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Design Review for EP at the ANL/FNAL Superconducting Cavity Surface Processing Facility (SCSPF)

Design Review for EP at the ANL/FNAL Superconducting Cavity Surface Processing Facility (SCSPF). February 12, 2007. ANL Group: Mike Kelly, Scott Gerbick, Bill Boettinger (NE) FNAL Collaborators: Cristian Boffo, Kerry Ewald Speaker: Mike Kelly. Charge to the Committee.

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Design Review for EP at the ANL/FNAL Superconducting Cavity Surface Processing Facility (SCSPF)

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  1. Design Review for EP at the ANL/FNAL Superconducting Cavity Surface Processing Facility (SCSPF) February 12, 2007 ANL Group: Mike Kelly, Scott Gerbick, Bill Boettinger (NE) FNAL Collaborators: Cristian Boffo, Kerry Ewald Speaker: Mike Kelly

  2. Charge to the Committee • Evaluate the technical soundness of the design to meet the ANL/GDE EP goals for FY07-FY09. Does the design meet the criteria in the specification document generated jointly by ANL/FNAL which was reviewed at the TTC-KEK meeting? • Will the system be ready for commissioning in July 2007 using a single-cell niobium cavity? • Assess the suitability of the design for performing up to 11 EP procedures in FY07. • Assess the suitability of the design for performing up to 50 EP procedures per year in FY08-09.

  3. Design Review at KEK, October 2006 • Conceptual Design Review for EP at the joint ANL/FNAL SCSPF • Attendees: Hasan Padamsee, Kenji Saito, Tsuyoshi Tajima, Kwang-je Kim, Lutz Lilje, Axel Matheisen, Marc Ross, Helen Edwards, John Mammosser, Cristian Boffo • Location/Time: KEK/September 26, 6-7:30 pm • Description: Mike Kelly presented on the approach for EP for the chemistry room 1 of the SCSPF. More detailed discussions two hardware items, a cavity holding fixture and a rotating seal assembly, took place. Committee chair (H. Padamsee) General Remarks • This was a presentation of the concept of the EP system to be built at ANL, and the status of the preliminary design of a few of the key components. The important next steps are to incorporate the suggestions below, and continue with a full engineering design, with assembly drawings and prints for fabrication. The design should also address the system for valve operation, quantities to be measured, and the arrangements for preliminary HPR of single cells after EP. • The preparations for the next stage should take until the end of the year. • It was recommended that the full engineering design be reviewed at the advanced stage before procurement and fabrication should proceed.

  4. Design Review at KEK, October 2006 Comments/Advice: • Holding fixture: Move rods out radially to so that the fixture/cavity may be set stably on a table or other flat surface. • Holding fixture: Consider extending the long support rods or having extensions to protect the cavity flanging. • Rotating Seal: Use support pins/cables to eliminate the possibility of excessive torque on the bellows • Rotating Seal: Minimize dead space/trapped volumes in the assembly when the cavity is rotated vertically. A small trapped volume at the top the cavity/seal assembly was pointed out for the proposed design. • Rotating Seal: Use the main flange at the back (body) of the seal assembly to retain the Teflon seal rather than the separate retaining ring. • Rotating Seal: Consider carefully the height of the cathode and “dam” relative to the cavity beam axis. The EP assembly must be suitably leveled so that the space for hydrogen removal is not blocked and that the cathode is never exposed to air during EP. The dam/acid plumbing should accommodate variable flow rates. • General Approach: Consider increasing the volume of acid (from 200 liters) in the circulation loop during EP. • General Approach: The aluminum heat exchanger for acid chilling may in practice have an unacceptably high corrosion rate. Have a plan to replace with a Teflon device if needed.

  5. Outline • (Brief) Historical Overview • Performance goals for the ILC EP system at the SCSPF • The ANL/FNAL joint Superconducting Cavity Surface Processing Facility (SCSPF) • Technical Approach and Details • Cost & Schedule

  6. I. Historical Overview: Four Decades of Electropolishing Niobium Cavities for SCRF (Helical Nb resonator developed at ANL for a heavy-ion linac: Surface Processing was EP in collaboration Karlsruhe) EP is still the most reliable method to achieve high performance in Nb SCRF cavities

  7. I. Historical Overview: ANL Recipe for EP • Based on the Siemens' process from the early 1970’s • Cavity (anode) - observed no polishing rate sensitivity to electrical connection point even for large cavities • High purity Al cathode • Electrolyte (acid): 85:10 mixture of Sulfuric, Hydrofluoric Acid Examples of EP at ANL Double spoke Quarter-wave Triple spoke Co-axial half-wave

  8. II. Performance goals: A specification document for EP at the SCSPF (Completed in ’06) …specifications are based upon the parameters discussed at the TTC meeting December 5-7, 2005 at Frascati (see summary spreadsheet prepared by J. Mammosser.) • https://ilcsupport.desy.de/cdsagenda/askArchive.php?base=agenda&categ=a0561&id=a0561s8/moreinfo/DESY_041205.pdf The system will be designed as a pre-production system with primary consideration for: • Flexibility of operating conditions to permit a study of the EP parameter space • The use of components with proven reliability, commercial availability and suitability for industrial or large-scale production. • Transferability of systems and techniques to other laboratories or industrial facilities. This specification and the engineering design to follow will be presented to an international group of technical experts who have agreed to provide guidance.

  9. II. Performance goals: GDE Planning for US Cavity Processing Throughput (Target 2)

  10. III. SCSPF LayoutLocation: Argonne Building 208 • Operations started in 2006; Facility Cost with manpower ~$2 M 20 m

  11. III. SCSPF: ANL Portion

  12. III. SCSPF: Class 1000 Anteroom

  13. III. SCSPF: ANL/FNAL (New) Shared Infrastructure 38 l/m 2-stage RO 3000 cfm NOx, HF scrubber 10 kW Chiller 1200 gallon storage 750 A @ 20 V Air Scrubber DI Water System Chiller/EP Supply

  14. III. SCSPF: Control Console/Procedure Monitoring Re-Entry into ANL chemistry room after EP – Jan 2007

  15. IV. Technical Approach: Technical goals for EP at the SCSPF • Tailor the system to the dimensions of the 1.3 GHz geometry • Design for ease of assembly and disassembly • Ensure tanks, pumps, acid lines are accessible and cleanable – no sulfur buildup • Use a pure aluminum heat exchanger for much improved heat transfer to the acid • Empty the cavity of acid and fill with water rapidly at the end of the procedure (keep the cavity wet before HPR) • Include a provision for separating the acid flow rate from the need to maintain constant temperature • Provide timely direct hands-on experience for FNAL/ANL personnel

  16. IV. Technical Approach: Horizontal Orientation during EP

  17. IV. Technical Approach: Flow schematic

  18. IV. Technical Approach: Control System • Ventilation (8 – valves) • Pumps (4 – Teflon bellows) • Acid Handling (11 two- and/or three-way valves)

  19. IV. Technical Approach: Pumps Astipure PFD2

  20. IV. Technical Approach: Two-way valves WB-2W8P

  21. IV. Technical Approach: Three-way diaphragm valve Furon UPM3

  22. IV. Technical Approach: Data Logging • Windows PC running LabView (8 ADC’s, 64 Control bits, 2 DAC’s, GBIP interface) • We will monitor/log temperature from three locations (2 locations inside cathode, inside cavity, external acid holding tank) using Teflon encapsulated thermocouples • We will monitor/log total current, voltage • We will measure flow rate using paddle wheel flow meter (on the return to the holding tank) • Additional Periodic Monitoring/Calculation of: • Hydrofluoric acid concentration within the electrolyte • Niobium salt concentration of the electrolyte • Cavity rotational speed • Rinse water pH and resistivity • Nitrogen/Air flow • Heat exchanger coolant flow

  23. IV. Technical Approach: Cathode Loading, Acid Draining, Water Rinsing

  24. IV. Technical Approach: A Cavity Holding Fixture

  25. IV. Technical Approach: A Rotating Acid Seal

  26. IV. Technical Approach: End Group Attachment to Cavity

  27. IV. Technical Approach: Cavity lowered into assembly using manual hydraulic lift

  28. IV. Technical Approach: Half Section of End Group Assembly

  29. IV. Technical Approach: Design Review at KEK, October 2006 Comments/Advice: • Holding fixture: Move rods out radially to so that the fixture/cavity may be set stably on a table or other flat surface. • Holding fixture: Consider extending the long support rods or having extensions to protect the cavity flanging. • Rotating Seal: Use support pins/cables to eliminate the possibility of excessive torque on the bellows • Rotating Seal: Minimize dead space/trapped volumes in the assembly when the cavity is rotated vertically. A small trapped volume at the top the cavity/seal assembly was pointed out for the proposed design. • Rotating Seal: Use the main flange at the back (body) of the seal assembly to retain the Teflon seal rather than the separate retaining ring. • Rotating Seal: Consider carefully the height of the cathode and “dam” relative to the cavity beam axis. The EP assembly must be suitably leveled so that the space for hydrogen removal is not blocked and that the cathode is never exposed to air during EP. The dam/acid plumbing should accommodate variable flow rates. • General Approach: Consider increasing the volume of acid (from 200 liters) in the circulation loop during EP. • General Approach: The aluminum heat exchanger for acid chilling may in practice have an unacceptably high corrosion rate. Have a plan to replace with a Teflon device if needed.

  30. IV. Technical Approach: Design Available on FNAL ILC Document Server

  31. Tour of the SCSPF

  32. V. Cost & Schedule: Work Packages

  33. V. Cost & Schedule 60

  34. V. Cost & Schedule: Proposed ANL SCRF to GDE/Gerry Dugan as presented May 2006 Activities to be completed in FY06 include: • Agreement by the ANL-FNAL-GDE collaboration on an EP specification • Performing engineering design of the physical EP apparatus to be located initially in the ANL portion of the chemistry facility • Performing engineering design review with technical experts from the U.S. and abroad • Initiating the procurement and construction of hardware for the EP apparatus Proposed FY07 activities are: • Assemble and commission an EP system by the middle of FY07 (0.75 FTE, $65 K M&S) • Electropolish ILC cavities in the second half of FY07 (0.75 FTE, $110 K for eighteen EP procedures) • Design and construction of an HPR system at the joint facility for rinsing after EP (1 FTE, $200 K M&S) • Interface with U.S. EP vendors/develop and optimize hardware suitable for large-scale EP (1 FTE) Cost summary (07): Labor (K$ M&S (K$) Indirect cost (K$) Total cost (K$) 612.5 375 307 1294.5

  35. V. Cost & Schedule: New Hardware Costs Total Hardware Jan 23, 2006

  36. EP Project Status • EP Design Specification 100% complete • EP Engineering Design 80% complete • EP Design Review 60% complete • EP System/component procurement 60% complete • EP Interface with industry 10% complete (this activity limited by funding in FY07) • EP system assembly 10% complete • Based on the proposed schedule and progress to date the EP design and engineering group believe this project is on track to perform electropolishing of a single-cell cavity by July 2007

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