWBS CD2DR-U1.02.01.03.05

John MammosserJefferson LabSRF R&D

DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

Outline Science / Technical Significance WBS Scope of this system Staff / Org Chart Requirements Design Interfaces Value Engineering (as applicable) Risks considered (as applicable) ES&H Cost Schedule

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DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

Science Case / Technical Motivation The technological development of superconducting deflecting

crab cavities, leverages current SRF technology for the production of short pulse X-Rays that’s both effective and compact.

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SPX Cryomodules Scope / Cost Summary

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Cryomodule Scope: Design, Fabricate and Qualify (2) Superconducting Cryomodules Designed To Chirp (Sector 5) and Unchirp (Sector 7) the APS Beam for the Development of Short Pulse X-Rays Two Cryomodule Operational Configurations:1) Beam Ready for the production of Short Pulsed X-Rays, Cavities at 2K2) Parked Configuration where Cavities are Detuned and at 80K

Labor Non-Labor TOTAL ($k)

U1 Short Pulse X-Ray (SPX) 3,388 11,556 1,198 1,450 17,592 U1 02.01.03 - SPX R&D 1,451 4,323 96 535 6,405

02.01.03.05 - Cryomodule R&D 868 2,963 72 333 4,237 02.01.03.07 - Cavity/Tuner/Damper System R&D 583 1,360 24 202 2,168

U1 03.03 - SPX Production 1,937 7,233 1,102 915 11,187 03.03.05 - Cavity & Cryomodule - ANL 1,937 518 332 560 3,346 03.03.12 - Cavity & Cryomodule - JLAB - 6,715 770 356 7,841

WBS DIV OH + ANL

G&A ($k)ESCALATION

($k)

DIRECT ($k)


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u START: Preliminary Design - SPX0 4/10

u START: Preliminary Design - SPX 2/12

u COMP: PDR - SPX0 7/12

u COMP: PDR - SPX 1/13

u SHIP: SPX0 Cryomodule to ANL 4/14

u COMP: SPX0 Cryomodule Test 6/14

u START: SPX0 Installation 8/14 (Note: Aug-14 Maintenance Shutdown)

u COMP: SPX0 Installation 10/14

u AVAIL: SPX0 Ready for Operation 1/15

u START: Final Design - SPX 6/14

u COMP: Final Design 9/15

u START: Major Procurement 10/15

u AWARD: Cryoplant Contract 10/15

u START: Cryoplant Installation 9/17

u COMP: Cryoplant 3/18

SHIP: Cryomodule #1 to ANL 10/17 uSTART: Cryom #1 Installation 5/18 u

COMP: Cryom #1 Installation 6/18 uAVAIL: Cryomodule #1 Ready for Operation 8/18 u

SHIP: Cryomodule #2 to ANL 8/18 uSTART: Cryom #2 Installation 12/18 u

COMP: Cryom #2 Installation 1/19 uAVAIL: Cryomodule #2 Ready for Operation 3/19 u

SPX SYSTEM

FY18 FY19 FY20FY10 FY11 FY12 FY13 FY14 FY15 FY16 FY17

Milestones – 1.02.01.03 & 1.03.03SPX Cryomodules / Cavities


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High Level Cryomodule Requirements:Stable Operation Installed in APS Low trip rates when operating with beam currents up to 150mA while chirping

beam for experiments are run (gain experience with SPX-0) Thermally stable operation in a parked configuration, cavities detuned (cooling to

remove heat generated from beam operations) No adverse affects to APS beam during operations (fast detuning of cavities in fault

condition)

Chirping (Beam Deflecting Mode) Independent control of cavities to provide 2MV of beam chirp and unchirp (gain

experience with SPX-0)

Critical Alignment of Cavities Design must minimize coupling out of beam power from misalignment (remote

alignment scheme will be employed to meet requirements) Beam based alignment required at setup and for drifts (signal feed back for

control)


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SPX Cryomodules Design Requirements:Physics parameters Value Unit Total crabbing voltage 2 MV Total de-crabbing voltage 2 MV Beam current ≤150 mA Number of cryomodules 2 Length of section, including magnetic elements 3.034 m Cryomodule length beam-line flange to flange TBD Number of cavities per cryomodule 4 Cavities Type Superconducting Duty cycle CW (8th harmonic of APS storage ring frequency)

Design Mark II Operating Frequency Deflecting Mode 2815.488 MHz Geometric factor 227.5 W R/Q’ 18.6 W Operating deflecting voltage 0.5 MV Active length 53.24 mm End flange to end flange distance 389.76 mm

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SPX Cryomodules Alignment Requirements:

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Alignment per module for APS installationValue Units X misalignment (Horizontal) ±500 µmY misalignment (Vertical) ±200 µm Z misalignment (Longitudinal) ±1000 µmYaw misalignment ±10 mradPitch misalignment ±10 mradRoll misalignment ±10 mrad

Alignment per cavity in cryomodule Value Units X misalignment (Horizontal) ±500 µmY misalignment (Vertical) ** ±200 µm Z misalignment (Longitudinal) ±1000 µmYaw misalignment ±10 mradPitch misalignment ±10 mradRoll misalignment ±10 mrad** with remote alignment


String Design Concept

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4 Crab Cavities Providing 2MV Chirp (Deflection) to the APS Beam

RF Tuner

HOM Absorber

RF Window


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Cryomodule Concept

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Warm RF Tuner

Shielded Valves

Vacuum Vessel

Fundamental Power Coupler SRF Cavity

Beam Line


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Cryomodule Concept

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Spaceframe

Helium GasReturn Header

Cold Tuner

LOM Window

HOM Load


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Alignment Concept

Alignment Procedure for Cryomodule1. Fiducialize each cavity to the electrical center on CMM using the stretched wire

setup (scan a wire in vertical “Y” plane, measure mechanical center in the horizontal “X” plane)– Cavity flanges machined for fiducial balls (shown in pink)

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Cryomodule Alignment

2. Weld helium vessels on the four cavities and recheck vertical alignment on CMM

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3. With string assembly tooling align the four cavities with laser tracker (mock assembly out side cleanroom)

4. Clean all components and process cavities5. Qualify cavities individually in vertical test 6. Perform string assembly and align with laser tracker7. Build out cold mass (instrumentation, magnetic shielding, MLI)

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8. Insert cold mass into space frame (support structure)

9. Transfer alignment to space frame (fiducial features on space frame)

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10. Complete cryomodule assembly (access ports for checking alignment)11. Transfer alignment to vacuum shell (fiducial features outside shell)12. Align cryomodule in APS, support stand adjustment of cryomodule in place13. Perform low power beam test and use active alignment to positions cavities and

optimize alignment

– Remote alignment concept– (4) Nitronic rods support the cavity– External mechanical adjustment

• Allows for 2 mm movement of each rod


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Cavity

Nitronic rod

External Remote Alignment Adjustment

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Cryomodule DesignCryomodule design will be based on the SNS redesign:

Vacuum vessel will be the pressure boundary

End cans and Vacuum Shell will be pressure stamped to meet 10CFR851

Cryogenic heat exchanger inside end can

SNS First Spare HB Cryomodule

Vacuum Vessel Pressure Stamped in Industry!!

SPX Cryomodule Org Chart

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SXP Project Management

(M. White, T. Mann)

Jlab Project Manager

(J. Mammosser)

Engineering Team(J. Matalevich)

Fabrication / Assembly Team

(J. Preble)

ANL Project Manager/ Technical

Representative(G. Wu)

Window/ Load Development Team

(G. Waldschmit)


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Interfaces Cryomodule Installation Major Interfaces

– Cryogenic system and controls– Deflecting Cavity RF System and Controls– Tunnel Utilities (Water cooling etc.)– Tunnel Alignment

Fabrication Interfaces– ANL will provide the HOM/LOM loads and waveguides– ANL will provide RF cables and instrumentation and safety

controls


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SPX Cryomodule Risks / Contingency

1. Stability of cryomodule performance in ring operations does not meet APS beam availability or quality expectations– Mitigation: SPX-0 ring test should identify critical issues and the schedule will allow

time for resolution of these issues before production modules are needed

2. Alignment of cavity electrical centers after cool down can not be compensated with the remote alignment scheme– Mitigation: Removal and rework of cavity alignment possible if tunnel adjustment of

cavity alignment unsuccessful

3. Cavity performance degraded due to contamination– Mitigation: Cavities are independently driven by RF and an individual cavity voltage can

be compensated by the other cavity voltages first order– Mitigation: Helium and plasma processing can be applied during maintenance periods

to gain back performance


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Cryomodule ES&H Integrated Safety Management System (ISMS)

– APS-U Project following Argonne’s ISMS program requirements – Argonne Integrated Safety Management System (ISMS) Description recently

revised and submitted to DOE ASO• Describes framework for integrating ESH requirements with mission objectives• References Argonne LMS procedures which implement specific portions of the ISMS

General Safety Requirements for SPX Cryomodule Design and Fabrication– Cryomodule must comply with 10 CFR 851 worker safety and health

requirements– Pressure safety ASME Boiler and Pressure Vessel Code– ASME B31.3 pressure piping– Vacuum safety– Ionizing radiation safety– ANL Safety Requirements– Jlab Safety Requirements


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BOE Contingency – 1.02.01.03 & 1.03.03SPX Cryomodules / Cavities

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SPX Cryomodules Value Engineering

The cryomodule vacuum shell design will be a modified SNS design where pressure vessel design is applied to this component (fabricated and pressure stamped from industry)

Existing VAT RF shielded valves will be used for the warm and cold valves (off the shelf)

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Cryomodule Cost Summary Chart by FY

TPC as shown is in k$, FY10

Design and FabSPX-0

Testing of SPX-0

Procurement and Fab of SPX Cryomodules

Commissioning of SPX


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Work between CD-2 and CD-3

Complete the SPX Cryomodule Design– Develop Cavity Remote Alignment Design and Procedure– Develop the Engineering Design and Document– Procure all Cryomodule Major Components– Fabricate and Deliver SPX-0 Cryomodule


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Summary• The critical design concepts for the SPX Cryomodule will be

fully tested during the SPX-0 R&D phase• What is learned from the SPX-0 testing will provide the

guidance for SPX cryomodule design improvements and the operational knowledge to provide stable operation for an APS installation

• SPX Cryomodule Design Concept is well underway• All significant technical issues are being addressed

• We are ready for CD2

spx cryomodules wbs cd2dr-u1.02.01.03.05

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