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SPX Cryomodules WBS CD2DR-U1.02.01.03.05 . John Mammosser Jefferson Lab SRF R&D DOE Lehman CD-2 Review of APS-Upgrade 4-6 Decem ber 2012. Outline. Science / Technical Significance WBS Scope of this system Staff / Org Chart Requirements Design Interfaces

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SPX Cryomodules WBS CD2DR-U1.02.01.03.05

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Spx cryomodules wbs cd2dr u1 02 01 03 05

SPX CryomodulesWBS CD2DR-U1.02.01.03.05

John Mammosser

Jefferson Lab

SRF R&D

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


Outline

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

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


Science case technical motivation

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.

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

SPX Cryomodules Scope / Cost Summary

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:

Beam Ready for the production of Short Pulsed X-Rays, Cavities at 2K

Parked Configuration where Cavities are Detuned and at 80K

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

4


Spx cryomodules wbs cd2dr u1 02 01 03 05

Milestones – 1.02.01.03 & 1.03.03SPX Cryomodules / Cavities

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

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

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)

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

SPX Cryomodules Design Requirements:

Physics parametersValue 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 Mode2815.488 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

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

7


Spx cryomodules wbs cd2dr u1 02 01 03 05

SPX Cryomodules Alignment Requirements:

Alignment per module for APS installationValueUnits

X misalignment (Horizontal) ±500 µm

Y misalignment (Vertical) ±200 µm

Z misalignment (Longitudinal) ±1000 µm

Yaw misalignment ±10 mrad

Pitch misalignment ±10 mrad

Roll misalignment ±10 mrad

Alignment per cavity in cryomoduleValueUnits

X misalignment (Horizontal) ±500 µm

Y misalignment (Vertical) ** ±200 µm

Z misalignment (Longitudinal) ±1000 µm

Yaw misalignment ±10 mrad

Pitch misalignment ±10 mrad

Roll misalignment ±10 mrad

** with remote alignment

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

8


Spx cryomodules wbs cd2dr u1 02 01 03 05

String Design Concept

HOM Absorber

RF Tuner

RF Window

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

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

9


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Concept

Warm RF Tuner

Vacuum Vessel

Shielded Valves

Fundamental Power Coupler

SRF Cavity

Beam Line

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

10


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Concept

Spaceframe

HOM Load

Helium Gas

Return Header

Cold Tuner

LOM Window

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

11


Spx cryomodules wbs cd2dr u1 02 01 03 05

Alignment Concept

1

Alignment Procedure for Cryomodule

  • 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)

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

12


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Alignment

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

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

13


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Alignment

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

  • Clean all components and process cavities

  • Qualify cavities individually in vertical test

  • Perform string assembly and align with laser tracker

  • Build out cold mass (instrumentation, magnetic shielding, MLI)

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

14


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Alignment

2

  • Insert cold mass into space frame (support structure)

  • Transfer alignment to space frame (fiducial features on space frame)

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

15


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Alignment

3

  • Complete cryomodule assembly (access ports for checking alignment)

  • Transfer alignment to vacuum shell (fiducial features outside shell)

  • Align cryomodule in APS, support stand adjustment of cryomodule in place

  • 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

Cavity

Nitronic rod

External Remote Alignment Adjustment

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

16


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Design

  • Cryomodule 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!!

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


Spx cryomodule org chart

SPX Cryomodule Org Chart

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

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

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

SPX Cryomodule Risks / Contingency

  • 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

  • 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

  • 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

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

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

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

BOE Contingency – 1.02.01.03 & 1.03.03SPX Cryomodules / Cavities

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

22


Spx cryomodules value engineering

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)

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

Cryomodule Cost Summary Chart by FY

Design and Fab

SPX-0

Testing of SPX-0

Procurement and Fab of SPX Cryomodules

Commissioning of SPX

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

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

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


Spx cryomodules wbs cd2dr u1 02 01 03 05

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

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


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