SPX Cryomodules WBS CD2DR-U1.02.01.03.05

1. SPX CryomodulesWBS CD2DR-U1.02.01.03.05 John Mammosser Jefferson Lab SRF R&D DOE Lehman CD-2 Review of APS-Upgrade4-6 December 2012

2. Outline • Science / Technical Significance • WBS Scope of this system • Staff / Org Chart • Requirements • Design • Interfaces • Value Engineering (as applicable) • Risks considered (as applicable) • ES&H • Cost • Schedule DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

3. Science Case / Technical Motivation • The technological development of superconducting deflecting crab cavities, leverages current SRF technology for the production of short pulse X-Rays that’s both effective and compact. DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

4. SPX Cryomodules Scope / Cost Summary Cryomodule Scope: Design, Fabricate and Qualify (2) Superconducting Cryomodules Designed To Chirp (Sector 5) and Unchirp (Sector 7) the APS Beam for the Development of Short Pulse X-Rays Two Cryomodule Operational Configurations: Beam Ready for the production of Short Pulsed X-Rays, Cavities at 2K Parked Configuration where Cavities are Detuned and at 80K DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 4

5. Milestones – 1.02.01.03 & 1.03.03SPX Cryomodules / Cavities DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

6. High Level Cryomodule Requirements: Stable Operation Installed in APS • Low trip rates when operating with beam currents up to 150mA while chirping beam for experiments are run (gain experience with SPX-0) • Thermally stable operation in a parked configuration, cavities detuned (cooling to remove heat generated from beam operations) • No adverse affects to APS beam during operations (fast detuning of cavities in fault condition) Chirping (Beam Deflecting Mode) • Independent control of cavities to provide 2MV of beam chirp and unchirp (gain experience with SPX-0) Critical Alignment of Cavities • Design must minimize coupling out of beam power from misalignment (remote alignment scheme will be employed to meet requirements) • Beam based alignment required at setup and for drifts (signal feed back for control) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

7. SPX Cryomodules Design Requirements: Physics parameters Value Unit Total crabbing voltage 2 MV Total de-crabbing voltage 2 MV Beam current ≤150 mA Number of cryomodules 2 Length of section, including magnetic elements 3.034 m Cryomodule length beam-line flange to flange TBD Number of cavities per cryomodule 4 Cavities Type Superconducting Duty cycle CW (8th harmonic of APS storage ring frequency) Design Mark II Operating Frequency Deflecting Mode 2815.488 MHz Geometric factor 227.5 W R/Q’ 18.6 W Operating deflecting voltage 0.5 MV Active length 53.24 mm End flange to end flange distance 389.76 mm DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 7

8. SPX Cryomodules Alignment Requirements: Alignment per module for APS installation Value Units X misalignment (Horizontal) ±500 µm Y misalignment (Vertical) ±200 µm Z misalignment (Longitudinal) ±1000 µm Yaw misalignment ±10 mrad Pitch misalignment ±10 mrad Roll misalignment ±10 mrad Alignment per cavity in cryomodule Value Units X misalignment (Horizontal) ±500 µm Y misalignment (Vertical) ** ±200 µm Z misalignment (Longitudinal) ±1000 µm Yaw misalignment ±10 mrad Pitch misalignment ±10 mrad Roll misalignment ±10 mrad ** with remote alignment DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 8

9. String Design Concept HOM Absorber RF Tuner RF Window 4 Crab Cavities Providing 2MV Chirp (Deflection) to the APS Beam DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 9

10. Cryomodule Concept Warm RF Tuner Vacuum Vessel Shielded Valves Fundamental Power Coupler SRF Cavity Beam Line DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 10

11. Cryomodule Concept Spaceframe HOM Load Helium Gas Return Header Cold Tuner LOM Window DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 11

12. Alignment Concept 1 Alignment Procedure for Cryomodule • Fiducialize each cavity to the electrical center on CMM using the stretched wire setup (scan a wire in vertical “Y” plane, measure mechanical center in the horizontal “X” plane) • Cavity flanges machined for fiducial balls (shown in pink) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 12

13. Cryomodule Alignment • Weld helium vessels on the four cavities and recheck vertical alignment on CMM DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 13

14. Cryomodule Alignment • With string assembly tooling align the four cavities with laser tracker (mock assembly out side cleanroom) • Clean all components and process cavities • Qualify cavities individually in vertical test • Perform string assembly and align with laser tracker • Build out cold mass (instrumentation, magnetic shielding, MLI) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 14

15. Cryomodule Alignment 2 • Insert cold mass into space frame (support structure) • Transfer alignment to space frame (fiducial features on space frame) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 15

16. Cryomodule Alignment 3 • Complete cryomodule assembly (access ports for checking alignment) • Transfer alignment to vacuum shell (fiducial features outside shell) • Align cryomodule in APS, support stand adjustment of cryomodule in place • Perform low power beam test and use active alignment to positions cavities and optimize alignment • Remote alignment concept • (4) Nitronic rods support the cavity • External mechanical adjustment • Allows for 2 mm movement of each rod Cavity Nitronic rod External Remote Alignment Adjustment DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 16

17. Cryomodule Design • Cryomodule design will be based on the SNS redesign: • Vacuum vessel will be the pressure boundary • End cans and Vacuum Shell will be pressure stamped to meet 10CFR851 • Cryogenic heat exchanger inside end can SNS First Spare HB Cryomodule Vacuum Vessel Pressure Stamped in Industry!! DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

18. SPX Cryomodule Org Chart DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

19. Interfaces • Cryomodule Installation Major Interfaces • Cryogenic system and controls • Deflecting Cavity RF System and Controls • Tunnel Utilities (Water cooling etc.) • Tunnel Alignment • Fabrication Interfaces • ANL will provide the HOM/LOM loads and waveguides • ANL will provide RF cables and instrumentation and safety controls DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

20. SPX Cryomodule Risks / Contingency • Stability of cryomodule performance in ring operations does not meet APS beam availability or quality expectations • Mitigation: SPX-0 ring test should identify critical issues and the schedule will allow time for resolution of these issues before production modules are needed • Alignment of cavity electrical centers after cool down can not be compensated with the remote alignment scheme • Mitigation: Removal and rework of cavity alignment possible if tunnel adjustment of cavity alignment unsuccessful • Cavity performance degraded due to contamination • Mitigation: Cavities are independently driven by RF and an individual cavity voltage can be compensated by the other cavity voltages first order • Mitigation: Helium and plasma processing can be applied during maintenance periods to gain back performance DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

21. Cryomodule ES&H • Integrated Safety Management System (ISMS) • APS-U Project following Argonne’s ISMS program requirements • Argonne Integrated Safety Management System (ISMS) Description recently revised and submitted to DOE ASO • Describes framework for integrating ESH requirements with mission objectives • References Argonne LMS procedures which implement specific portions of the ISMS • General Safety Requirements for SPX Cryomodule Design and Fabrication • Cryomodule must comply with 10 CFR 851 worker safety and health requirements • Pressure safety ASME Boiler and Pressure Vessel Code • ASME B31.3 pressure piping • Vacuum safety • Ionizing radiation safety • ANL Safety Requirements • Jlab Safety Requirements DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

22. BOE Contingency – 1.02.01.03 & 1.03.03SPX Cryomodules / Cavities DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012 22

23. SPX Cryomodules Value Engineering • The cryomodule vacuum shell design will be a modified SNS design where pressure vessel design is applied to this component (fabricated and pressure stamped from industry) • Existing VAT RF shielded valves will be used for the warm and cold valves (off the shelf) DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

24. Cryomodule Cost Summary Chart by FY Design and Fab SPX-0 Testing of SPX-0 Procurement and Fab of SPX Cryomodules Commissioning of SPX DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

25. Work between CD-2 and CD-3 • Complete the SPX Cryomodule Design • Develop Cavity Remote Alignment Design and Procedure • Develop the Engineering Design and Document • Procure all Cryomodule Major Components • Fabricate and Deliver SPX-0 Cryomodule DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012

26. Summary • The critical design concepts for the SPX Cryomodule will be fully tested during the SPX-0 R&D phase • What is learned from the SPX-0 testing will provide the guidance for SPX cryomodule design improvements and the operational knowledge to provide stable operation for an APS installation • SPX Cryomodule Design Concept is well underway • All significant technical issues are being addressed • We are ready for CD2 DOE Lehman CD-2 Review of the APS Upgrade Project 4-6 December 2012