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SRF Vertical Test Cryostat Design Review

SRF Vertical Test Cryostat Design Review. 16 May 2006 IB1. Introduction. Welcome and introductions Charge to the committee: Assess the technical design of the ILCTA IB1 SRF Vertical Cryostat and its readiness for the procurement/fabrication process

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SRF Vertical Test Cryostat Design Review

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  1. SRF Vertical Test CryostatDesign Review 16 May 2006 IB1

  2. Introduction • Welcome and introductions • Charge to the committee: • Assess the technical design of the ILCTA IB1 SRF Vertical Cryostat and its readiness for the procurement/fabrication process • Comment on all technical aspects of the Cryostat design, including integration to the IB1 cryogenic system • Provide a written report. ILCTA-VTC Design Review

  3. …not a facility safety review • Focus on • Cryostat technical specifications • Readiness for procurement • Review outline • Location of and purpose of facility in IB1 (Joe Ozelis) • Cryostat system requirements (Mayling Wong) • Integration with IB1 Cryogenic System, P&ID, and Cryogenic Design Parameters (Roger Rabehl and Yuenian Huang) • 3D model overview (Clark Reid / Mayling Wong) • Documentation requirements (Mayling Wong) • Cost estimate, procurement plan, and schedule (Cosmore Sylvester) ILCTA-VTC Design Review

  4. Goals of the ILC Vertical Cavity Test Program • Verify cavity processing improvements by quantifying cavity performance in a reliable, reproducible, and efficient manner. • Measure Q0 vs Temperature • Measure Q0 vs E • Measure Field Emission (radiation) • Investigate effect of low temperature externally performed bakeout on Q-drop • Initial throughput expected to be ~ 2 cavities/month, increasing to ~ 2 cavities/week. Multiple tests/cavity (Q-drop) increase this. • System is to be capable of testing cavities designed for the ILC Main Linac cryomodule. • Baseline Design: Tesla cell shape, 9 cells, 1.3 GHz. Alternate geometries, # cells, superstructures, may also be evaluated. ILCTA-VTC Design Review

  5. Cavity Test Facility Location ILCTA-VTC Design Review

  6. Cavity Test Facility Location Existing cryogenic services Approx size/location of cryostat pit/hole ILCTA-VTC Design Review

  7. Cavity Test Facility Cryostat/Cryogenic Requirements • LHe bath capable of operation between 4.3 and ≤ 1.6K • Cooldown rate from 300K to 4K that minimizes Q–disease susceptibility (minimize time spent between 100-150K) • Sufficient volume of LHe above cavity to preclude need for active LHe level control during testing (190-200cm – 165cm to top cavity flange) • Instrumentation to provide readout of Dewar pressure, temperature, and LHe level • Fast turnaround – • Cooldown & fill : 4-6 hours • Pumpdown : 2-4 hours (can be concurrent w/ fill if not performing Q0 vs T measurements) • Remnant LHe boiloff : 3-5 hours (150-180W for 800L) • Warmup to 300K : 10-12 hours (400K He gas at ~2g/s) ILCTA-VTC Design Review

  8. Example Test Cycle (w/ Q0 vs T measurement) Insert stand into Dewar Leak check Dewar seal Leak check test stand Attach RF & instrumentation cables Pump/purge Dewar w/ GHe, check for contamination Cooldown Fill @ 4K Cable calibrations @ 4K Measure cavity frequencies (all modes) Perform low field (2-3 MV/m) Q0 measurement (1W amplifier) Begin pumpdown to ~1.5K, take low field Q0 data Warm back up to 2K Perform Q vs E measurements at 2K Boiloff remnant LHe Warm Dewar 0.5hr 0.5hr 1hr 0.25hr 1hr 1.5hrs 4hrs 0.5hr 0.25hr 0.5hr 3hrs 0.5hr 2hrs 4hrs 12hrs Total warm-warm cycle time = 31.5hrs ILCTA-VTC Design Review

  9. Example Test Cycle (w/o Q0 vs T measurement) Insert stand into Dewar Leak check Dewar seal Leak check test stand Attach RF & instrumentation cables Pump/purge Dewar w/ GHe, check for contamination Cooldown Fill @ 4K, begin pumping to 2K when LHE collects Cable calibrations @ 2K Measure cavity frequencies (all modes) Perform Q vs E measurements at 2K Boiloff remnant LHe Warm Dewar 0.5hr 0.5hr 1hr 0.25hr 1hr 1.5hrs 4hrs 0.5hr 0.25hr 2hrs 4hrs 12hrs Total warm-warm cycle time = 27.5hrs ILCTA-VTC Design Review

  10. Example Test Schedule (includes Q0 vs T msmt) Day 1 : Load test stand, all checkouts, cooldown & fill to 4K Day 2 : Q0 vs T, Q0 vs E, boiloff Lhe and begin Dewar warmup Day 3 : Remove test stand, setup for 120° C bake – 24 hours Day 4 : Load test stand, all checkouts, cooldown & fill to 4K Day 5 : Q0 vs T, Q0 vs E, boiloff LHe and begin Dewar warmup This scenario supports 2 tests per week of the same cavity, with a 24hr 120° C bake between tests. If Day 3 is a Friday, can do a 48hr bake over a weekend. ILCTA-VTC Design Review

  11. Example Test Schedule (w/o Q0 vs T msmt) Day 1 : Load test stand, all checkouts, cooldown, fill, pump to 2K, Q vs E, start boiloff & warmup script (long day) Day 2 : Remove test stand, setup for 120° C bake – 48 hours, swap cavities Day 3 : Load test stand, all checkouts, cooldown, fill, pump to 2K, Q vs E, start boiloff & warmup script (long day) Day 4 : Remove test stand, setup for 120° C bake – 48 hours, swap cavities (baked one) Day 5: Load test stand, all checkouts, cooldown, fill, pump to 2K, Q vs E, start boiloff & warmup script (long day) This scenario supports 3 tests per week, 2 different cavities, one of which gets a 48hr 120° C bake between tests. ILCTA-VTC Design Review

  12. Conclusions • The aggressive test schedules described here can be fully supported by a • cryostat/cryogenic system that provides: • LHe bath capable of operation between 4.3 and ≤ 1.6K • Cooldown rate from 300K to 4K that minimizes Q–disease susceptibility (minimize time spent between 100-150K) • Fast turnaround – • Cooldown & fill : 4-6 hours • Pumpdown : 2-4 hours (can be concurrent w/ fill if not performing Q0 vs T measurements) • Remnant LHe boiloff : 3-5 hours (150-180W for 800L) • Warmup to 300K : 10-12 hours (400K He gas at ~2-4g/s) • The present design will be shown to meet these requirements. • Additionally, it does not preclude testing of alternate cavity designs or • more extensive (R&D) testing. ILCTA-VTC Design Review

  13. Cryogenic System Requirements ILCTA-VTC Design Review

  14. Cryogenic System Requirements ILCTA-VTC Design Review

  15. IB1 Refrigeration Capability • Calculated cooling capacity of 125 W at 2 K. • Assumes 88-90% efficient J-T heat exchanger pre-cooling the supplied LHe. This HX is identical to one used in the MTF LHC quadrupole feed box. • Assumes 3 Torr pressure drop through the pumping line between the new test facility and the Kinney pumps. ILCTA-VTC Design Review

  16. ILCTA-IB1 Vertical Dewar P&ID ILCTA-VTC Design Review

  17. Integration with IB1 Refrigerator • LHe supplied across the roof of IB1 through the existing transfer line from the 10 kl dewar. Drawn off a phase separator, 5 K boiloff will cool a dewar intercept and a baffle. • GHe pumped away via Kinney pumps, returned directly to compressor suction, or vented to atmosphere. The first option requires a new pumping line, the last two options will use existing VMTF piping. • LN2 supplied from 10 kgal dewar, tying into existing VMTF piping. • GN2 vented to atmosphere, tying into existing VMTF piping. ILCTA-VTC Design Review

  18. Helium Vessel Thermal Design • Heat load to 2 K helium bath is controlled 80 K shield and heat intercepts at 80 K and 5 K level • 80 K shield and intercept will be cooled by LN2 • 5 K heat intercept will be cooled by GHe vapor from phase separator, 10 W heater to control vapor flow • Heat load to 2 K from other sources (pumping line and instrumentations wired) will be estimated later, however, it should be around 2 W or so level ILCTA-VTC Design Review

  19. Helium Vapor Pressure Drop • The total vapor pressure drop will be about 3 torr and that’s our design goal • 2” line is 150 ft and 6” line is 300 ft • Total vapor pressure drop breaks down to three parts in the pumping line in our calculation • Pressure drop within JT heat exchanger, < 1 torr • Pressure drop along 150 ft, 2” insulated piping, 3.5 K inlet and 5 K outlet, the average pressure drop is 1.01 torr • Pressure drop along 300 ft, un-insulated 6” piping, 5 K inlet and 300 K outlet, the average pressure drop is estimated to be 0.843 torr ILCTA-VTC Design Review

  20. Cryostat Layout ILCTA-VTC Design Review

  21. Helium Vessel • ASME BPVC vessel • Dimensions - 304SS shell • 28-inch OD • 0.094-inch thick • Thickness driven by external pressure (due to leak in insulating vacuum) • To minimize thickness (& conduction heat load) use Stiffeners every 30-inch along length • L1X1X1/4-inch angle bent & intermittently welded • 16-feet long ILCTA-VTC Design Review

  22. Helium Vessel (cont’d) • Relief system • Burst disc • 65-psig set pressure • 1.5-inch - Sized assuming complete helium vaporization during leak of insulating vacuum (resulting flux of 0.6 W/cm2) • Code Relief valve • 50-psig set pressure • Connected to top plate of removable insert (not part of this assembly/procurement) • Heater for dewar warm-up • Temperature of helium 420K • Helium pressure 3-psig ILCTA-VTC Design Review

  23. Top flange of helium vessel • Thickness 1-inch • Sized to ensure welded joint to the helium vessel shell is adequate, following guidelines of ASME BPVC Top flange of Helium vessel ILCTA-VTC Design Review

  24. Status of Documentation • Engineering drawings • 75% exist for initial design iteration • Engineering notes • Helium vessel: 75% complete • Vacuum vessel • Pressure drop calculations • Heat load analysis • Relief valve sizing • Technical specification for vendor (required at the time the RFP is issued) ILCTA-VTC Design Review

  25. Cost Estimate ILCTA-VTC Design Review

  26. Procurement Plan • Complete the Design of the Cryostat assembly and release via. an RFP. Select the “best” qualified vendor based on a technical evaluation of the vendor’s proposal - not solely on lowest bid. While cryostat Procurement is underway- • Continue to work towards a final design of the magnetic shielding and release these drawings for fabrication (estimated del: 6 weeks ARO) • Continue to work on the final design of the top plate and suspension components and then release these for fabrication • located a supplier of the Lead and has a quote and estimated delivery (6 weeks ARO) • located a supplier for an encapsulant (rated for 4.5K use) which could be used on the exposed lead surfaces ILCTA-VTC Design Review

  27. Schedule ILCTA-VTC Design Review

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