Needs of a European SCRF Facility the BIG plan
Lutz Lilje
DESY -MPYDESY 11/2006
• Planning
• Resource needs
References
• Letter-of-intent for CERN Council Strategy Group
– http://council-strategygroup.web.cern.ch/councilstrategygroup/BB2/contributions/Wagner.pdf
• For ESGARD discussion:
– A SCRF Infrastructure for Europe;
http://esgard.lal.in2p3.fr/Project/Activities/Current/Networking/N2/E
LAN/Documents/2006/ELAN-Document-2006-004.pdf
• Technical interest
– CLEAN-ROOM FACILITIES FOR HIGH GRADIENT RESONATOR
PREPARATION; K.Escherich, A.Matheisen, et al.; http://wwwdapnia.cea.fr/Phocea/file.php?class=std&&file=Doc/Care/careconf-05-033.pdf
– Proposes improved layout of cleanroom for the EP process
– Does not contain redundancy
Lutz Lilje DESY -MPY-
31.07.2017
Overview
•
•
•
•
Motivation
General layout
General timeline
Detailed Planning
– Critical path items
– Role models
– Project resources
– Proposal for Role models
Lutz Lilje DESY -MPY-
31.07.2017
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 postelectropolishing 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
Lutz Lilje DESY -MPY-
31.07.2017
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
Lutz Lilje DESY -MPY-
31.07.2017
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
Lutz Lilje DESY -MPY-
31.07.2017
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
Lutz Lilje DESY -MPY-
31.07.2017
Layout of Tuning
Preparation Facility
Tank welding
Chem. Supply Plant
BCP
Pre-
EP
Cleanroom
Clean
Oven
Ultra-pure Water Plant
EP
Alt.
Rinses
HPR
HPR
Cleanroom
10
Assembly
Autom.Parts Clean
Lutz Lilje DESY -MPY-
2x 120 C
Pumps
31.07.2017
Timelines for R&D Infrastructure
ILC 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
Lutz Lilje DESY -MPY-
31.07.2017
Scheme of Cryomodule Production (Research phase)
Fabrication of cavities
Procurement of couplers
Pre-treatment of cavities
In Industry
Coupler Processing
Inspection
Final Cavity Preparation
Low-power
testing
Tank welding
In Labs
Tuners
High-power
testing
Tuner Tests
BPM
Module Test
Module Assembly Cleanroom
Lutz Lilje DESY -MPY-
Magnet
Cryostat
31.07.2017
Scheme of Cryomodule Production (Technology Transfer)
Fabrication of cavities
Procurement of couplers
Pre-treatment of cavities
In Industry
Coupler Processing
Inspection
Final Cavity Preparation
Low-power
testing
Tank welding
In Labs
Tuners
High-power
testing
Tuner Tests
BPM
Module Test
Module Assembly Cleanroom
Lutz Lilje DESY -MPY-
Magnet
Cryostat
31.07.2017
Scheme of Cryomodule Production (Industrialization Phase)
Fabrication of cavities
Procurement of couplers
Pre-treatment of cavities
Coupler Processing
Inspection
Final Cavity Preparation
Low-power
testing
Module Test
In Industry
Tank welding
Module Assembly
Cleanroom
Lutz Lilje DESY -MPY-
In Labs
Tuners
Tuner Tests
BPM
Magnet
Cryostat
31.07.2017
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.
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•
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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
Lutz Lilje DESY -MPY-
31.07.2017
Role models for SCRF facility
• All labs
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–
–
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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
Lutz Lilje DESY -MPY-
31.07.2017
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
Lutz Lilje DESY -MPY-
31.07.2017
Gantt Chart: Cavity Preparation Setup
• Does not exist
• Critical path
item
Lutz Lilje DESY -MPY-
31.07.2017
Gantt Chart: Testing Setups
• Not on critical path
– Timing should clearly be optimised for money flow
• Many opportunities (savings) already available –
see below
Lutz Lilje DESY -MPY-
31.07.2017
Gantt Chart: Material
• Niobium
order and
cavity
procurement
are the long
lead-time
items
Lutz Lilje DESY -MPY-
31.07.2017
Gantt Chart: Operation
• Assumption is a collaborative operation of the
facility as outlined in the role models
Lutz Lilje DESY -MPY-
31.07.2017
Current Estimate: Schedule
•
•
•
•
Project duration:
Cleanroom setup phase:
Material procurement:
Operation of preparation facilities:
Lutz Lilje DESY -MPY-
5,5 years
2 years
2,5 years
3,5 years
31.07.2017
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
Lutz Lilje DESY -MPY-
31.07.2017
Current Estimate: Cost
Lutz Lilje DESY -MPY-
•
•
Cleanroom + EP:
9,5 Mio €
•
•
Testing infrastructure:
15 Mio €
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Materials:
5 Mio €
•
•
Operation:
5 Mio €
31.07.2017
Current Estimate: Summary
– Cleanroom + EP etc.:
– Testing infrastructure:
– Materials:
– Operation:
• Total cost:
9,5 Mio €
15 Mio €
5 Mio €
5 Mio €
36 Mio €
• Of this total working cost: 5 Mio € ~129000 hours
• Total project duration: 5,5 years
Lutz Lilje DESY -MPY-
31.07.2017
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…
Lutz Lilje DESY -MPY-
31.07.2017
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. tmapping
– Only at DESY for multi-cells
Lutz Lilje DESY -MPY-
31.07.2017
•
Module assembly cleanroom
– Could be SM18
•
Parts (antennas, screws etc.) cleaning
– Several options at CERN
•
Available
equipments
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 € + ?!
Lutz Lilje DESY -MPY-
31.07.2017
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
Lutz Lilje DESY -MPY-
31.07.2017