Needs of a European SCRF Facility - the BIG plan

Lutz Lilje

DESY -MPY-

DESY 11/2006

• Planning• Resource needs

04/19/23 Lutz Lilje DESY -MPY-

References• Letter-of-intent for CERN Council Strategy Group

– http://council-strategygroup.web.cern.ch/council-strategygroup/BB2/contributions/Wagner.pdf

• For ESGARD discussion:– A SCRF Infrastructure for Europe;

http://esgard.lal.in2p3.fr/Project/Activities/Current/Networking/N2/ELAN/Documents/2006/ELAN-Document-2006-004.pdf

• Technical interest– CLEAN-ROOM FACILITIES FOR HIGH GRADIENT

RESONATOR PREPARATION; K.Escherich, A.Matheisen, et al.; http://www-dapnia.cea.fr/Phocea/file.php?class=std&&file=Doc/Care/care-conf-05-033.pdf

– Proposes improved layout of cleanroom for the EP process– Does not contain redundancy

04/19/23 Lutz Lilje DESY -MPY-

Overview

• Motivation• General layout• General timeline• Detailed Planning

– Critical path items– Role models– Project resources– Proposal for Role models

04/19/23 Lutz Lilje DESY -MPY-

Research and Development• GDE Discussions show that an effort is needed

– To make ILC-gradients more reproducible• The baseline process is clear, but some parameters are yet to be determined (details of post-

electropolishing rinses)– This is the work of the labs

• Any step in Europe should be integrated in the larger R&D framework– Step toward a integrated systems test

• Build a 4th generation module• At least the size of one RF unit, which determines the number of cavities to at least 30

– Knowledge transfer to industry• Significant work is needed enabling industry to produce cavities on the level of the ILC

gradients (see above)– After having worked out details, transfer this to industry

• But Industry can do things today (and the more in 2007/8)– Large contribution of the XFEL – Fabrication, First EP can/should be done in industry

• After results from the facility are available– Final preparation and tank welding in industry

• Final step– Module assembly in industry

• Other projects– Access to state-of-the-art cavity preparation

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Cavity Preparation Infrastructures Today

• Some infrastructure is available in Europe (not only DESY)• Most setups are still R&D size

– Often single-cell cavities– Small through-put

• Single-line of processing– No redundancy

• Have come to age– Materials– Overall layout needs significant re-work with today‘s knowledge

• Electropolishing as the baseline process• required number of high pressure water rinses

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Next Generation Cavity Preparation Infrastructure I

• Main Features– Improved electropolishing

• Focus to avoid sulphurus contamination• Redundancy

– Improve Final cleaning• Flexibility needed here e.g. alcohol rinses

– High pressure rinse (HPR)• Online particle count integrated in drain water line• Redundancy

– Cleaning of parts • Automation needed: screws used as example

– Improved/novel methods of QA/QC

04/19/23 Lutz Lilje DESY -MPY-

Next Generation Cavity Preparation Infrastructure II

– Modular setup• Institutes get responsibility for part of the process (HPR design, EP

design etc.)– Redundant setup

• 2 x EP, • 2 x HPR, • 2-3 120 °C bakeout stations

– Other infrastructure• Etching needed (e.g. outside cleaning) • designated 800°C furnace• Sufficient pump stations, etc.

– Optional• Dry-ice cleaning

– Needs feasibility demonstration

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EP EP

Cleanroom

HPR

Pumps

BCP HPR

Oven

2x 120 C

Cleanroom

10

Assembly

Pre-

Clean

Autom.Parts Clean

Alt. Rinses

Tuning

Chem. Supply Plant Ultra-pure Water Plant

Tank weldingLayout ofPreparation Facility

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Timelines for R&D InfrastructureILC Work Other projects

Setup phase • Installation of infrastructure• Procurement of parts (e.g. cavities)

Define cavity shapes etc.

Research phase •Use of preparation and test systems •Defining the details of the preparation (e.g. rinsing parameters)

Design of infrastructure (e.g. EP bench)

Transfer phase Transfer parameters for final cavity preparation to industry

Installation of infrastructure

Industrialization phase

Module assembly in industry Use of Infrastructure

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Scheme of Cryomodule Production (Research phase)

Final Cavity Preparation

Inspection

Tuners

Low-power testing

Module Assembly CleanroomMagnet

Tuner TestsTank welding

Fabrication of cavities Procurement of couplers

BPM

Module Test

Coupler Processing

Cryostat

Pre-treatment of cavities

High-power testing

In Industry

In Labs

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Scheme of Cryomodule Production (Technology Transfer)

Final Cavity Preparation

Inspection

Tuners

Low-power testing

Module Assembly CleanroomMagnet

Tuner TestsTank welding

Fabrication of cavities Procurement of couplers

BPM

Module Test

Coupler Processing

Cryostat

Pre-treatment of cavities

High-power testing

In Industry

In Labs

04/19/23 Lutz Lilje DESY -MPY-

Scheme of Cryomodule Production (Industrialization Phase)

Final Cavity Preparation

Inspection

Tuners

Low-power testing

Module Assembly Cleanroom Magnet

Tuner TestsTank welding

Fabrication of cavities Procurement of couplers

BPM

Module Test

Coupler Processing

Cryostat

Pre-treatment of cavitiesIn Industry

In Labs

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Detailed Planning• Most details on critical path items

– Cavity procurement– Cleanroom installation

• Less detail in testing infrastructure– A lot of this is available

• Organisation– Defined role models of the labs e.g.

• Main Lab• Coupler Lab• Tuner Lab• + generic labs: A,B,C,D,E

– The work load can be re-distributed to some degree of course• Cost estimation assumptions

– Greenfield site– 37,50 €/manhour– Hardware + running cost figures are a mix of TTF experience and XFEL

preparation cost estimate

04/19/23 Lutz Lilje DESY -MPY-

Role models for SCRF facility• All labs

– Layout of facility esp. cleanroom– Define cryostats (in GDE context, of course)– Preparation of assembly cleanroom – Controls

• Could be specialized lab• Main Lab

– Hosts main part of infrastructure• Cavity preparation, vertical testing and module testing

– Vacuum infrastructure incl. 120 C furnaces• Coupler Lab

– Coupler procurement, preparation and conditioning– Support assembly cleanroom– Assembly at main lab

• Tuner Lab– Tuner procurement, warm + cold testing– Support module assembly cleanroom at main lab– Assembly at main lab

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Role models for SCRF facility (ctd.)• Lab A

– EP Modules specification, procurement, installation at central facility– Support central team in cavity preparation– High-power testing of individual cavities

• Lab B– BCP Module specification, procurement, installation at central facility– Support central team in cavity preparation– High-power testing of individual cavities

• Lab C– HPR Modules specification, procurement, installation at central facility– Support central team in cavity preparation

• Lab D– Eddy-current scanning of niobium– 800 C furnace

• Lab E– Module cryostat specification, procurement– Support module assembly

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Gantt Chart: Cavity Preparation Setup

• Does not exist

• Critical path item

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Gantt Chart: Testing Setups

• Not on critical path– Timing should clearly be optimised for money flow

• Many opportunities (savings) already available – see below

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Gantt Chart: Material

• Niobium order and cavity procurement are the long lead-time items

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Gantt Chart: Operation

• Assumption is a collaborative operation of the facility as outlined in the role models

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Current Estimate: Schedule

• Project duration: 5,5 years

• Cleanroom setup phase: 2 years

• Material procurement: 2,5 years

• Operation of preparation facilities: 3,5 years

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Current Estimate: Manpower

• While the overall load seems reasonable• Details can of course still shift around

– Indivudual tasks can be refined e.g. coupler effort– ratio between main lab and collaborators– Distribution of work load over years

• E.g test infrastructure manpower could be shifted

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Current Estimate: Cost• Cleanroom + EP:• 9,5 Mio €

• Testing infrastructure:• 15 Mio €

• Materials: • 5 Mio €

• Operation: • 5 Mio €

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Current Estimate: Summary

– Cleanroom + EP etc.: 9,5 Mio €– Testing infrastructure: 15 Mio €– Materials: 5 Mio €– Operation: 5 Mio €

• Total cost: 36 Mio €• Of this total working cost: 5 Mio € ~129000 hours

• Total project duration: 5,5 years

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Remember:

• Large labs can supply cryogenics and a good deal of test infrastructure– E.g. CERN Plant– Trade additional XFEL test hall test stand vs. Existing

teststand– Several labs have infrastructure

• Coupler testing• Horizontal test setups

– Also usable for tuner tests

• This is to a large degree the big money…

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Missing equipments• Central cleanroom installation

– Cleaning modules (EP, BCP, HPR) must be new– Refurbishment of existing cleanroom seems more complicated – Distributed facility is not desirable strategy as QC is more

complicated

• Vertical testing must be close to cavity preparation– Fast feedback from RF test needed– Distributed facility is questionable strategy for R&D phase

• Will be done in the long run e.g. industrialization phase and also XFEL mass production scenario

• Vertical testing must include appropriate diagnostics i.e. t-mapping– Only at DESY for multi-cells

04/19/23 Lutz Lilje DESY -MPY-

Available equipments

• Module assembly cleanroom– Could be SM18

• Parts (antennas, screws etc.) cleaning– Several options at CERN

• 800 C furnace– DESY

• Vertical test stands– DESY, CERN (would need more resources)– other labs could specialize (e.g. t-mapping)

• Horizontal test stands– CEA, DESY, BESSY, CCLRC

• Module test stand– DESY CMTB

• Cheapest and quickest option provided we can trade for an additional XFEL test hall stand– CERN

• Is probably more expensive than DESY option, but still not greenfield price

• Coupler test stand– LAL

• Tuner test stand– Saclay, INFN, CCLRC, BESSY

• Eddy current scan– DESY

• ‘Savings’ ~5 Mio € + ?!

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Next steps

• By now a refined estimate on the roles is available– Both investment and manpower

• Commitments are needed for more detailed planning– Experts know much more on what can be taken as

existing and what needs to be upgraded (e.g. couplers)

• Knowing the current funding schemes on has to assess the possibilities for implementation– A large commitment of the parties would be required