Americas

Main Linac Cavity and Cryomodule WBS X.9 Resource Proposal

Shekhar Mishra

(Hasan Padamsee, John Mammosser, Mike Kelly)

For the WBS 9 Collaboration

Americas PreambleIn preparing this analysis of the scope and resources needed to carry out

1) GDE Task Force Recommendation (or under discussion recommendation)

– The R&D to address crucial issue with ILC cavity and Cryomodule&

2) Regional Interest Draft Recommendations to

– Strengthen U.S. SRF technical capabilities and prepare the U.S. with the infrastructure, expertise and industrial capabilities necessary to host the machine.

We have tried to make a balance between the scope and resources. The Cavity, Cryomodule and RF Unit R&D Program has a higher priority over the Regional Interest Recommendations.

We have discussed this with Gerry, Satoshi and others. This presentation includes their comments.

Please tell us what we have missed so that we can improve this program.

Americas Step - 1• At the ART meeting at SLAC we presented the scope of a

collaboration plan that attempts to capture both the “GDE R&D objectives” as well as the “Regional Interest objectives” as expressed by the US Regional Interest Panel

• The following table re-iterates the growth model and yield improvement model we presented.

• It scopes activities in terms of number of cavities, cryomodules, RF units per year.

• We analyzed the needed infrastructure to carryout this program with a vision for the future

• We invited people to submit comments on the scope so it could be adjusted.

Americas

Plan Presented at SLAC S0 S1 S2… (Including Regional Interest Discussions)

AmericasStep - 2

• We conferred with the principals and the management at MSU, LANL, JLab, ANL, Cornell and Fermilab– Described the scope as presented at the ART meeting

held at SLAC– Reviewed their capabilities to address the scope– Made specific proposals to these labs based on our

analysis of strength and interest.– Invited these labs to submit specific proposals and costs

to address the scope– Present the work package from each collaborating

laboratory later in the talk

AmericasStep - 3

• We have analyzed four programs based on the following budget guidance from Gerry– $75M (150% of Target 2)– $50M (100% of Target 2)– $25M (50% of Target 2 and Close to Target 1)– $10M (50% of Target 1)

• We started with determining the cost for the full scope plan as presented at SLAC.

• We call this Plan I.

• The cost for Plan I is came very close to Gerry’s 150% x Targets 2 for 08 and 09.

AmericasUS SRF Infrastructure Strength

• Cavity Processing and Vertical Testing R&D Facility– Jlab (30 FY07, 40 FY08, 50 FY09) cycles/yr– ANL/FNAL ( 50 FY08, 60 FY09) cycles/yr– Cornell (12) cycles/yr– VTS @FNAL 70 cycles/yr (07)

• Horizontal Test Stand– FNAL 24 cavities/yr

• Cavity Dressing and Cryomodule Assembly– FNAL 12/yr (FY07)

• Limited cavity fabrication capability in US industry

AmericasUS SRF Infrastructure Direction

• Automated Cavity Tuning– 100+ Cavity/yr (FY09)

• Processing and Vertical Testing (Pre-Production Next Generation Facility, with redundancy)– 100+ Cavity/yr (FY09)

• Horizontal Test Stand– Additional 48 Test/yr (Maximum Capacity needed)

• Cryomodule and RF Unit Assembly and Test without and with beam

• Increased cavity fabrication capability in US industry– Electron Beam Welder

AmericasJlab: Production Schedule for 31 Cycles / Year

With some Upgrade

This can be40-50 cy/yr

Americas

Schedule for Pre-Production and Next Generation Processing Facility

AmericasPlan I (150%) = 75 M$ for 08, 09

08 09

Cavities & Cryomodules, for S0, S1 and Regional Interest

32.2 54.5

Basic R&D to improve performance, incl ACD activities

4.3 3.4

Cavity, CM and RF Unit Infrastructure 37.7 17.7

Grand Total 74.2 75.6

Plan 1 Spreadsheet

Americas Distribution of FTE

FY08

FY09

AmericasPlan 1: Summary of FY08-09

Detailed Plan 1 Spreadsheet

AmericasDistribution of Fund

FY08

FY09

AmericasPlan II (50 M)

Plan 2 Spreadsheet

Strategy:

Drop processing and testing cavity and CM infrastructure,

Reduce regional interest cavities in 09

08 09

Cavities & Cryomodules, for S0, S1 and Regional Interest

32.2 44.7

Basic R&D to improve performance, incl ACD activities

4.3 3.4

Cavity, CM and RF Unit Infrastructure 12.8 2.2

Grand Total 49.3 50.3

AmericasPlan III (25 M)

• Plan 3 Spreadsheet

• Strategy: – Further reduce cavities and CM from Regional Interest, – Put all cavity processing and testing, cryomodule and RF Unit infrastructure

to zero

08 09

Cavities & Cryomodules, for S0, S1 and Regional Interest

20.4 20.8

Basic R&D to improve performance, incl ACD activities

4.3 3.4

Cavity, CM and RF Unit Infrastructure 0 0

Grand Total 24.7 24.2

AmericasPlan IV (10 M)

Plan 4 Spreadsheet Strategy: • No Cavity and Cryomodule processing infrastructure• Reduce Cavity and Processing R&D by x2, • Reduce cavity activity.

08 09

Cavities & Cryomodules, for S0, S1 and Regional Interest

7.75 8.81

Basic R&D to improve performance, incl ACD activities

2.14 1.7

Cavity, CM and RF Unit Infrastructure 0 0

Grand Total 9.9 10.5

Americas Plan 1: MSU Work Package

• Recommended Program– Cavity Autopsy– Single Cell Cavity (R&D)– Advanced Cavity and Material Science studies (R&D)

• SRF Infrastructure– Upgrade ultra-pure water and high pressure rinse– Nine-cell structure vertical test dewar

• Budget– UPW and HPR: $80k (08), $60k (09)– Vertical dewar: $150k (08), $60k (09)– Cavity Autopsy: $250k/year– Test single-cell cavities: $50k/year – Advanced Cavity and Material Science studies: $135k/year

FY08: $635k and FY09: $555k

Americas Plan 1: LANL Work Package

• Recommended R&D Program– Cavity Autopsy

• SRF Infrastructure (Partly Funded in FY07)– Re establish cavity testing at LANL– 1.3 GHz Power Amplifier– Thermometry provided by Fermilab

• Budget– 2.5 FTE FY08,09 : $208k and $214k– M&S FY08,09: $495k and $689k– Indirect Cost FY08,09: $288k and $297k

FY08: $991k and FY09: $1,200k

Americas Plan 1: Cornell Work Package

• Goal : S0.2 Contributions, Determine if a new cavity is qualified to reach high gradients

• Plan: Vertical EP, HPR, test new 9-cell cavities

• Background– Proven successful for single cells – EP under development for 9-cells – Scope of Work : Process and test one cavity per month: (Production cavity

activities)– Heat treatment and tuning to be carried out elsewhere (need to include cost

of those treatments and shipping in overall budget).

• Budget:– 2 FTE + 100 K (liquid helium, acids…)– RF power source 300 – 400 Watt (60 K$) (if not funded in 07)– Smaller diameter vertical test dewar (60 K$) (if not funded in 07)– Present dewar was used for very large 200MHz cavities– Reduce liquid helium usage per test

• M&S cost = 220 K each in 08, 09

AmericasPlan 1: Cornell Work Package (R&D)

• Explore basic parameters for HPP with 9-cell ILC Cavity– Qe, Pulse Length, Power Level

• Complete vertical test stand insert for HPP of 9-cell cavities (0.5 FTE)– Test stand design started in 06, continue in 07

• Available– About 2 MW, 1.3 GHz source, 250 us pulse length– Waveguide to coax switch and waveguide run to test pit– Input coupler/cold window

• Scope: EP, HPR and Vertical tests 9-cell cavities with HPP including vacuum accidents and recovery. 6 tests per year (1 FTE + 50 K M&S)

AmericasPlan 1: Cornell Work Package (ACD)

• Design 9-cell cavity with HOM couplers to achieve adequate damping (0.5 FTE) – Chose best aperture 60 – 70 mm

• Order two 9-cell re-entrant cavities with HOM couplers (250 K)– One with fine-grain, one with large-grain Nb?

• Process and test two 9-cell re-entrant cavities (0.5 FTE)– Fine grain with EP, large-grain with BCP– 6 tests per year

Americas

Plan 1: Cornell Work Package Budget Summary

2008 2009

FTE M&S FTE M&SS0 9-cell EP and Vertical Test

2 220 2 100

HPP 9-cell 1.5 50 1 50

ACD:

9-cell Reentrant

0.5 250 0.5 50

Totals 400 k 520 k 350 k 200 k

With Overhead 680 k 710 k 595 k 340 k

Total 1390 k 940 k

Americas Jlab: Modified Funding Request for FY07

• Existing FY07 MOU would need modification– Include costs for 31 process cycles (≈ 32.2K/cycle)

• 999.4K$ w/ 5 FTE’s, ½ from Jlab

– Infrastructure support• Dedicated RF system 100K$• Second Test-stand 60K$• Tooling Development 60K$• Process monitoring 60K$ (implement witness sample program)• Total 280K$

– Contingency 15% on 31 cycles• 192K$

• Total $1471K in FY07 (We recommend this: S0)

AmericasPlan 1: Jlab Work Package

• Processing and Vertical Testing of 9 Cell Cavity – 30 cy/yr in FY07 (Estimate Based on Previous Slides, additional M&S

resources may be needed in 08 and 09)– Process 40 cy/yr in FY08, 32 k per (1.23 M)– 50 cy/yr in FY09 (1.6 M)– $200k per year as an estimate for additional resources contingency– $365k per year Cryogenic cost

• Single Cell R&D to improve the Processing (0.25M each year)

• Field Emission studies for tracking the contamination (0.1M each year)

• ACD: LL Shape Cavities, Large Grain and Single Crystal (0.5 each year)

FY08: $2.65M and FY09: $2.62M

AmericasPlan 1: ANL Work Package 08

• Electropolish S0.2 ILC cavities - 1.5 FTE, $225 K M&S for full-time operation and throughput of 1 procedure/week

• Install new HPR system, $200k

• High-pressure rinse S0.2 ILC cavities –1.0 FTE, $60K M&S

• Installation of a PLC-based control system for EP - 0.5 FTE, $75 K

• Optimize existing EP hardware/Interface with U.S. EP vendors/develop and optimize hardware suitable for large-scale EP (1 FTE)

AmericasPlan 1: ANL Work Package 09

• Electropolish S0.2 ILC cavities – 2.0 FTE, $337 K M&S for full-time operation and throughput of 1.5 procedures/week

• High-pressure rinse S0.2 ILC cavities – 1.0 FTE, $60 K M&S

• Optimize existing EP hardware/Interface with U.S. EP vendors/develop and optimize hardware suitable for large-scale EP (1 FTE)

FY08: $1.4M and FY09: $1.5M

Americas

• Order 125 cavities

• Heat treat, tune, HPR and Vertical test: 50 cycles/ EP at Argonne

• Horizontal test 16 “good” cavities

• Work with LANL and MSU to supply thermometry diagnostics for failed cavities

• Single cell R&D

• Materials R&D collaboration

• Continue Testing First cryomodule (type III) assembled in 07 from DESY supplied cavities

• Assemble cryomodule #2 (Type III)

• Test cryomodule #2

Plan 1: Fermilab Work Package 08

AmericasPlan 1: Fermilab Work Package 08

• Assemble cryomoudle #3 (Type IV)

• Order parts for 4 Cryomodule Gen IV – For S2 RF units, & industrialization start

• Continue Next Generation CM design, manufacturability, transportability, cost reduction

• Involve industry in activities

• Test and treatment facility operations

• Refrigeration (and misc) for Operation, S0, S1

Americas Plan 1: SRF Infrastructure Work Package 08

• Install 2 sets of vertical test stands VTS including refrigeration

• Install one additional HTS

• Install CM test stand (RF is in X.8)

• RF unit infrastructure

• Install one beam welder for cavity industry to increase number of cavity vendors

• Install Next Generation and Pre-Production cavity processing (scanning, EP, BCP, tuning, heating) and preparation (HPR, clean room, baking) infrastructure to handle 100 cycles per year

Americas

• Order 218 cavities

• Heat treat, tune, HPR and Vertical test 90 - 100 cycles/ EP at Argonne & FNAL

• Horizontal test 48 “good” cavities

• Assemble 4 cryomodules (Type IV)

• Test 4 CM

• Order parts for 12 CM (Type IV) – CM industrialization (18 M)

• Continue Next Generation CM design, manufacturability, transportability, cost reduction

• Test facility operations

• Involve industry in activities

• Single cell R&D

• Materials R&D collaboration

Plan 1: Fermilab Work Package 09

AmericasPlan 1: SRF Infrastructure Work Package

• Finish and commission cavity processing (scanning, EP, BCP, tuning, heating) and preparation (HPR, clean room, baking) infrastructure to handle 100 cycles per year

• Install one beam welder for cavity industry, increase number of cavity vendors

• Finish installation of module test stand 2 M

• RF unit infrastructure

AmericasNext Step

• Take a Break

• Take a over all view of the ILC Projects in US and see if all topics are covered.

• Look at balancing the plan, schedule, resources.

• Study and discuss other R&D and Production models

• Suggest a more realistic 2010 and beyond plan