Overview of the HWR Project:
Technology, Management, ES&H
P.N. Ostroumov
Physics Division
March 5, 2012
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
2
Content
Project motivation
Functional specifications of the HWR cryomodule
Technical developments
– Cryomodule design features
– Cavity design features
– High power RF coupler
Management
– ES&H, QA
– Project team
– M&S cost, Schedule
– Milestones
– Major procurements
Summary
Project Motivation
Acceleration of H beam from 2.1 MeV to 10 MeV in CW regime
Difficulty: transition from very low accelerating gradients in RFQ to much higher gradients in the SC section – not efficient use of SC structure
Total accelerating voltage 1.7 MV 8=13.6 MV
– First 2-3 accelerating periods - just 1 MV
Replaces 3 cryomodules of 325 MHz spoke cavities from the original design of Project X (beginning of 2011)
– More naturally fits to 162.5 MHz RFQ
Significantly reduces the cost of the front end (PXIE) as compared with the 325 MHz system
Favorable beam dynamics: higher accelerating gradients, less defocusing, linear motion in longitudinal phase space
Can be realized in reasonable length of the cryomodule below 6 meters
– Comparable with ATLAS cryomodules
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
3
Functional Specifications (revision 2/21/2012)
Parameter Value
Minimum beam aperture (ID), mm 33
Overall module length; flange-to-flange, m 5.8 5.9
Maximum allowed heat load to 70 K, W 250 250
Maximum allowed heat load to 4.5 K, W 80 60
Maximum allowed heat load to 2 K, (target), W 25 24
Thermal intercept temperatures, K 5 and 45-80
Number of cavities 8
Operating Accelerating Voltage, cavities 1 and 2, MV/cavity 1.0
Operating Acc. Voltage, cavities 3 through 8, MV/cavity 1.7
Transverse alignment error, displacement, mm 0.5
Transverse alignment error, angle, mrad 2.5
Coupler Power Rating (full reflection), kW 10
Number of SC solenoids with steering correctors 8
Number of BPMs 8
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
4
March 13, 2011
P.N. Ostroumov Lattice options for 40 MeV Linac SARAF ISC Meeting, March 13-15, 2011
5
Basis for Cryomodule Development at ANL
ATLAS Energy Upgrade cryomodule, average voltage =2.1 MV/cavity, limited by VCX
Being used since July 2009, current performance is even better than original one
Carbon beam energy measured after each cavity
Basis for HWR Cryomodule Development: ATLAS
Efficiency and Intensity Upgrade
Experience with reduced- cavities and Cryomodules
5.2 meter cryomodule
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
6
Performance of 170 MHz HWR (2004) and 72 MHz
QWR (2011) Technology has been improved since 170 HWR was built in 2003-2004
– Highly optimized EM design, reduced BPEAK and EPEAK
– Extensive wire EDM of all parts prior to EBW
– EP after all mechanical work is complete (+600C baking)
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
7
Q
1010
109
=0.25 HWR, f0=172.5 MHz
1.8 MV/Cavity(4 K)
(See Kelly et al. THP06, LINAC 2004)
Cryomodule Layout
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
8
In October 2011 we started with the cryomodule concept which included 9 cavities and 5 SC solenoids
Beam physics studies resulted in 8 cavities, 8 solenoids, 8 BPMs
The first upstream element is a SC solenoid to mitigate vacuum transition from NC to SC linac
Cryomodule Design Features
2K operation
Relatively short cryomodule, 5.9 m
– Reduction of the length by ~10” is being pursued
Compact lattice: short focusing periods to be able to apply high accelerating voltages
Compact SC solenoid
– no-iron, return coils to reduce stray fields
– H- and V-steering correctors
Improved alignment techniques
BPMs attached to each SC solenoid
Incorporate JT valve and heat exchanger into the cryomodule
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
9
Preliminary Design of the Cryomodule
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
10
Cavity, slow tuner and RF coupler are nearly final
Cavity and solenoid alignment hardware is identified and being implemented
Incorporate and position internal J-T valve & heat exchanger
Modify vacuum, helium manifolds
Develop cavity-BPM-solenoid design which is more compact and suitable for assembly in clean room
Beam
Cryomodule Interfaces
The following interfaces are identified in FRS
– Bayonet connections for helium supply and return
– Cryogenic valve control system connections
– Pumping and pressure relief line connections
– Cryomodule positioning and alignment supports
– Beam tube connections terminated by a low particulate vacuum valve
– RF cables to the input couplers
– Instrumentation connectors on the vacuum shell
– Power supply cables for the solenoid and correctors connections
– Alignment fiducials on the vacuum shell with reference to cavity position
Several items from the list are obvious (bayonets, pumping, RF transmission line, beamline connection, instrumentation)
All these interfaces have been discussed conceptually with FNAL experts
During FY12 we need to identify detailed design for all interfaces
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
11
Resonator Design Features
Highly optimized
– Low BPEAK due to double conical shape of the CC and OC
– Increased shunt impedance
– “Donut” shape of the CC drift tube to eliminate quadrupole component of the accelerating field
Four 2-inch diameter ports for EP, 2 ports will be used for pumping and pick-up loops, one 2-inch port is for the high power coupler
– Blending radius on toroid-port joins is 0.5” – significant development by AES
to minimize BPEAK
Pneumatic slow tuners
10-kW RF coupler, fast tuner is not required
– 4-kW RF power will provide ~20
at 1 mA ( is the rms frequency noise)
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
12
162.5 MHz Cavity Assembly (Dimensions are in cm)
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
13
EM optimization
Excellent EM properties. Recommended design voltage is 1.7 MV which corresponds to EPEAK = 38 MV/m and BPEAK =44 mT
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
14
Freq
MHz
βOPT LEFF
(cm)
EPEAK/EPEAK BPEAK/EPEAK
mT/[MV/m]
R/Q
Ω
G
Ω
162.5 0.112 20.7 4.6 5.0 271 48
No ports With ports
10-kW Adjustable Coupler
Based on successful development of 4-kW input coupler (1-5/8” coax) for 72 MHz cavities
Increased diameter of the outer conductor, 2”
1” stroke, 70K cooled alumina window, 4.6K intercept
The coupler is being fabricated
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
15
Resonator port
To RF Amplifier
Electropolishing after all Mechanical Work is Complete
72 MHz QWR
162.5 MHz HWR
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
16
Project Management EBIS Review
17
ANL Laboratory Management System (LMS) and
ES&H
A primary objective of this project is to protect the environment and the safety of workers and the general public
The PXIE-HWR project fully complies with ANL LMS
– All work is controlled by Work Processing and Control Documents
– All Project Team members are fully trained for the tasks they perform
– Integrated safety management (ISM) is incorporated into the project planning and execution and includes
• Defining the work
• Analyzing all potential hazards
• Developing and implementing hazard controls
• Performing work within controls
• Providing feedback and continuous improvement
January 30-31, 2012
Project Management EBIS Review
18
LMS and ES&H (cont’d)
The Project complies with all applicable ANL and Physics Division ES&H requirements. – ANL ES&H Manual and the Physics Division Safety Policy,
– Physics Division Electrical Safety Manual,
– Physics Division Radiation Safety Manual,
– Physics Division Chemical Hygiene Plan,
– Building 203 Emergency Plan,
– ATLAS Operating Procedures
Technical and ES&H reviews: – General Safety Committee Reviews as needed at ANL
• We plan to invite FNAL safety committee members for these Reviews
– Next Review: cavity mechanical design as a pressure/vacuum vessel
January 30-31, 2012
Engineering and Technical Standards (FRS)
All vacuum vessels, pressure vessels, and piping systems will be designed, documented, and tested in accordance with the appropriate Fermilab ES&H Manual (FESHM) chapters.
– This includes the superconducting cavities and their associated helium vessels which must be designed, manufactured, and tested in accordance with FESHM chapter 5031.6, Dressed Niobium SRF Cavity Pressure Safety.
– Bellows shall be designed using the requirements of the Expansion Joint Manufacturers Association (EJMA).
– The cryomodule as a whole shall be designed to be free of frost and condensation when in operation in air with a dew point of 60 F.
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
19
Quality Assurance
The quality culture is the cornerstone of the project management philosophy
Quality Assurance for the HWR Cryomodule Project is performed according to ANL LMS Policies and Procedures
Main purpose of the QA
– Meet all parameters defined in Functional Requirement Specification (FRS)
– Avoid costly reworks
– Reduced cost of the project
General guidance from Tom Mullen, PHY ES&H and QA engineer
The Project “Quality Professional” is Jim Morgan – an engineer with 30-year experience and previous experience with QA in large LCLS project
FRS: A complete cryomodule traveler is to be developed documenting all stages of materials inspection, cryomodule component fabrication, piping and weld inspection, cryomodule assembly, and test.
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
20
Project Team
January 30-31, 2012
Project Management EBIS Review
21
Project Team Glenn Cherry (NE), designer FT Zack Conway, physicist PT Rick Fischer (NE), engineer FT Scott Gerbick, engineer PT Mark Kedzie, engineer PT Sang-hoon Kim (postdoc, starts on 4/2/12) FT Mike Kelly, physicist PT Sergei Kutsaev, postdoc PT Peter Ostroumov, physicist PT Jim Morgan (NE), engineer PT Ryan Murphy (HEP), engineer PT Brahim Mustapha, physicist PT Tom Reid (HEP), engineer PT Dale Schrage (TechSource), consult. <5% Kenneth Shepard (TechSource), consult. <5% Undergraduate Students
Project Support (less than 5% time) FNAL PXIE Team Albert Barcikowski (NE) Sergei Kondrashev Amichay Perry (PhD student) Arturo Ortega Bergado (visitor) Gary Zinkann ATLAS Electronics Group ATLAS Cryogenics Group
Schedule
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
22
Testing of the prototype cavity complete August 2013
Fabrication, cleaning of production cavities complete August 2014
Cryomodule mock-up assembly December 2014
Cryomodule off-line testing complete November 2015
Project M&S Cost
Includes procurement and services of the ANL machine shop
Cost estimate was created in November 2011
Cost estimate has been done for the following configuration:
– one prototype cavity
– 9 production cavities with fast and slow tuners (8)
– 5 SC solenoids (8)
– No BPM (8)
– Includes 14% taxes and 3% escalation,
– No contingency is applied
– Cryogenic valve box is not included
– 10-kW RF amplifier is not included
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
23
M&S Cost Distribution (k$), Created in Dec. 2011
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
24
2015 TOTALS
WBS ITEM 1st HALF 2nd HALF 1st HALF 2nd HALF 1st HALF 2nd HALF 1st HALF
1.01 Project Management 0
1.02 Physics, Engr, & Des
Design Software 23 23
1.03 Prototyping
procure niobium 64 64
hydroforming dies & prototype cavity parts 228 228
machining, brazing, wire EDM 59 59
Fixturing (Sciaky/NPI/ADRON) 57 57
EBW 29 29
Chemistry (etching) and HPR during fabrication 6 6
Fixturing for EP and HPR 69 69
SS vessel 36 36
Prototype cavity RF surface processing 16 16
Design and fab of TC3 fixture 36 36
Install cavity into TC3 and test 21 2 23
1.04 Cryostat
Fabrication liaison, supervision, Q&A 0
box/lid, thermal shield 442 442
magnetic shield 63 63
beam valve spool assemblies (2) 37 37
cryo, vac plumbing/manifolds 69 69
cavity string support system 52 52
cavity vac sys (not including interlocks & controls) 41 41
insulating vacuum system 41 41
cryostat stands 28 28
alignment hardware 28 28
alignment labor 0 0
JTHX, 2K 76 76
Miscellaneous (He plumbing, feedthroughs,…) 88 88
2012 2013 2014
M&S Distribution(cont’d)
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
25
1.05 Cavities (9)
procure cavity niobium 576 576
hydroforming, die forming 281 281
machining, brazing, wire EDM 546 546
EBW 116 116
chemistry (etching) 28 28 56
additional fixturing for production cavities 34 34
Install the cavities & sub-systems into TC3 & test 31 21 51
1.06 Sub-systems
SS LHe tanks 326 326
couplers 369 369
fast tuners 143 143
slow tuners 89 89
solenoids including He vessel, dipole coils 245 245
instrumentation (TCs, press gauges,..) 43 43
beam line systems 44 44
up-to-air system 12 12
current leads (<100 A ) + magnet hardware 31 31
1.07 Cleaning
Electropolishing, HPR effort 0
Consumables incl. disposal 16 112 32 160
Cleaning of aux components 0
1.08 Assembly, test
Various tools, equipment for assembly and testing 46 46
Cavity string clean assy incl mock-up clean assy 0
Cryomodule assembly 40 40
Cryomodule off-line test 40 40
Maintenance platform 6 6
1.09 Spare parts
HWR 0
SC solenoid and its LHe vessel 49 49
RF coupler 30 30
Fast tuner 16 16
Slow tuner bellows unit 3 3
1.1 Commissioning
TOTALS 663 662 1278 1761 389 131 80 4963
Comments on M&S Cost
We already see higher cost of die fabrication and forming of Nb parts for the prototype cavity as compared with our Dec. 11 prediction
Cost estimate will be updated after Conceptual Design is complete (June 2012)
– Apply FRS dated 2/21/2012
– Obtain quotes for fabrication of cryostat vessel, niobium, SC solenoids, RF couplers, BPMs, cavity He vessel
– Update the cost of cavity fabrication
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
26
Project Management EBIS Review
27
Project Milestones
# Milestone Date
1 Place contract for niobium dies and forming of the prototype cavity Q2FY12
2 Conceptual and Preliminary Design complete
Niobium for production cavities is delivered and inspected
Q4FY12
3 Complete fabrication drawings and start procurement of the cryostat vessel including
thermal and magnetic shields.
Fabrication of the prototype cavity including SS vessel
Q2FY13
4 Prototype cavity tested Q4FY13
5 Fabrication of the cryostat vessel complete Q2FY14
8 Fabrication of production cavities complete Q4FY14
7 Mock-up cavity string assembly Q2FY15
8 Cryomodule off-line testing complete Q4FY15
9 Cryomodule installed on PXIE beamline Q2FY16
January 30-31, 2012
Cavity Design Status
Multi-physics and engineering design of the niobium cavity is complete
Nb and SS vessel stresses are within specs
df/dp is +4.3 kHz/atm and can be nulled with further optimization of the SS vessel
Comfortable range of slow tuner – 85 kHz at 6000# of applied force
ProE model is created per AES request
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
28
Major Procurements in FY12 and FY13
AES has quoted fabrication of dies for niobium forming and forming niobium parts for the prototype cavity
We are waiting for quotes both from Wah Chang and Denkai for niobium
Niobium for prototype cavity is available from existing inventory (should be replaced by new purchase)
Parts for the 10-kW RF coupler are being developed with the US industry
If funding is available, all major procurements must take place in FY12 and FY13
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
29
March 5, 2012
P.N. Ostroumov Project Overview HWR for PXIE, FNAL Internal Review
30
Summary
HWR cryomodule project is well advanced
– Management plan was created
– Management of ES&H and QA are well understood
– Schedule and budget were developed
– Procurement plan exists and being implemented
Next steps are:
– Place contract with AES for Nb forming
– Continue engineering analysis and optimization of the jacketed HWR
– Start procurement of the prototype cavity parts (braze joints, bellows,..)
– Call Safety Committee to finalize mechanical design and engineering analysis of the dressed cavity
– Place contract to purchase Nb for production cavities
– Fabricate and test 10-kW coupler
– Complete Conceptual and Preliminary design of the cryomodule
– Revise and update cost estimate per most recent FRS and current status of the design
Top Related