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Fermilab Budget Overview International Linear Collider FY05 - FY08 Bob Kephart February 27, 2006

Fermilab Budget Overview International Linear Collider FY05 - FY08 Bob Kephart February 27, 2006. Outline. Fermilab ILC Goals Goals of FNAL ILC R&D Program GDE activities RF infrastructure Industrialization Program for FY05-06 Program for FY07 with PBR & flat to FY08

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Fermilab Budget Overview International Linear Collider FY05 - FY08 Bob Kephart February 27, 2006

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  1. Fermilab Budget Overview International Linear Collider FY05 - FY08 Bob Kephart February 27, 2006 Fermilab Budget Briefing

  2. Outline • Fermilab ILC Goals • Goals of FNAL ILC R&D Program • GDE activities • RF infrastructure • Industrialization • Program for FY05-06 • Program for FY07 with PBR & flat to FY08 • Funds needed in FY07-08 to support an FY12 ILC start at FNAL • Conclude Fermilab Budget Briefing

  3. Goals of Fermilab’s ILC R&D • As part of the Global Design Effort (GDE) our goal is to help design the machine, estimate the cost, and gain international support. • We also must establish credentials in machine design and SCRF technology such that FNAL is the preferred international site to host the ILC. • This is not the responsibility of the GDE and is not funded via the FNAL/GDE MOU in FY06 • In what follows this effort is summarized under the budget line “RF infrastructure”. In FY06 it is funded via FNAL’s core budget Fermilab Budget Briefing

  4. FNAL: Global Design Effort • Working with international partners to develop a feasible ILC machine design • FNAL has focused on the Main Linac and Civil Design, these represent the bulk of the ILC cost • Goal: Reference Design Report and cost by 2006 • FNAL has taken on many RDR leadership and engineering tasks in FY06 at request of GDE • GDE Directed R&D Program: • FNAL effort is focused on R&D to produce SCRF cavities that reliably achieve Eacc=35 MV/M • FY06 funds allow a significant start on the ILC Fermilab Budget Briefing

  5. RF infrastucture Goals: • Host the ILC at FNAL • Acquire needed ILC Accelerator & SCRF expertise • Develop the required SCRF infrastructure to build & test the components of the ILC main linac • Develop U.S. Industry for high volume components • Develop good U.S. cost estimates • Develop civil designs for specific sites near FNAL • Many aspects are not fully funded by GDE in FY06 • Funding this from FNAL “core” program • A separate DOE funding stream (ie not via the GDE) needs to be created to support these activities Fermilab Budget Briefing

  6. SCRF Infrastructure • A cold ILC require extensive infrastructure • Bare cavities • Fabrication facilities ( e.g. Electron beam welders) • Buffered Chemical Polish (BCP) and Electro-polish (EP) facilities • Ultra clean H20 & High Pressure Rinse systems • Vertical Test facilities ( Cryogenics + low power RF) • Cavity Dressing Facilities ( cryostat, tuner, coupler) • Class 100 clean room • Horizontal cavity & Coupler test facility ( RF pulsed power) • String Assembly Facilities • Large class 100 clean rooms, Large fixtures • Class 10 enclosures for cavity inner connects • Cryomodule test facilities • Cryogenics, pulsed RF power, LLRF, controls, shielding, etc. • Beam tests  electron source (e.g. FNPL Photo-injector) • Some example slides attached at end of the talk Fermilab Budget Briefing

  7. SCRF infrastructure • Following the technology choice in Aug 04 FNAL launched a major effort to develop the needed SCRF infrastructure and experience • The required infrastructure is complex • It takes time to develop • It takes time to train personnel to achieve cavities with high operating gradients • Major investment required! DESY spent > $ 150 M M&S on TTF and the associated infrastructure • Our ability to make progress is funding limited Fermilab Budget Briefing

  8. SCRF Infrastructure • DESY Collaboration • Fermilab and DESY have collaborated on SCRF for many years as part of the Tesla collaboration (TTF & FNPL) • Currently Fermilab is building a 3.9 GHz cryomodule for the TTF VUV-FEL (Deliver in 2007) • Serving as a pilot program for much of our FNAL SCRF infrastructure (cavities, processing, cryomodule design, etc) • DESY will send us parts in 2007 to build a complete 8 cavity 1.3 GHz TTF cryomodule (i.e. ILC like) • 1st ILC type cryomodule built in the U.S. • Current plan is to assemble & test it in 2007 Fermilab Budget Briefing

  9. Fermilab Cryomodules • 1st TTF Type III Cryomodule (2007) • Assemble from the “kit” of part provided by DESY • 2nd TTF Type III Cryomodule (2008) • 1st to use cavities that are processed and tested in the US • Still must buy the rest of parts from Europe in FY06 • 3rd-4th Cryomodules (2008-09) • 1st type IV ILC cryomodules built anywhere ( try for 35 MV/M) • Begin industrial production of components in U.S. in FY07 • Only cavity work and the Type IV cryomodule design are funded via the GDE MOU in FY06 Fermilab Budget Briefing

  10. Near-term Plan • Overall objective is to assemble one, then two ILC RF units in New Muon building (ILCTA_NM) • 1st by about 2009, 2nd a year or so later • 3 Cryomodules • Modulators • 10 MW Klystrons • Waveguide and RF distribution • LLRF & controls • Move FNPL photo injector to provide electron beams • Initially we plan to use components assembled in U.S. labs using parts produced in industry • Next step: Cryomodules, klystrons, modulators fully built by industry but using laboratory infrastructure One ILC RF unit Meas acc gradient, emm preserv, wakeflds Fermilab Budget Briefing

  11. ILC Industrialization • Goal is to establish in US industry the capability and infrastructure to mass produce high volume components • Another important goal is cost reduction • ~ 2000 Cryomodules • ~ 16000, SCRF Cavities, RF couplers,Tuners • ~ 600 Klystrons, modulators • A host of other RF & vacuum components, etc. • Civil construction ( huge: ~ 40% of the ILC cost) • US industrialization for ILC is just beginning • Industrial Forum in 2005 • Plan the 1st U.S. industrial involvement in cost estimates in FY06 • However, we really need to build things in U.S. industry ! • Funding levels must allow this to happen Need experience in fab to get good est? PO: Is it US goal to build technical components? RS only goal is get ILC here; if it requires tech comp., so be it. Fermilab Budget Briefing

  12. ILC Systems Tests • It is Fermilab’s opinion that a significant systems test will be required in advance of ILC construction to verify: • Technical performance of critical/cost driving components • Systems integration • U.S. vendor performance • Reliability of cost estimate • Should include ~2 % of ML cryomodule, modulator, and klystron count, produced by vendors in a pre-production run • Could include a demonstration damping ring • FNAL will propose to host such a facility • Believe the correct approach is to develop requirements first, then evaluate existing or newly constructed facilities. • Our plan is to engage the GDE to help develop the requirements. Fermilab Budget Briefing

  13. Industrialization of Cryomodules DESY TTF ILC Type IV ILC cryomodule Cavity, RF Coupler Blade-Tuner • Cryomodules are complex • Need to evolve for ILC • U.S. Industry needs to learn how to build these Fermilab Budget Briefing

  14. A Path to Industrialization XFEL ~80 cryomodules Main Linac System Test Assume 1/3 built in US; start in FY12; production up in FY14; latency in industry – 2yrs. Similar for klystrons Fermilab Budget Briefing

  15. SCRF infrastructure and Industry • It takes about ~2 yrs from the time one spends money on parts for ML components until the component is finished and ready for test. • True for cryomodules, klystrons, & modulators = bulk of ILC ML cost • The plot assumes: • 1/3 of the technical components for the ILC ML come from the U.S. • Required infrastructure is in place when required. • E.g. Electron beam welders, clean rooms, vertical and horizontal test facilities, cryomodule, coupler & klystron test facilities • 1-2 yr delay if we must establish these AFTER project approval • Plot assumes that after a 2012 ILC project start U.S. industry can produce 48 ILC quality cryomodules in ~2014  This will require extensive infrastructure and industrial experience Fermilab Budget Briefing

  16. SCRF infrastructure and Industry • It is unlikely that the 1st industrially produced cryomodules will meet the requirements of ILC… cryomodules are just too complex!  need a program to ramp this up • Similar plot for U.S. produced 10 MW 1.3 GHz klystrons • Can argue about details, but the bottom line is inescapable • To build the ILC in the U.S. on anything like the schedule being discussed the U.S. must make big investments in SCRF infrastructure and industrialization very soon. • Technically a schedule with Project approval in ~2012 and start of construction in ~2014 is still achievable but will slip by one year if no FY07 funds are available for industry Fermilab Budget Briefing

  17. FY 2005 & FY 2006 Analysis GDE funded Direct Funds only Shift to GDE Directed R&D Available M&S x2 down vs going up ! No M&S for 2nd cryomodule In FY06 # FTE Planned 64 115 Fermilab Budget Briefing More labor = good!

  18. FY 2005 – FY 2006 ILC Program • FNAL has taken on major GDE responsibilities for the main linac design, engineering, and cost estimates • FY06 Budget supports increased labor for ILC and SCRF infrastructure (~64 FTE in FY05 to ~115 FTE in FY06) This is great ! • However, even at these funding levels the physicists & engineers working on the RDR are not fully funded by GDE (FNAL core funds) • The FY06 budget does not support sufficient M&S funds to acquire needed SCRF infrastructure AND experience • Without $ 2.5 M supplemental funds in FY06 we cannot: • Finish cryomodule test facility1 yr delay in test of 1st U.S. cryomodule • Buy the parts to build the 2nd U.S. cryomodule (U.S cavities)1 yr delay • Finish outfitting the New Muon building, and move the FNPL photo-injector in 2006  one year delay in putting ILC-like beam through a high gradient cryomodule Facility in New Muon in jeopardy Fermilab Budget Briefing

  19. FY2007 funding at the PBR Proposal Direct Funds only Need M&S for cryomodule parts & infrastructure No Industry! Labor but NO M&S for cryomodules & infrastructure # FTE Planned 115 174 59 Machine design RDR TDR requires larger SWF  Budgets will not support sufficient M&S for SCRF infrastructure Fermilab Budget Briefing

  20. FY07 ILC Program • At the PBR FNAL will be able to further increase labor on ILC design and SCRF infrastructure ( Good!) • However, the budget does not support adequate M&S • An ILC funding stream dedicated to supporting the ILC in the U.S. in general, and the ILC at Fermilab in particular should be established in FY07 • Funds should be allocated to develop the required expertise and SCRF infrastructure at FNAL • Funds should be allocated to support industrialization of high volume ILC components in U.S. industry • Funds should be allocated to support U.S. A&E firms to develop ILC sites on or near the Fermilab site. The last 3 items all require M&S but are not the responsibility of the GDE Fermilab Budget Briefing

  21. FY2007 at PBR and Flat to FY08 Direct Funds only No Industry No M&S for infrastructure # FTE Planned 64 115 174 218 Labor overbalance; would not want but need to retain Fermilab Budget Briefing

  22. FY07 at the PBR and Flat to FY08 • Assuming PBR in FY07 & flat to FY08 we cannot: • Start serious U.S. Industrialization of ML components • Start serious work with A&E firms to developing the design for an ILC site near FNAL • Complete the required SCRF infrastructure at FNAL ( no M&S) • A sensible industrialization plan would fund one industrially produced ILC RF unit in FY07-08, 2nd in FY08-09. • Have an industrial estimate of $ 17 M per RF unit • Delivery could be expected 2-3 yrs after order. • Without additional funds U.S. industrialization and Civil work to develop of a U.S. site near Fermilab will be delayed 2 yrs • All this will jeopardize our opportunity to host the ILC industry would need infrastructure at FNAL Fermilab Budget Briefing

  23. FY07-08 Funding Request to support a 2012 ILC construction start @ FNAL Direct Funds only • An additional $13 M is needed in FY07 vs PBR • In FY08 the shortfall is ~ $ 31 M vs Flat FY08 $ 2.5 M supl request Fermilab Budget Briefing

  24. Conclusions • Fermilab has a large and growing ILC R&D effort • Our prime objective is to achieve technical excellence in the Main Linac systems and to position ourselves to be a strong candidate to host the ILC • We work closely with international partners in the GDE on: • ILC machine design (RDR) and the cost estimate • High Gradient SCRF Cavity R&D • We are trying to acquire the SCRF expertise and extensive infrastructure required to support a U.S. bid-to-host the ILC at FNAL • A separate funding stream should support this activity • Progress on ILC and our hopes to host this machine in the U.S. are at risk given the available funding Robin; no Japan interest in host and apart from CERN, none in EU Are we underinvested or behind? Bob – both! SNS is not a guide in gradient, and were difficulties in processing. Robin: argument for shifting money within FNAL budget. Proton driver = $10M; why? Argument need intermediate effort works for Nova, can’t see it with PD work. Pier: high intensity sources are important to develop. Robin: but $10M over 3 yrs is noticeable. Fermilab Budget Briefing

  25. Additional Information • Cavity R&D • SCRF infrastructure • Cryomodule assembly area • Various SCRF Test Areas Fermilab Budget Briefing

  26. SCRF Cavity R&D • The goal is to rapidly advance the intellectual understanding of SCRF surface physics and establish process controls to reliably achieve high gradient ( 35 MV/M) SCRF cavity operation • Approach: Establish a “tight loop” processing and test infrastructure in the U.S. • Tight loop elements: • Cavity fabrication improvements ( e.g. single crystal) • BCP & Electro-polish facilities • High purity water and High pressure rinse • Vertical test facilities • SCRF experts & materials program to interpret results • Portions of our RDR work and of this R&D effort are funded via specific tasks listed in an MOU with GDE Fermilab Budget Briefing

  27. Examples: SCRF infrastructure Horizontal Test of Dressed Cavity @ DESY TJNL e-beam welding Chemistry Cryomodule Test at DESY TTF TJNL Electro polish Fermilab Budget Briefing

  28. Examples: Cryomodule Assembly Assembly of a cavity string in a Class 100 clean room at DESY The inter-cavity connection is done in class 10 cleanroom Cryomodule Assemby at DESY Lots of new specialized SCRF infrastructure needed for ILC! Fermilab Budget Briefing

  29. FNAL SCRF Infrastructure • A Cryomodule Assembly Facility (CAF) is being built in (MP9) • Vertically tested cavities will be dressed (He vessel, coupler, etc) in smaller clean rooms prior to horizontal test • Horizontally tested cavities assembled into a string in large clean room before final Cryo-module assembly takes place CAF-MP9 Class 10 and 100 clean rooms ordered, operational by Summer 06 Parts for new Cryomodule Assembly fixture in IB4 Plan = expand CAF into Industrial Center Bldg after LHC quads Fermilab Budget Briefing

  30. ILC Test Areas (ILCTA) • SCRF test facilities are needed to carryout the ILC program • Vertical Test (bare cavities) IB1 • IB1 has 60 W @ 1.8 K now • Horizontal Test (dressed cavities) • IB1 & Meson Bldg (PD) • Meson will have 60 W @ 1.8 K soon • Cryomodule test facility • Cleaning out New Muon Lab • Remove CCM install cryogenics • Photo injector moves  e beam • Power 1st cryomodule in 2007 • RF Power & Cryogenics  These are Big expensive facilities! Industrial Building 1 New Muon Lab Fermilab Budget Briefing

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