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X-FEL Cryomodule Development

X-FEL Cryomodule Development. XFEL-WP 10 ‚Module Test‘ Bernd Petersen DESY –MKS- 1st ILC-Workshop, KEK, November 2004. Overview. Industrial Cryomodule Assembly Studies ( Single-) C ryo m odule T est B ench X-FEL Cavity&Cryomodule Test Facility.

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X-FEL Cryomodule Development

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  1. X-FELCryomodule Development XFEL-WP 10 ‚Module Test‘ Bernd Petersen DESY –MKS- 1st ILC-Workshop, KEK, November 2004 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  2. Overview Industrial Cryomodule Assembly Studies ( Single-) Cryomodule Test Bench X-FEL Cavity&Cryomodule Test Facility 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  3. Scope of the Industrial Module Assembly Studies ‘In view of the European X-FEL-project and other FEL light sources like the BESSY-FEL-project, which will use the superconducting linear accelerator TESLA technologies, the already existing design and assembly procedures of prototype cryomodules have to be reviewed by industrial studies in respect to series production, reduction of efforts and costs, and increase of performance.This review shall be part of the EUROFEL design study work package DS6 ‘Cryomodule Technology Transfer.’ In addition, for the time being, the TESLA technology represents the most developed approach for a superconducting linear collider, which will be the basis for the design of the futureInternational Linear Collider (ILC). ‘ 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  4. Industrial Studies on assembly Procedures Procurement of cryomodules – legal restrictions For the time being DESY can not start the complete cryomodule procurement ( only after final agreement with other XFEL- partners) On the other hand: in order to adapt the cryomodule design to industrial series production, industry should be involved as soon as possible -> Industrial assembly studies are separated from the final procurement procedure for the cryomodules EU-procurement for industrial studies will be started open to industry Results will be published open to public and industry -> equal information and chances for industry at the start of the final module procurement 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  5. Industrial Studies on assembly Procedures Specifications for the procurement of the studies : - Review of present cryomodule design & design changes for XFEL - Analysis and review of the present assembly procedures ( inside /outside cleanroom) - Suggestions for design/ assembly changes in respect to performance, cost savings and series production 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  6. At least 2 competent companies shall analyze the assembly of modules 6 an 8 The studies will be published ! Procurement of the studies is in Progress: December 2004 (Completely separated from the final cryomodule procurement procedure) 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  7. Industrial Studies on assembly procedures CLR string assembly Preserve performance of cavities ! Save assembly costs ! -> Assembly procedures can be verified only in module tests assembly outside CLR 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  8. Objectives of the test bench: • In general: cryomodule tests independent from TTF-linac operation • RF cavity processing / performance • processing of RF couplers • cryogenic performance • tests of vacuum systems • tests after repairs before installation into linac • tests of new design features ( 2K quad ...etc.) • dark current • Wire Position Monitors • thermal cycling • insulation vacuum / beam vacuum venting • ...etc......... 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  9. Types of Cryomodules XFEL 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  10. CMTB test hall TTF Hall3 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  11. CMTB test hall (2) Cave cross section 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  12. Status of cryogenic components end cap (ordered) cryomodule feed box (odered) feed cap (ordered) supports (designed) feed cap transfer line (ordered) 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  13. Line of construction DN250 tranfer line DN150 30mbar line DN100 water pipe RF wave guides cable traces ______________ DN200 LP DN80 HP 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  14. CMTB-transfer line (ordered)FEL-subcooler box -> CMTB feed box DN25 4.5K forward DN50 4.5K return DN25 40K forward DN25 80K return 80K shield covered DN250 vacuum tube 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  15. cryogenic supply of the CMTB 11/2005 12/2004 SMES MOD TEST VUV-FEL LINAC HEX SC&V BOX VD1 VD2 CHECHIA VD3 VC2 VC1 TTF CB HERA CB TTF SCREWS HERA SCREWS 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  16. Cryo Module Test Bench Some details: Cryogenic equipment: After EU call for tender now in the process of making contracts RF-equipment: Modulator, puls-transformer on DESY site Klystron ordered, will be delivered in 2005 Call for tender for wave guides etc…. Civil engineering: Final specifications ready, procedures prepared and will be started now 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  17. Cryo Module Test Bench First operation / commissioning: November 2005 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  18. X-FEL Cavities: Test Scheme about 1000 Cavities production rate: 8 / week Out of DESY Fabrication DESY Site Preparation CLR BCP/EP 100% Tests Tank Welding Coupler etc ? CHECHIA Optional Tests 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  19. Single Cavity Test Schedule 4 cavities tested in 31 h -> 2 Cryostats +1 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  20. Horizontal Test (CHECHIA) Test Schedule optional Test of one cavity : 8 – 12 d -> 2 cryostats 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  21. Cryomodule Test Schedule Test of one cryomodule: 14 d Production rate: 1/ week -> 3 (+ 1) Test Benches 100% Test of all cryomodules 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  22. X-FEL Test Hall Layout optional 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  23. Test Hall Layout 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  24. Cryogenic Supply overall design average heat loads 10 KW at 40/80 K ( HERA CB 20 KW) 1 KW at 4.5 K (HERA CB 6.8 KW) ( 0.6 KW at 2K) + 50 g/s liquefaction at 4.5K ( HERA CB 20.5 g/s) 4.5 K peak loads will be buffered by one 10 m3 storage dewar no 2K helium distribution system distributed warm helium pumping units 10 g/s ( 20 mbar) at module test benches 20 g/s ( 20 mbar) at vertical dewars 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  25. RF components 5+1 10MV Klystrons 5+1 Modulators waveguide distribution / circulators for 3+1 module test benches and 2 horizontal test cryostats 350 KW/ coupler 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  26. X-FEL Testhall: Staff profile 0peration: 3 years after start of project 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

  27. Summary Industrial XFEL-cryomodule assembly studies are started now A cryomodule test stand will be in operation end of 2005 XFEL-cryomodule test hall will start operation in 2009 1st ILC-Workshop KEK 11/04 Bernd Petersen DESY

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