Accelerator/WP 11.5.3 High BetaStructures

Alan WheelhouseHIGH-BETA CAVITY DELIVERY

www.europeanspallationsource.seApril 21, 2015

WP 11.5.3 Outline

• Schedule• Technical Performance• Selected Technologies• Integration & Verification• Organisation Structure• Budget & Cost Book• Major Procurement• Risks• Next Steps• Summary

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Schedule

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Schedule

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Milestone Description Date1 Infrastructure preparation start 4/5/152 Infrastructure preparation finish 13/3/173 Niobium procurement start 29/8/164 Niobium procurement finish 16/7/185 Cavity testing procedure training start 4/1/166 Cavity testing procedure training finish 26/2/187 Cavity procurement start 18/8/178 Cavity procurement finish 6/3/209 Cavity testing start 3/8/18

10 Cavity testing finish 25/11/2011 Cavity shipment start 3/10/1812 Cavity shipment finish 4/12/20

HBCM Assembly at CEA start 5/4/19HBCM Assembly at CEA finish 11/11/21

WP 11.5.3 Technical Performances

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84 (+ 4 spare) high-β dressed elliptical cavities capable of achieving 22.9 MV/m at 704 MHz, with a Qo better than 5 x 109

• Niobium procurement: STFC to procure the high RRR Niobium for the high-β elliptical dressed cavities in agreement with the SRF collaboration for the ESS linac.

• Cavity fabrication of the 84 (+4 spare) high-β elliptical dressed cavity in industry including:– Cavity fabrication.– Chemical processing.– Heat treatment.– Vacuum processing.– High pressure rinsing.– Field flatness and frequency tuning.– Assembly of RF antenna and isolation valve in cleanroom.– Shipment of dressed cavities to STFC.

• Procedure Qualification and Training:– Documentation for all the processes and procedures to be defined and

agreed– Training on the processes to be performed and monitored– Process trials to be performed– Cavity preparation and final test QC documentation prepared.

WP 11.5.3 Technical Performances

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• Cavity Qualification:– Installation of cavities onto vertical insert– Installation into VTF cryostat– Qualification in a vertical test facility of cavities at 2K to the required gradients

of 22.9MV/m for the high-β cavities.– Assessment and provision of test data

• Test data to be reviewed and approved– Removal of cavities from VTF Cryostat and vertical insert.– Complete final sealing, leak checks and QC processes.– Sealing and packing of cavities– Arrangement for delivery of cavities to cryomodule integration team (CEA-

Saclay).– Maintenance of the equipment

• Cavity Rework:– HPR of cavities– Repeat qualification

• Preparation and shipping of cavities to cryomodule integration site:– STFC to design and procure shipping fixtures for SRF dressed cavities for transport from industry.– STFC to transport SRF cavities from STFC to the cryomodule integration site.– STFC to support transport cost in accordance with ESS transportation policy.

WP 11.5.3 Selected Technologies

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• Niobium procurement• Specifications for the Nb material need to be agreed with ESS and CEA-Saclay

• Cavity fabrication• Cavity drawings, specifications and processes required. To be agreed with

ESS and CEA-Saclay, also in conjunction with INFN• Vendor qualification to be performed

• Preparation of infrastructure• Vertical test facility to be upgraded

• Larger diameter cryostat capable of holding 3 dressed cavities• RF system for 704 MHz

• Cavity qualification and testing• Procedure qualification and training

• In house procedures to be developed• Staff to be trained in processes

• Trials to be performed

WP 11.5.3 Selected Technologies

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Quality Assurance• STFC Technology Department at Daresbury Laboratory operates a quality system that meets

the requirements of ISO 9001:2008. • The quality system defines how a project will be coordinated and documented. • The management of a project is based on an agreed Project Specification and a series of

reviews at key stages in the work. • The detailed implementation of the Quality Management system is described in standardised

group procedures, processes and local instructions. • These provide the core of the Quality Management System and provide the detail required to

operate the system. • The processes and procedures are followed by STFC staff undertaking specified activities.• The work undertaken will be defined under an agreed series of bespoke processes and

procedures based on existing Daresbury Laboratory vacuum and cleanroom procedures, in association with procedures developed by ESS/CEA-Saclay.

• These procedures and processes would then be followed and tracked by the technicians assembling the equipment to ensure a repeatable, auditable standard is achieved.

QUALITY MANAGEMENT SYSTEM – ISO 9001:2008

WP 11.5.3 Integration and Verification

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• Drawings, specifications and procedures to be provided by ESS• Timescales are defined to enable the procurement processes for the

Nb material and cavities to formally commence

• Systems of work, procedures and processes will be defined in conjunction with CEA-Saclay and in conjunction with INFN• Aim to learn from the work performed on the medium-β cavity

• Procedures will need to deal with cavity non-conformance issues • Will have to understand the impact for the CM integration

A formal ESS/CEA/STFC/INFN coordination process is critical to ensure specifications/drawings/procedures are collectively agreed and utilised

WP 11.5.3 Organization at Partner Lab

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Project Sponsor (ASTeC)

Project Manager (Technology)

Material/Cavity Procurement (Technology)

Vendor Monitoring(Technology)

Quality Assurance (Technology)

QA Documentation Preparation(Technology)

SRF Infrastructure (Technology)

Cleanroom/HPR/VTF Preparation (Technology)

Production Preparation/Training(Technology/ASTeC)

SRF Cavity Testing (ASTeC)

Cleanroom Assembly

(Technology)

Vertical Testing (ASTeC)

Preparation/Shipment

(Technology)

Project Management Committee (PMC)

(Technology & ASTeC)

Project Management Board

(ASTeC, Technology & Independent)

TMVE/T@DL Programme

Management (Technology)

STFC ESS-IKC Project Board

ESS/CEA Elliptical Cavity

Collaboration Board Stakeholder planning

Financial reportingProject planning (& current R,A,G status) Change ManagementRisk Register

WP 11.5.3 Budget and cost-book

• Costs for 84 high-β cavities • No spares factored in• No rework costs included• Costs based as of 31st January 2013• No inflation factored in Final costs will include appropriate

indexed costs for staffing and hardware

• No contingency factored at present Needs to be agreed on how this is to

be managed LHe will need to have a higher level ESS to cover Nb material contingency

• UK funding commences 16/17 UK issue with availability of funds for

15/16 11

Procurement and Qualification Costs Cost 15/16 Cost 16/17 Cost 17/18 Cost 18/19 Cost 19/20 Cost20/21 Total

Nb Material for High-β Cavity € 2,958,710 € 4,438,064 € 7,396,774Total Nb Material Cost € 2,958,710 € 4,438,064 € 7,396,774High-β Cavity Fabriaction € 0 € 2,646,589 € 6,844,201 € 1,095,566 € 10,586,356Total Cavity Fabriaction € 0 € 2,646,589 € 6,844,201 € 1,095,566 € 10,586,356704MHz VTF Fixtures, Cryostat, Insert, RF, Alignment, Support Fixtures, & Maintenance € 479,475 € 236,352 € 73,860 € 24,620 € 24,620 € 24,620 € 863,547Trial Cavity Testing and Procedure Qualification € 104,185 € 208,369 € 312,554High-β Cavity Testing € 300,071 € 1,144,890 € 1,144,890 € 112,334 € 2,702,185Staff Effort € 574,095 € 596,863 € 637,781 € 862,540 € 862,540 € 646,905 € 4,180,724Total Cavity Testing € 1,053,570 € 955,865 € 1,220,081 € 2,032,050 € 2,032,050 € 783,859 € 8,077,475Total € 1,053,570 € 3,914,575 € 8,304,734 € 8,876,251 € 3,127,616 € 783,859 € 26,060,604

Contingency € 0 € 0 € 0 € 0 € 0 € 0 € 0

Grand Total (Ex VAT) € 1,053,570 € 3,914,575 € 8,304,734 € 8,876,251 € 3,127,616 € 783,859 € 26,060,604Grand Total (Incl VAT) € 1,149,464 € 4,578,117 € 9,838,125 € 10,478,994 € 3,580,631 € 811,250 € 30,436,580

WP 11.5.3 Major Procurements

Niobium Material• Scope:-

– Specification– Vendor validation– Agreed delivery timescales– Quality and delivery

monitoring

• Value - €7.4M (Cost as at 31st January 2013)

• Timescales:-– Niobium procurement start:

29/8/16– 4 month procurement process– Niobium procurement finishes:

16/7/18

• Provisional Nb quotes received from Wah Chang, Tokyo Denkai & Ningxia:– Based upon drawings supplied by

CEA Saclay– Inflation costs of Nb uncertain Nb specification needs to be

clarified by ESS to allow procurement to commence

• Prefer two suppliers for Nb– Minimise delivery timescales– Ensure timescales can be achieved– Minimise risk against other known

external procurements for Nb over this period (e.g. SLAC – LCLS-II)

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WP 11.5.3 Major Procurements

Cavity Fabrication• Scope:-

– Specification– Vendor qualification– Agreed delivery timescales– Quality and delivery monitoring

• Value - €10.6M (Cost as at 31st January 2013)

• Timescales:-– Cavity fabrication start: 18/8/17– 4 month procurement process– Cavity fabrication finishes:

6/3/20

• Refined quotes obtained from RI and AES

• Discussions held with Zanon and MHI

• Processing requirements to be agreed Finalised engineering drawings

required from ESS Cavity process requirements to

be defined by ESS ESS to provide tolerance

requirements to aid HOM management

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WP 11.5.3 Top risks

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Next Six Months

• STFC ESS Project Board to approve defined programme – April 2015– UK contingency level to be defined and how it is to be centrally managed.

• Need to resolve 15/16 funding issue caused by expected UK funding timescales.

• UK-IKC Technical Annex to be defined and agreed• Formal UK – IKC agreement to be agreed and approved:

– Date: TBD

• NDA agreement to be set-up with CEA Saclay– Date: TBD– Commence discussions on refining requirements for the high-β cavity

• Integration of Vertical Test Facility– Design of systems– Commence procurement

• Continue on-going discussions with potential suppliers– Defining requirements

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WP 11.5.3 Summary

• STFC has developed a plan for the provision of the high-β elliptical cavities which meets the timescales for the ESS RFI schedule.

• A cost book has been developed and is under negotiation with ESS

• Infrastructure needs to be integrated to achieve the production requirements

• STFC needs to have strong coordination with ESS/CEA & INFN to ensure requirements and timescales are fully integrated:– Specifications, drawings, procedures, QA processes and project

management integration is critical for successful delivery.

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