Transcript Summary of Regional Interest Panel Meetings Discussions on S0,S1,S2 - Related Proposals (Updated Aug.20, 06)

Summary of Regional Interest Panel
Meetings Discussions on
S0,S1,S2
- Related Proposals
(Updated Aug.20, 06)
Guiding Principle for
Regional Interest Panel SRF Activities
1. Plan for US activities to be a strong contribution to
GDE ILC R&D.
2. Natural outcomes of 1. would be to
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Develop technical competency and strength to
demonstrate that US can be a host to ILC
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Promote support of US industry to participate in
ILC project
3. Carry out detailed site analysis not covered by GDE
4. Scope above activities to provide guidance to
funding agencies
Starting Point: What can US Institutions
contribute to S0 ?
• The situation before us : low yield for 35 MV/m
• The tasks before us
– Improve the reproducibility of cavity processing
– Achieve an overall yield of cavity production & cavity processing for E > 35
MV/m for > 95%? for N cavities
– All institutions should converge towards similar preparation and test
procedures to establish comparable data for 9-cells
– Carry out coupled R&D programs in parallel to improve processes
(multi-cell tests with diagnostics, single cells prep/tests, preparation
R&D, materials R&D, diagnostics on EP, HPR…systems)
– Results from R&D programs should feed into 9-cell activities
– Establish final best recipe to use for subsequent productions
• Need to make substantial progress towards these goals by mid
to end of 2008, and complete S0 by mid-2009
– Could impact final choice of gradient for TDR (due end of 2009)
S0: Need to Improve Yield of Cavities
&Yield of Preparation Cycles
• How many cavities will we need to do
the job? 100?
• How many tests will we need to do the
job? 200? 300?
Thoughts Towards a Model Plan for US
Contribution to S0, S1, S2
• Step 1: Assess the max cavity capability of US institutions for
preparation and testing between now and end of 2008?
– If we accept the proposals put forward for establishing preparation
and testing capabilities
• Step 2: How many CM and RF units are possible in later years
from these cavities?
• Compare US institutions with Global capabilities
• Sources for capabilities assessment
– Jlab – discussions with John Mammosser
– ANL/FNAL – Shepard/Shekar presentation June 1 FNAL S0S1
meeting
– LANL – 07 DOE proposal documentation
– MSU - discussions with Richard York
– DESY – Lutz
– KEK - Hayano
Summary Table for Max Possible US Capacity
(Supporting slides given later)
• 21 M$ for cavities and processing (06 – 08)
• ++ Combined cost for Infrastructure for : ANL, FNAL, LANL,
MSU (06 - 07)
• Cost numbers may be needed by us later to determine cost of
GDE R&D
S0 Summary: US Capability for Cavity Preparation and Testing
(Supporting details in following slides)
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06: ramp up, get facilities in shape, parallel R&D
– Jlab – max 6 cycles, parallel R&D
– Cornell – 3 cycles (qualify vertical EP), Parallel R&D
– Others (MSU, LANL): upgrade facilities & Parallel R&D
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07: first stage assembly line, install some process improvements, R&D
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Jlab – 36 cycles, Cornell – 12 cycles
ANL/FNAL – 6 (qualify new EP, new test stand)
ANL/LANL/FNAL – 8 (qualify 8-cavity test stand capability)
MSU – 6
08: second stage assembly line, install final process improvements, R&D
– Jlab 48, Cornell – 12, ANL/FNAL – 24, ANL/LANL/FNAL – 24, MSU - 12
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Total number of cycles for 06 – 08 = 200
Total number of cavities to buy: 150
+ Infrastructure investment EP, HPR, vertical test
– (lots of infra-structure is in place already at JLab, Cornell, MSU, LANL,
Argonne…pictures at end)
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Max output: Total number of good cavities > 35 MV/m : 130
This is NOT the official S0 plan, we can do part of this, or we can do
variations
• Final Plan will depend on GDE plan
Year by Year Summary
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Possible goals for 06, 07, 08
Max no. of tests : 9, 68, 120
Process yield (model) 0.3, 0.6, 0.9
Cavity yield (model) 0.8, 0.9, 0.9
Max number of tests > 35 MV/m
2, 32, 97
Scale in 07 and 08 is appropriate for initial
industrial involvement in cavity preparation
– Key step toward commercialization of SRF
technology
Possible
variations (under consideration by
GDE Task Force S0) could lead to fewer
cavities !
• Reduce number of cavities by carrying out
tight-loop operations on good cavities
– Tight loop operation on EP/HPR/test
– Tight loop operation on HPR/test
• Some labs can work on reject cavities with
diagnostics
– Determine nature of defects: weld, material
• Feedback to cavity production to improve
yield
We also need a Parallel-Coupled
R&D Plan…
Many Arenas of R&D Coupled to S0
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Single cell prep/tests
Process monitoring
S-deposition studies
H- contamination studies
Field emission studies
Material studies
Thermometry diagnostics
Do we need tumbling?
Do we need eddy current scanning?
…
Looking Forward to Contributing to S1 Goals
(Re-iterate: GDE S1 Goals are still developing)
• What is the max number of cryomodules possible from
S0 related activity (if successful & if maximal)?
– Take one year lag between cavities and modules
• 2007, 2008, 2009
• 0 , 4, 12
• How many (max) RF Units are possible in 08, 09, 10:
• 0, 1, 4
– Max Possible match to emerging goal for S1 and S2 (Stage 1)
– still under discussion in Task Forces
• Need to make compatible with GDE plan when ready
• Compare with max global capacity
– (see Table next page)
– Number of RF Units possible globally in 2008, 2009, 2010:
– 0, 3, 7
Max Global Capabilities and Cost
Note: DESY cycle rate is lower because cavities which
pass 28 MV/m are removed from the cycle for XFEL
Example: FNAL (Expanded from SMTF Plan)
Cryomodule
Modulator
Photo-injector A
Modulator
Number
07
1
08
2
09
3
10
4-5
load
klystron
cryomodule
cryomodule
klystron
Photo-injector B
Modulator
Year
cryomodule
Photo-injector B
Modulator
load
klystron
cryomodule
cryomodule
Cryomodule IV
klystron
Photo-injector B
Cryomodule IV
Cryomodule IV Cryomodule IV
By FY10, One RF unit= basic building block of ILC ML
By FY11, Two RF units
ILC RF unit = three ILC Type IV cryomodules, modulator,
10 MW klystron
Type IV design will
not exist until FY07
~ 2 years before a
module is delivered
Looking forward to S2 goals
(developing in our Task force)
• Determine max. capacity for US contribution to cryomodules
from cavities tested in US facilities
• By 08: capacity possible for 97 cavities with Eacc > 35 MV/m
• Module assembly rate possible for 2009: 12 = 4 RF units
• Possible evolution path for 2010….the “high-end” scenario
• If we continue cavity fabrication and processing/testing cycle
with industry in 09
• Module assembly rate possible for 2010: 12 = 4 RF units
• Total = 8 RF units (1% ILC)
• Compatible with module scenario proposed at May 22 O’Hare
meeting by Kephart…also presented at Vancouver S2 meeting
• “Low-end” scenario could be 1/3 smaller => 3 RF units
(expanded SMTF plan)?
Summaries of Max Possible Capability
for Contribution to S0, S1, S2
Anticipated Scope and Timelines for S0
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First milestone for S0 by mid-2008
– establish process reproducibility
– e.g. 40 cavities, 70 cycles, divided into several stages with improvements in
between
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Final yield goal by mid-2009
– establish cavity and process reproducibility
– e.g.110 cavities each in 08 and 09, 120 cycles each
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Install infrastructure at institutions
– EP, HPR, Vertical tests (2007)
– Add improvements in infrastructure determined from R&D (2008)
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Involve industry in cavity preparation and testing
Install infrastructure in industry for cavity production (2007, 2008)
– e-beam welder (takes a long time to acquire and commission)
– basic chemistry
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Pursue parallel-coupled R&D program for yield improvement (20072009)
Anticipated Scope and Timelines for S1, S2.1
(similar to Expanded SMTF plan)
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S1: Assemble several cryomodules, <Ea> > 31.5 MV/m:
– (1 module ) 2007, (3 modules) 2008, 12 modules (2009)
– Install infrastructure for Horizontal Tests, Coupler tests, String Assembly,
Cryomodule Assembly at labs
– Acquire cryomodule components in 07, 08, 09
• Including couplers, tuners, cryostat…
– High power test couplers
– Assemble cryomodules using successful cavities from S0 activity
– Involve industry in cryomodule assembly at labs
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S2.1: Assemble 1st RF unit (3 modules) in 2009
– Install RF, LLRF and Refrigeration in 2009
– Carry out tests for R2, R3… some with beam (08-10)
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S2.1: Assemble 2nd RF unit in 2010 (to run in parallel with 1st)
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With higher performance cavities
Next generation cryomodule
Continue tests for R2, R3…with higher performance modules
Some tests with beam
Anticipated Scope and Timelines:
S2.2
• Assemble 2 module test stands in 08, 09 for testing many
modules in parallel with S2.1 RF Unit activities
• Assemble RF, LLRF and Refrigeration for RF units by end 2009
• Industry assembles cryomodules using lab infrastructure:
– 12 modules in 2009, 12 in 2010
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Determine cost and cost reduction measures in 2009
Implement cost reduction measures for modules in 2010
Test industrially produced cryomodules at module test stands
Assemble RF units from industrially produced modules in 2009
and 2010
• Test RF Units at RF test stand between 2009 - 2011
Detail Supporting Information
Follows for Determination of Max
Capacity, US and Global
Determine timeline for ONE cycle
of operations
• Assumptions
– One set-up available each for EP, HPR,
furnace, tuning system, and vertical test
– Assume one shift, and 5 working
days/week
– Ramp-up only in remainder of 06
Cycle Modeled After DESY Procedure
Described by Matheisen, ILC@KEK 2004
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Degrease & EP 80 um (3 days)
HPR 1 day
Drying 1 day
H-removal, 600 – 800 C (3 days)
Tune field flat (1 day)
EP 10 um (1 day)
HPR (1 day)
dry (1 day)
First stage assembly & HPR (1 day)
Dry 1 day
Final assembly to test stand, evacuation (2 days)
120 C bake on test stand (2 days)
Cold test, warm up (3 days)
Total 21 days (4 weeks)
Jlab Assembly Line Rate With Many Cavities
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Test stand occupied 7 days
All other facilities occupied < 3 days
=> possible to do 3 cavities in 21 days (one month)
=> 36 cavities per year
– A bit less because of bottleneck at EP (needed twice)
• Can be increased to 72 per year for two test stands,
– But Jlab will also have other commitments, so use 48 per
year.
• 08: 48 tests, 09: 48 tests
Cornell
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Assume Cornell vertical EP working by September
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EP 80 um (3 days)
HPR 1 day
Drying 1 day
Ship to FNAL for furnace and tuning 2 days
H-removal, 600 – 800 C (3 days)
Tune field flat (1 day)
Ship back to Cornell 2 days
EP 10 um (1 day)
HPR (1 day)
dry (1 day)
First stage assembly & HPR (1 day)
Dry 1 day
Final assembly to test stand, evacuation (2 days)
120 C bake on test stand (2 days)
Cold test, warm up (3 days)
Total 25 days (5 weeks)
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3 tests in 06
Other commitments ERL and basic studies => 12 tests in 07 and 08
MSU
• All new infrastructure implemented by
early 07 (no formal proposal for this)
• Same prep/test cycle as Cornell
• 6 cycles in 07, 12 in 08
Argonne/FNAL
• EP facility ready in mid-07 at Argonne
• Vertical test facility ready in mid-07 at FNAL
• According to Argonne Talk at Fermilab June 1, they
propose to carry out 18 EP cycles in 07, 60 cycles in
08 and 250 cycles in 09.
• All of these cavities can go to FNAL for remainder of
prep (HT, tuning, HPR)
• Test at FNAL or LANL
• For Argonne/FNAL, Initial test rate for 07 = 1/month,
total 6
• 08: increase to 2/month, total 24
Argonne/LANL
• LANL proposes to build an 8-cavity test
set-up as written up for DOE proposal
07
• Send 8, 24 cavities to LANL for testing
in 07, 08 and 09
• (rest of preparation – 800 C, tuning - to
be carried out at FNAL)
Cost Bases
• Cavity 100 k$ ea.
• Process/test cycle 30 k$ ea.
– 5-6 FTE, 36 cycles/year + M&S
• Plus infrastructure costs