Needs of a European SCRF Facility - the BIG plan

1. Needs of a European SCRF Facility - the BIG plan Lutz Lilje DESY -MPY- DESY 11/2006 Planning Resource needs

2. References • Letter-of-intent for CERN Council Strategy Group • http://council-strategygroup.web.cern.ch/council-strategygroup/BB2/contributions/Wagner.pdf • For ESGARD discussion: • A SCRF Infrastructure for Europe; http://esgard.lal.in2p3.fr/Project/Activities/Current/Networking/N2/ELAN/Documents/2006/ELAN-Document-2006-004.pdf • Technical interest • CLEAN-ROOM FACILITIES FOR HIGH GRADIENT RESONATOR PREPARATION; K.Escherich, A.Matheisen, et al.; http://www-dapnia.cea.fr/Phocea/file.php?class=std&&file=Doc/Care/care-conf-05-033.pdf • Proposes improved layout of cleanroom for the EP process • Does not contain redundancy Lutz Lilje DESY -MPY-

3. Overview • Motivation • General layout • General timeline • Detailed Planning • Critical path items • Role models • Project resources • Proposal for Role models Lutz Lilje DESY -MPY-

4. Research and Development • GDE Discussions show that an effort is needed • To make ILC-gradients more reproducible • The baseline process is clear, but some parameters are yet to be determined (details of post-electropolishing rinses) • This is the work of the labs • Any step in Europe should be integrated in the larger R&D framework • Step toward a integrated systems test • Build a 4th generation module • At least the size of one RF unit, which determines the number of cavities to at least 30 • Knowledge transfer to industry • Significant work is needed enabling industry to produce cavities on the level of the ILC gradients (see above) • After having worked out details, transfer this to industry • But Industry can do things today (and the more in 2007/8) • Large contribution of the XFEL • Fabrication, First EP can/should be done in industry • After results from the facility are available • Final preparation and tank welding in industry • Final step • Module assembly in industry • Other projects • Access to state-of-the-art cavity preparation Lutz Lilje DESY -MPY-

5. Cavity Preparation Infrastructures Today • Some infrastructure is available in Europe (not only DESY) • Most setups are still R&D size • Often single-cell cavities • Small through-put • Single-line of processing • No redundancy • Have come to age • Materials • Overall layout needs significant re-work with today‘s knowledge • Electropolishing as the baseline process • required number of high pressure water rinses Lutz Lilje DESY -MPY-

6. Next Generation Cavity Preparation Infrastructure I • Main Features • Improved electropolishing • Focus to avoid sulphurus contamination • Redundancy • Improve Final cleaning • Flexibility needed here e.g. alcohol rinses • High pressure rinse (HPR) • Online particle count integrated in drain water line • Redundancy • Cleaning of parts • Automation needed: screws used as example • Improved/novel methods of QA/QC Lutz Lilje DESY -MPY-

7. Next Generation Cavity Preparation Infrastructure II • Modular setup • Institutes get responsibility for part of the process (HPR design, EP design etc.) • Redundant setup • 2 x EP, • 2 x HPR, • 2-3 120 °C bakeout stations • Other infrastructure • Etching needed (e.g. outside cleaning) • designated 800°C furnace • Sufficient pump stations, etc. • Optional • Dry-ice cleaning • Needs feasibility demonstration Lutz Lilje DESY -MPY-

8. Tuning Tank welding Oven Chem. Supply Plant Ultra-pure Water Plant Alt. Rinses BCP EP EP HPR HPR Pre- Clean Cleanroom Cleanroom 10 Assembly 2x 120 C Pumps Autom.Parts Clean Layout ofPreparation Facility Lutz Lilje DESY -MPY-

9. Timelines for R&D Infrastructure Lutz Lilje DESY -MPY-

10. Scheme of Cryomodule Production (Research phase) Fabrication of cavities Procurement of couplers Pre-treatment of cavities In Industry In Labs Coupler Processing Inspection Final Cavity Preparation Tuners Tuner Tests Low-power testing High-power testing Tank welding BPM Magnet Module Test Module Assembly Cleanroom Cryostat Lutz Lilje DESY -MPY-

11. Scheme of Cryomodule Production (Technology Transfer) Fabrication of cavities Procurement of couplers Pre-treatment of cavities In Industry In Labs Coupler Processing Inspection Final Cavity Preparation Tuners Tuner Tests Low-power testing High-power testing Tank welding BPM Magnet Module Test Module Assembly Cleanroom Cryostat Lutz Lilje DESY -MPY-

12. Scheme of Cryomodule Production (Industrialization Phase) Fabrication of cavities Procurement of couplers Pre-treatment of cavities In Industry Coupler Processing Inspection In Labs Final Cavity Preparation Tuners Tuner Tests Low-power testing Tank welding BPM Module Assembly Cleanroom Magnet Module Test Cryostat Lutz Lilje DESY -MPY-

13. Detailed Planning • Most details on critical path items • Cavity procurement • Cleanroom installation • Less detail in testing infrastructure • A lot of this is available • Organisation • Defined role models of the labs e.g. • Main Lab • Coupler Lab • Tuner Lab • + generic labs: A,B,C,D,E • The work load can be re-distributed to some degree of course • Cost estimation assumptions • Greenfield site • 37,50 €/manhour • Hardware + running cost figures are a mix of TTF experience and XFEL preparation cost estimate Lutz Lilje DESY -MPY-

14. Role models for SCRF facility • All labs • Layout of facility esp. cleanroom • Define cryostats (in GDE context, of course) • Preparation of assembly cleanroom • Controls • Could be specialized lab • Main Lab • Hosts main part of infrastructure • Cavity preparation, vertical testing and module testing • Vacuum infrastructure incl. 120 C furnaces • Coupler Lab • Coupler procurement, preparation and conditioning • Support assembly cleanroom • Assembly at main lab • Tuner Lab • Tuner procurement, warm + cold testing • Support module assembly cleanroom at main lab • Assembly at main lab Lutz Lilje DESY -MPY-

15. Role models for SCRF facility (ctd.) • Lab A • EP Modules specification, procurement, installation at central facility • Support central team in cavity preparation • High-power testing of individual cavities • Lab B • BCP Module specification, procurement, installation at central facility • Support central team in cavity preparation • High-power testing of individual cavities • Lab C • HPR Modules specification, procurement, installation at central facility • Support central team in cavity preparation • Lab D • Eddy-current scanning of niobium • 800 C furnace • Lab E • Module cryostat specification, procurement • Support module assembly Lutz Lilje DESY -MPY-

16. Does not exist Critical path item Gantt Chart: Cavity Preparation Setup Lutz Lilje DESY -MPY-

17. Not on critical path Timing should clearly be optimised for money flow Many opportunities (savings) already available – see below Gantt Chart: Testing Setups Lutz Lilje DESY -MPY-

18. Niobium order and cavity procurement are the long lead-time items Gantt Chart: Material Lutz Lilje DESY -MPY-

19. Assumption is a collaborative operation of the facility as outlined in the role models Gantt Chart: Operation Lutz Lilje DESY -MPY-

20. Current Estimate: Schedule • Project duration: 5,5 years • Cleanroom setup phase: 2 years • Material procurement: 2,5 years • Operation of preparation facilities: 3,5 years Lutz Lilje DESY -MPY-

21. While the overall load seems reasonable Details can of course still shift around Indivudual tasks can be refined e.g. coupler effort ratio between main lab and collaborators Distribution of work load over years E.g test infrastructure manpower could be shifted Current Estimate: Manpower Lutz Lilje DESY -MPY-

22. Cleanroom + EP: 9,5 Mio € Testing infrastructure: 15 Mio € Materials: 5 Mio € Operation: 5 Mio € Current Estimate: Cost Lutz Lilje DESY -MPY-

23. Current Estimate: Summary • Cleanroom + EP etc.: 9,5 Mio € • Testing infrastructure: 15 Mio € • Materials: 5 Mio € • Operation: 5 Mio € • Total cost: 36 Mio € • Of this total working cost: 5 Mio € ~129000 hours • Total project duration: 5,5 years Lutz Lilje DESY -MPY-

24. Remember: • Large labs can supply cryogenics and a good deal of test infrastructure • E.g. CERN Plant • Trade additional XFEL test hall test stand vs. Existing teststand • Several labs have infrastructure • Coupler testing • Horizontal test setups • Also usable for tuner tests • This is to a large degree the big money… Lutz Lilje DESY -MPY-

25. Missing equipments • Central cleanroom installation • Cleaning modules (EP, BCP, HPR) must be new • Refurbishment of existing cleanroom seems more complicated • Distributed facility is not desirable strategy as QC is more complicated • Vertical testing must be close to cavity preparation • Fast feedback from RF test needed • Distributed facility is questionable strategy for R&D phase • Will be done in the long run e.g. industrialization phase and also XFEL mass production scenario • Vertical testing must include appropriate diagnostics i.e. t-mapping • Only at DESY for multi-cells Lutz Lilje DESY -MPY-

26. Available equipments • Module assembly cleanroom • Could be SM18 • Parts (antennas, screws etc.) cleaning • Several options at CERN • 800 C furnace • DESY • Vertical test stands • DESY, CERN (would need more resources) • other labs could specialize (e.g. t-mapping) • Horizontal test stands • CEA, DESY, BESSY, CCLRC • Module test stand • DESY CMTB • Cheapest and quickest option provided we can trade for an additional XFEL test hall stand • CERN • Is probably more expensive than DESY option, but still not greenfield price • Coupler test stand • LAL • Tuner test stand • Saclay, INFN, CCLRC, BESSY • Eddy current scan • DESY • ‘Savings’ ~5 Mio € + ?! Lutz Lilje DESY -MPY-

27. Next steps • By now a refined estimate on the roles is available • Both investment and manpower • Commitments are needed for more detailed planning • Experts know much more on what can be taken as existing and what needs to be upgraded (e.g. couplers) • Knowing the current funding schemes on has to assess the possibilities for implementation • A large commitment of the parties would be required Lutz Lilje DESY -MPY-