Production Preparations at JLAB

1. Production Preparations at JLAB JLab SRF Team EDMS – PLM DESY TeamCenterMeeting at SLAC 31 MAR 2014

2. Outline • Strategy • Preparations for LCLS-II Cavity Production at Vendors • Preparations for Cryomodule Production at JLab • Vertical Test Area (VTA) • Horizontal Test Bed (HTB) • Cavity String Assembly • Cold Mass Assembly • CMTF (Cryomodule Test Facility) • Prototype, Acceptance and Commissioning Tests • Issues / Challenges • Summary EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

3. Strategy – One Design, Two Production Lines Designs for Prototypeand Production CMs • Identical Prototypes - utilize as much existing hardware as possible to reduce schedule risk and reduce overall costwhile achieving the same performance as the production CMs • Identical Production Designs - utilize as much of the DESY/XFEL design as practically possible to reduce schedule risk and reduce overall cost IdenticalParts Received at Partner Labs • Well-developed drawing packages, clear requirements and specifications • Concurrent reviews within LCLS-II project • Procurement activities – lead technical contacts at Jlab/FNAL work together during all phases (SOTRs) Identical Tooling Interfaces • Interfaces between CM hardware and tooling are identical • Avoid adding custom features to CM • Adapt non-CM hardware interfaces to Jlab-specific tooling Equivalent Processes yielding Equivalent Performance • Recognize that some tools are different at each lab (e.g. HPR, vertical testing systems, vacuum leak checking equipment, etc.) • Monitor key process variables in consistent fashion (e.g. samples to verify etch rates) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

4. Preparations for Cavity Procurement • Approach – procure dressed cavities processed with high-Qo recipe from multiple vendors • Niobium to be purchased and provided to cavity vendors • FNAL leads niobium procurement activities and is developing spec • Capture best-available high-Qo process to be included as part of cavity specification • Three-lab collaboration proceeding with development • Cavity procurement activities led by JLab • Need well-developed drawing packages, clear requirements and specifications • XFEL specification is considered point-of-departure • Need to define level of oversight at cavity and component suppliers to ensure performance • Reviewing acceptance criteria, processing steps and hold points (where necessary) • Lead technical contacts at Jlab/FNAL work together during all phases (SOTRs) • JLab/FNAL/SLAC involved during evaluation of offers EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

5. Cavity Procurement – High Level Comparison • SNS – 81 bare cavities, 2 types, 1 supplier • Niobium supplied to vendor • Reactor-grade end groups required post-purification by JLab • No performance guarantee; Vendor needed to demonstrate that proscribed manufacturing process was followed • Visits to vendor to monitor progress • C100 – 85 bare cavities, 1 supplier • Niobium procured by vendor • Received with bulk BCP and initial tuning • No performance guarantee; Vendor needed to demonstrate that proscribed manufacturing process was followed • Visits to vendor to monitor progress • XFEL – 800 dressed cavities, 2 suppliers • Multiple niobium procurements • Receive ready for vertical testing • Performance guarantee? • Availability and use of in-process data? • Support at vendor’s facility? EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

6. CM Production Preparations • Adapt existing infrastructure to accommodate LCLS-II components, sub-assemblies, final assembly and testing • Define processes required for component handling, assembly and testing • Develop test plans – key activities are cavity qualification from vendors and cryomodule acceptance testing • Employ SRF QA Tools used for 12 GeV 100 MV CW cryomodules (aka C100) production and SNS production EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

7. Vertical Test Area / Horizontal Test Bench VTA • Up to four test stands available for production acceptance testing capable of testing one cavity at a time • Utilize same cavity hardware (test flanges, feedthroughs, etc.) provided by project to cavity suppliers • Small modifications required to existing supports • Ensure low magnetic field environment (“magnetic hygiene”) HTB • Plan to conduct five tests during production effort to provide feedback on cavity assembly process or for production development activities • Modifications to top hat for XFEL-style FPC and small modifications to existing supports EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

8. Cavity String Assembly in Clean Room • “Lollipop” supports for each cavity • TBD for SC magnet and bpm • Use mobile rail system rather than rail-in-floor used at DESY, CEA/Saclay and FNAL • Transfer to CM assembly rails for cold mass assembly EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

9. Cold Mass / VV Assembly • “Lollipop” supports for each cavity • TBD for SC magnet and bpm • Use two-rail system to transfer cavity string onto Return Pipe • Use two-rail system to transfer cold mass into vacuum vessel • Crane access in high-bay for shipping EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

10. CMTF • HPRF system suitable for individual cavity testing or 8 cavities in short duration steady state • TBD system for testing SC magnet • Magnetic shielding encloses testing volume reducing external fields to ~50 mG • Cryogenic capacity for testing individual cavities in CW mode • End Caps – specific for LCLS-II CM testing • Interface to CM piping and existing junction box using u-tubes EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

11. CM Testing • Three types of CM testing should be considered: • PrototypeTesting that may include additional (non-routine) activities for system verification • Acceptance Testing in CMTF includes some CMTF-specific checks • CMTF procedures may vary from in-tunnel procedures • HP RF equipment may not be identical • Commissioning Tests in-situ may include tests that • Require additional equipment (Network Analyzer) • Verify RF zone operations (EPICs controls, Klystrons, etc.) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

12. Comments on Prototype Testing • Testing Facility (CMTF) Checks • Electrical, water, cryo, controls, LLRF, HPRF, Data acquisition • Includes collection of tests envisioned for production CMs • Both Low Power and High Power • Includes specific tests that may verify CM performance, but might not be conducted on all CMs • FPC Qext range vs. CM heat load • Detailed microphonicsstudies • LLRF development activities EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

13. C100 CM Production : LP RF Tests* *Major Steps taken from C100 Low Power RF Test Traveler • Cavity ID's • Warm Frequencies • Mechanical Tuners: Tuner Range and Hysteresis • Cold Frequencies including pass-bands and loaded Q’s • Mechanical Tuner Resolution • Piezo Tuner Range and Hysteresis • Piezo Tuner Resolution • Piezo Tuner Impulse Response • Microphonics • Mechanical Mode Measurements • HOM Coupler Qext's and HOM Survey • Cavity Detuning for Warm up EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

14. C100 CM Production : HP RF* *Major Steps taken from C100 HP RF Traveler • Checklist • Qext's, FPC's and HOM's • Maximum Gradient Determination (Emax) • Extended (One Hour) Run (Emaxop) • Field Emission Measurements • QoMeasurements / Static Heat Load - Primary Circuit • Pressure Sensitivity Measurements • Static Lorentz Measurement • Swept AM Lorentz Transfer Function EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

15. C100 CM Production : HP RF Checklist • Record Cavity ID #’s • Calibrate RF Cables • Verify Interlocks • Arc Detectors / IR Sensors • Beamline / Waveguide Vacuum • G-M Tubes • Inspect waveguide connections • Inspect Heliax cable connections • Verify Personnel Safety System (PSS) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

16. C100 CM Production : Testing in Tunnel* *Major Steps taken from C100 Commissioning Traveler • Low Power RF • Initial Cold Frequencies • Cavity Tuning • Final Cold Frequencies and Passbands • HOM Measurements • Interlock Checkout • High Power RF • EmaxDetermination: Qext’s and Probe Calibrations • EmaxDetermination: Emax • EmaxopDetermination (One Hour Run) • Field Emission Survey • Qovs. EaccMeasurements • Static Heat Load • Microphonics • Eight Cavity Run (at low duty cycle) EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

17. Shipping Method XFEL CM Shipping Fixture • LCLS-II CMs will be shipped from partner labs to SLAC using shipping fixture on flat-bed trailer with cover • Plan to use identical shipping fixtures and covers as for XFEL Design verification can be accomplished with the first article LCLS-II cryomodule. • Instrument cavity string, quadrupole, piping and vacuum vessel with triaxial accelerometers to measure shock attenuation and vibration isolation during transport • Evaluate performance before / after simulation of loading and shipping environment • RF performance • Static heat loads • Alignment Shipping Covers - provide hermetic seal and piping support Aeroflex Isolator - wire rope spring provides triaxial shock attenuation and vibration isolation EDMS PLM DESY TeamCenterMtg at SLAC, 31 MAR 2014

18. Issues / Challenges • Defining level of oversight at cavity and component suppliers • Defining acceptance criteria and hold points where necessary at cavity and component suppliers • Defining requirements for niobium inspection – e.g. correlating eddy current scanning to cavity performance • Goal for production of CMs at Jlab/FNAL is “identical design, identical parts, equivalentprocesses to yield equivalent performance” • Developing coherent QA plan with appropriate QC systems across project partner labs • Developing travelers for CM production lines at two labs that utilize equivalent processes  “local customization” • Availability of XFEL design information and production QA tools as point of departure for LCLS-II design • Success-oriented schedule • Others? EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014

19. Summary • Goal for production of cavities at vendors is “identical design, identical parts, equivalent processes to yield equivalent performance” • Goal for production of CMs at Jlab/FNAL is “identical design, identical parts, equivalentprocesses to yield equivalent performance” • Need to identify appropriate QA tools to use during vendor production and lab CM production EDMS PLM DESY TeamCenter Mtg at SLAC, 31 MAR 2014