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Status of the CLIC two-beam module program

CLIC Workshop 2014 ( 3-7 February 2014 ). A. Samochkine, G. Riddone Acknowledgements to the Module WG members 4 February 2014. Status of the CLIC two-beam module program. Content. Introduction to module TBM LAB TBM CLEX Test program

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Status of the CLIC two-beam module program

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  1. CLIC Workshop 2014 (3-7 February 2014) A. Samochkine, G. Riddone Acknowledgements to the Module WG members 4 February 2014 Status of the CLIC two-beam module program

  2. Content • Introduction to module • TBM LAB • TBM CLEX • Test program • Module design, component fabrication and assembly • TBM LAB • TBM CLEX • Conclusions

  3. TBM LAB. Overview • No beam, thermo-mechanical tests • 3 modules in series (final configuration “0 - 1 – 0”) • Real mechanical interfaces, quasi-nominal assembly procedure • Functional RF • mock-ups T0 T0 • Systems to test: • Supporting & pre-alignment • RF structures • Vacuum • Cooling • MBQ stabilization T1

  4. TBM CLEX. Overview • RF and beam • 1 module + existing PETS • Real RF structures TBM CLEX One TBM Priming RF Network Integration in CLEX TBM

  5. TBM Test Program 2011 - 2015 • Validation of different types of girders and movers • Pre-alignment of girders/quadrupolesin the module environment • Validation of interconnections and vacuum system under different thermal loads • Measurement of resonant frequencies • Simulation of several thermal cycles and alignment verification • Transport of the module and alignment verification LAB • Demonstration of the two-beam acceleration with fully fledged two-beam module • Address feasibility issues in an integrated approach • (detailed program under finalization) CLEX

  6. TBM LAB T0#1. Overview Consideringthe module consisting of several “layers”: Supporting/ pre-alignment RF Components Vacuum system Cooling system

  7. TBM LAB Main Beam. Accelerating Structures See talk “Experience assembling structures with damping manifolds” on Wed 05.02.’14 • Overall length  2010 mm • Simplified parts = reduced cost • Mechanical interfaces are equal to real AS • Internal surface area is equal to real AS • Cooling system is equal to real AS DISK STACK COOLING SYSTEM COMPACT LOAD VACUUM MANIFOLD CONNECTOR ( x 64 ) ( x 8 ) INTERFACE ( x 16 ) ( x 32 ) WAKE FIELD AS – VAC. TANK RF NETWORK INTERMODULE MONITOR ( x 32 ) INTERFACE ( x 16 ) INTERCONNECTION ( x 2 ) INTERCONNECTION ( x 8 )

  8. TBM LAB Main Beam. Accelerating Structures

  9. TBM LAB Main Beam. Accelerating Structures Welding (EBW) of two stacks together EBW Brazing of 2 stacks 1005 mm + Interconnections MB-MB; Cu tubes x 1 Standard fittings: x 2

  10. TBM LAB Drive Beam. PETS mock-up PETS ON-OFF (COUPLERS) PETS MINITANK PETS MOCK-UP DAMPING INSERT INTERCONNECTION • Octants replaced by simplified single body bar • Simplified damping inserts • On-Off actuator is replaced by the plug • The inner geometry is simplified • Using of interconnection flanges • Using of screw cooling fittings

  11. TBM LAB Drive Beam. PETS mock-up EBW General assembly. EB welding. Mock-up Compact Coupler. Brazing. CC subassemblies. Brazing. Compact Coupler subassemblies. Brazing. Minitank. Brazing & Welding.

  12. TBM LAB PETS mock-up, EBW Final assembly step. Electron beam welding accomplished by CERN main workshop.

  13. TBM LAB RF network COOLING PIPE The RF network (incl. hybrid, splitter and CMF) is meant to transfer the RF power from PETS (Drive Beam) to accelerating structures (Main Beam). REINFORCEMENT CHOKE MODE FLANGE TO LOAD HYBRID FROM PETS • standard WR90 profiles • the inner geometry of machined parts is simplified • using of interconnection RF flanges • The assembly procedure is similar to one for real component TO AS TO AS SPLITTER TO AS

  14. TBM LAB RF network General assembly. Brazing. Cooling pipe. Brazing. Reinforcement. Low temp. brazing. Hybrid (also splitters and elbows). Brazing. Splitter sub-assy. Brazing. CMF sub-assy. Brazing.

  15. TBM LAB Vacuum Network TUBES Ø28 • Network connected rigidly to the vacuum tank • Bellows used between compact loads and vacuum network • PETS and AS connected to vacuum tank COLLECTOR TUBE Ø64 BELLOWS TO VAC. TANK FROM AS COMPACT LOAD MOCK-UP FROM AS MAIN BEAM FROM AS

  16. TBM LAB Cooling System Nominal cooling system simulated to cool about 7.5 kW dissipated power Standard fitting are used to avoid brazing or welding operations: Insert tube Tighten the nut

  17. TBM LAB Experimental results SAS, example TAMB= 20 °C, VAIR = 0.4 m/s, VSAS= 0.0686 m3/h 28.2 27.6 28.3 28.5 25.5 24.8 25.0 25.5 Heat power: 50% 28.4 27.2 28.1 26.6 27.7 28.6 27.1 27.3 • Surface temperature:  average: 28.0 °C Max: 28.6 °C • Average water temperature increase per SAS: +3 °C Heat power: 100% 31.4 30.7 32.0 32.1 25.5 24.8 25.0 25.5 • Surface temperature :  Average: 31.4 °C  Max: 32.1 °C • Average water temperature increase per SAS: +6.3 °C • Transient time from 50% to 100%: ~20 min. 31.8 29.7 31.7 28.5 32.1 32.0 29.5 30.5 Measurements in agreement with expectation

  18. TBM CLEX. Integration TWO-BEAM MODULE • Priming RF network specially developed for providing the RF power • Fully equipped module (with supports) integrated in the CLEX line 2320 1360 PB 750 DB

  19. TBM CLEX Supporting System Validation of the positioning system before starting the assembly of the module (by SU colleagues) Installation of the motorized stations of the 1st batch supporting systems at the supplier facility 1st batch supporting systems (SiC) at the supplier facility Alignment measurements Delivered at CERN: currently under CMM, first measurements within the specification

  20. TBM CLEX DB BPM. Assembly • Installation of SiC rings (assembled with copper interface parts) inside the body; • Welding of the drift tube; • Welding of the bellows; • Screwing of RF-fingers. • Fabrication of all pieces under completion • Feedthroughs under testing CF FLANGE & BELLOWS ASSEMBLY RF-FINGER & SiC RING ASSEMBLY SIC RING & CU-INTERFACE ASSEMBLY QCF FLANGE & BELLOWS ASSEMBLY RF-FINGER DRIFT TUBE FEEDTHROUGH MAIN BODY ASSEMBLY

  21. TBM CLEX. PETS • The production of the 2nd PETS has been launched by CIEMAT: • 8 x Octants production is finished; • Assembly of 8 x Octants ready; • Production of mini tank and couplers finished • Electron beam welding is expected in the coming weeks (CERN); PETS#1 finalized and successfully checked PETS#2 RF check before final welding OK PETS RF check PETS before EBW

  22. TBM CLEX. Severalothercomponents Few hundreds pieces needed for one module

  23. Schedule

  24. Summary • Module program very important to understand technical issue on integrated approach • All the components of the TM0 #1 have been successfully manufacturedand module assembled in the LAB 169. Module currently under test. • The important lessons learnt during the fabrication of the components and module assembly are taken into account for the next TBM prototypes, especially the experience on SAS mock fabrication was indispensable for the production of real structures for CLEX • Alignment system fully validated • Heating/cooling systems operating as expected • Final duty cycles and failure scenarios under completion (thermal behaviour and alignment of components) • TM0 #2 under fabrication and assembly • Module review on roadmap for TBM LAB in Nov 2013: • TBM LAB: final configuration ‘0-1-0’ • TBM CLEX: final configuration ‘0’ • TBM CLEX under fabrication and assembly (installation from June 2014)

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