In collaboration with STFC 1

Procurement & Quality Control

Mike Ellis

STFC Daresbury Laboratory, UK

ESS High-Beta Cavities

In collaboration with STFC

ESS High Beta Cavities

2

• Introduction

• STFC & IKC scope for ESS HβC

• Schedule & concurrent engineering challenges

• Procurement – Nb + cavity fabrication strategy

– Cavity fabrication responsibilities

• Quality Assurance schemes – Overview

– Acceptance levels

– Detailed scheme

• Spare slides: HβC (H) Vertical Test Facility preparations

In collaboration with STFC

STFC Scope for ESS Hβ Cavity

3

STFC UK In-Kind Contribution:

• Bespoke 704.42 MHz ‘horizontal’ Vertical Test Facility

• Niobium procurement

• Manage Eddy Current Scanning (DESY)

• Validation of industry processes using ‘pre-series’ cavities • Cavity fabrication of 84 (+4) high beta cavities in industry

• 2K RF qualification of cavities to 20.9MV/m, Q0 ≥ 5 x 109

• Transport to Saclay

Outside STFC Scope

• Cavity design – STFC strategy mix: mainly “build-to-print” – only essential adaptations for industry (prototypes fab @ CEA)

• Prototype cavities (CEA Saclay)

In collaboration with STFC

ESS Cryomodule IKC Collaborators

Procure &

build

Production + assembly

x 21 Hβ Cryomodules

Cavity Design & Specification

x 84(+4) Hβ

SRF cavities

In collaboration with STFC

Hβ Cavity Schedule

5

Concurrent engineering

• May accelerate schedule

• Risk of change vs

opportunity for early test

data

• Requires robust systems for:

– Change control system

– Configuration mgmt

– Communications

– Risk mgmt

In collaboration with STFC

Procurement: Cavity & Nb

6

Single vendor for all Nb, Single vendor for all cavities – Don’t have team bandwidth to validate & manage 2+ vendors

– Vendors’ capacity sufficient (faster than STFC testing!)

Open tenders – Schedule & budget did not allow pre-qualification

– Requires very careful procurement selection questions & quality measures

Cavity design specification: – Mechanical drawings

– RF & ‘performance’ requirements

– Quality control measurements & checks

– Cavity treatment specifications (BCP, heat + vacuum, etc)

Specification development: – Original aim to launch tenders with precisely defined specification

– Ongoing development of cavities & cryomodules (CEA Saclay)

– More flexible approach: high level specification for tender

– Final specification agreed in formal kick-off mtg

In collaboration with STFC

Procurement: Cavity & Nb

7

Open questions:

• Cavity fabrication: Precise, detailed specification vs ‘flexible’ specification & use of industrial know-how? – Experienced suppliers know how to make cavities

• Concurrent engineering: – ‘Indicative’ vs ‘final’ specification in OJEU tender process?

– Which specification elements most drive cavity cost / schedule?

– Incorporating learning from prototypes (CEA) into series (STFC)?

• Responsibility: – What constitutes “cavity design”?

– Collaborative vs build-to-print?

In collaboration with STFC

Preseries Fabrication Procurement

8

Industry: – Manufacturing drawings, tooling, final process specifications

– Produce pre-series undressed cavities

– Propose trimming, cavity component selection

– Optimise / validate treatment processes

– All treatments (BCP, tuning, annealing, HPR etc)

– Collect all QA data & reports – Dimensional, RF frequency /spectra, vacuum etc – Treatment process parameters – Align to acceptance levels required

– Helium tank integration after 2K undressed test

Cavity undressed testing @ 3rd party (TBD) – 2K test of undressed cavities

STFC: – Specify “high level” QA data required & approve manufacturer’s QA report templates

– Supervision of all steps

– Approve manufacturing plans & detailed manufacturing drawings

– Approve treatment processes

– Approve component trimming, composition etc

– Review & approve Acceptance Level data

– Cold RF test of dressed cavities

In collaboration with STFC

Series Fabrication Procurement

9

Industry: – Optimise QA data & reports for series (joint with STFC)

– Mechanical fabrication of cell & cavity components – (Starts in parallel with treatments of pre-series cavities)

– Propose trimming, cavity component selection

– All treatments (BCP, tuning, annealing, HPR etc)

– Collect all quality data & reports – Dimensional, RF frequency /spectra, vacuum etc – Treatment process parameters – Align to acceptance levels required

– Helium tank integration

STFC: – Optimise QA data & reports for series (joint with industry)

– Supervision of all steps

– Approve component trimming, composition etc

– Review & approve Acceptance Level data

– 2K RF test of dressed cavities

– Shipping of qualified cavities

– 1x HPR of non-conforming cavities where required after 2K RF test

In collaboration with STFC

Quality Assurance

10

• (H) Vertical Test Facility – Design process w/ formal checkpoints – Commissioning process fully documented – Qualification against known cavity performance

• Niobium supply – Industry provides Nb ingot & sheet samples – DESY to perform Eddy Current Scanning (directly contracted to ESS)

• Cavity fabrication – Industry provides QA measurements – STFC approve – STFC / ESS (+CEA Saclay ) jointly review Non-Conformances

• Cold testing – Incoming, outgoing inspections & tests – 2K cavity RF testing by STFC – If required, 1x HPR per cavity + retest at STFC – Defined, controlled & repeatable processes for all steps

In collaboration with STFC

QA: Facility Validation

11

• Facility commissioning & validation plan in development – Cleanroom & HPR process validation – Commissioning each subsystem independently – Integration of hardware & controls – Process development & staff training – RF measurement repeatability & accuracy: cross-reference to other labs? – Transport, shipping & cavity handling tools & processes

• Collaborative effort (STFC, ESS, CEA, INFN) to define:

– Document storage systems – Reports & data parameters / criteria – Cavity material & fabrication data requirements – SRF test data

In collaboration with STFC

QA: Cavity Fabrication

12

Acceptance level

Assembly stage Data types Data from Approver

0 (tbc) Half-cells End groups

Mechanical, RF, visual Mfg Mfg Preseries: STFC?

1 Assembled cavity Surface treatment

Mechanical, RF, vacuum, visual Mfg STFC

2 Tank integration, final treatment

Mechanical, RF, vacuum, treatments, tank

Mfg STFC

3 Final assembly Treatment, RF, vacuum, transfer measurements, accessory BoM, visual, packing, Factory Outgoing

Mfg STFC

4 After 2K RF test STFC Receiving, RF performance, STFC outgoing, HPR (if performed)

STFC ESS (CEA?)

5 Ready for CM string assembly

CEA incoming (visual inspection, G-shock log reading, vacuum, RF antennae?)

CEA ESS

In collaboration with STFC

QA: Cavity Fabrication

13

Acceptance level

Assembly stage Data types Data from Approver

0 (tbc) Half-cells End groups

Mechanical, RF, visual Mfg Mfg Preseries: STFC?

1 Assembled cavity Surface treatment

Mechanical, RF, vacuum, visual Mfg STFC

2 Tank integration, final treatment

Mechanical, RF, vacuum, treatments, tank

Mfg STFC

3 Final assembly Treatment, RF, vacuum, transfer measurements, accessory BoM, visual, packing, Factory Outgoing

Mfg STFC

4 After 2K RF test STFC Receiving, RF performance, STFC outgoing, HPR (if performed)

STFC ESS (CEA?)

5 Ready for CM string assembly

CEA incoming, visual CEA ESS

• Formal review points • Aligned to INFN proposal

for ESS Mβ cavities • Based on proven XFEL

schemes • Consistent across ESS

collaborators

In collaboration with STFC

QA: Cavity Fabrication

14

• Detailed STFC cavity QA scheme in development

• Aligning with known systems – XFEL, LASA, industrial experience

• Incorporate prototype learning

• Incorporate any requirements specific to ESS Cryomodule design

• Will include all required control measurements

– RF frequency, FF, HOM spectra

– Mechanical dims, CMM etc

– Visual inspections, ultrasound

– Treatment parameters

– Mass measurements

Nb (cell), Nb/Ti (flange) and Ti (He vessel) Material Certification Inspection Test/Measurement Procedure Analysis Data Type Frequency

Cavity Cell Nb Material

Vendor certification Y

RRR Y Data Array (from RRR instrument) Single Measurement

Thickness Y Data Array (from CMM) Single Measurement

Eddy current qualification (possible) Y

Water test verification Y Y

Magnetic field characterisation Y Y Y Data Array (from Hall Probe) Single Measurement

Qualification and test procedures Y Procedure Document

Flange Nb/Ti Material

Vendor certification Y

Dimensional comformance Y Y Data Array (from Hall Probe) Single Measurement

Magnetic field characterisation Y Y Y Data Array (from Hall Probe) Single Measurement

Ti helium vessel

Vendor certification Y

Dimensional comformance Y Y Data Array (from Hall Probe) Single Measurement

Magnetic field characterisation Y Y Y Data Array (from Hall Probe) Single Measurement

Cavity Fabrication

Receipt of Nb and Nb/Ti material from vendor Y Inspection Report

Cavity fabrication process Y Procedure Document

Cavity cell forming validation (CMM) Y Y Y Data Array (from CMM) Single Measurement

Cavity cell forming validation (RF) Y Y Y Data Array (from Network Analyser) Single Measurement

Cavity cell wall unifomity Y Y Y Data Array (from CMM) Single Measurement

Cell preparation prior to EBW (BCP) Y Procedure Document

EBW parameters Y Y Y Procedure Document

Dumbell frequency verification Y Y Y Data Array (from Network Analyser) Single Measurement

Cavity alignment Y Y Y Data Array (from CMM) Single Measurement

Cavity frequency tuning Y Y Y Data Array (from Network Analyser) Single Measurement

Field flatness Y Y Y Data Array (from Bead-pull system) Single Measurement

HOM characterisation Y Y Y Data Array (from Network Analyser) Single Measurement

BCP procedure Y Y Y Y Procedure Document

HPR procedure Y Y Y Y Procedure Document

Probe coupling measurement Y Y Y Data Array (from Network Analyser) Single Measurement

Vacuum leak check Y Y Y Y Procedure Document

RGA scan Y Y Y Y Data Array (from RGA) Single Measurement

Cavity QL measurement Y Y Y Y Data Array (from Network Analyser) Single Measurement

Helium vessel Fabrication and attachment

Receipt of Ti material from vendor Y Inspection Report

Helium vessel fabrication process Y Procedure Document

Attachment of helium vessel to cavity Y Procedure Document

HOM characterisation Y Y Y Data Array (from Network Analyser) Single Measurement

Probe coupling measurement Y Y Y Data Array (from Network Analyser) Single Measurement

Vacuum leak check Y Y Y Y Procedure Document

RGA scan Y Y Y Y Data Array (from RGA) Single Measurement

Cavity QL measurement Y Y Y Y Data Array (from Network Analyser) Single Measurement

Cavity VTF Assembly

Receipt of Cavities from industry Y Inspection Report

Dimensional and RF measurements Y Y Y Data Array (from NA and CMM) Single Measurement

Assembly onto insert in Cleanroom Y Y Y Y Procedure Document

Diagnostics assembly (thermocouples) Y Procedure Document

Assembly in VTF Y Procedure Document

Interface connections (RF, vacuum, Cryo, diagnostics) Y Y Procedure Document

Application of LHe Y Y Y Procedure Document

Cavity Performance Testing

RF, temp and vacuum measurements during cooldown Y Y Y Data Array (from control system) 60 secs (?)

Cryogenic pressure stability Y Y Y Data Reading Single Measurement

Cryogenic temperature Y Y Data Reading Single Measurement

VTF LHe level Y Y Data Reading Single Measurement

RF power Y Y Data Reading (from control system) Single Measurement

Cavity temperature (cavity x2, end group x2, helium jacket x2, flanges x2) Y Y Data Array (from control system) Single Measurement

Cavity vacuum Y Y Data Reading (from control system) Single Measurement

Cavity frequency Y Y Data Reading Single Measurement

QL Y Y Y Data Reading Single Measurement

Gradient Y Y Data Reading Single Measurement

Qo Y Y Data Reading Single Measurement

Microphonics Y Y Y Data Array Single Measurement

Cavity Test Configuration

To be included in this section:

1. Full details of all test and measurement equipment used

(Make, model, serial number, configuration settings etc)

2. Relevant calibration information

3. Serial number and location on VTF insert

Cavity Test Diary

A full chronological record of all significant events in the testing process including:

1. Date/Time

2. Details of test or procedure

3. Person responsible

4. Comments

Nio

biu

m

Acc

epta

nce

A

ccep

tan

ce

leve

l 1

A.L

. 2

A

ccep

tan

ce

Leve

l 3

Thanks & acknowledgement to DESY, INFN, CEA for guidance & advice on series QA

In collaboration with STFC

Additional slides

15

• VTF & shielding design cut-away view

• Cryostat & inserts

• Modular cleanroom / VTF assembly area

• Cryoplant subsystem

• Modular Cleanroom

• Main cleanroom & HPR

• RF system

• VTF overview

• Cavity interfaces to STFC cryostat

In collaboration with STFC

VTF & Shielding Overview

16

Cryostat pit >1.86m

concrete all sides CSI

Cryostat Thermal radiation shield Magnetic shield

Existing mezzanine

Helium Liquefier LHe Dewar

→ To

cleanroom & HPR

In collaboration with STFC

Cryostat & Inserts

17

• ‘Horizontal’ VTF

• Previously presented by Shrikant Pattalwar, TTC 2015

Radiation shield being manufactured at Criotec (26/01/2017)

Inner vacuum vessel being manufactured at Criotec

(26/01/2017)

Cryostat Outer dia. 2.2m Height 4.25m

Mag shield <1uT in cavity zone

2K box Cryo valves

JT valve 2K Heat exchanger

In collaboration with STFC

Cryostat & Cryoplant Scheme

18

Cavity 1

Cavity 2

Cavity 3

Helium bath

Inle

t 4

0K

Pu

rge

40

K

Inle

t 4

K

Boil off bath

Return 40K shield

Return 2K

2K heatexchanger

TT1010K50

TT1011K20

TT1009K2

TT1000K2

TT1002K2

TT1003K2

TT1005K2

TT1006K2

TT1008K2

TT3005K50

TT3004K50

TT3003K50

TT3001K50

TT3002K50

TT3000K50

TT1012K300

TT2002K2

TT2003K2

TT2004K2

TT2010K4

TT2006K50

TT2007K50

TT2008K50

TT2000K4

HT2040kW6 HT2044

kW5

HT2041kW2.5

PRV2182

barg5

PRV2184

barg10

PRV2183

barg5

TT2001K4

HT2042W100

Ph

ase

sep

arat

or

PT2150bar1-2

PRV2180

barg2.5

LI2090m1

PT1162bar1-2

LI1090m2

PT1161mbara10-100

TT1007K2

TT1004K2

TT1001K2

Ph

ase

separato

r

PRV1180

mbarg250

PRV1182

mbarg100

BD1170mbarg450

HT3044W600

PT2152bara1-2

PRV2181

barg0.1

VG2156mbara10-6

PRV1181

barg0.1

VG1160mbara10-6

TT2005K300

TT2011K300 TT2009

K300

2K pump

Recovery

compressor

Raw gas storage

Helium liquefier

Liquid helium storage (3000 l)

Gas bag

HP pure helium storage

Aux LHe

TT1013K2

HT1046W200

Warm helium gas

FM2230

g/s4

FM2232

g/s1.5

FM2231

g/s2.5

HT3045W600

PRV3180

barg0.1

VG3150mbara10-6

TT1014K2

TT1015K2

Pu

rge

pu

mp

CSI vacuum

pump

LI1091m2

OVC vacuum

pump

2K box vacuum

pump

PV1200NCPV

PV1201NCPV

PV1202NCPV

PV1203NCPV

PV2206NCPV

PV2207NCPV

PV2208NCPV

PV2209NCPV

CV2210NCCV

CV2211NCCV

HV2212NCHV

PT2151mbara10-100

CV2201NCCryo

PV2204NCCryo

CV2205NCCryo

PV2203NCCryo

CV2202NCCryo

CV2200NCCryo

Oil/water removal system

Kaiser

compressor

Oil removal system

Dryer

WP

3

WP

4

WP3WP4

In collaboration with STFC

STFC Cryo plant – first plant arriving

19

15 Jan 2017: Delivery 1

- Compressor

- Oil removal system

Right:

View overlooking future cryostat & radiation shielding bunker

Cryoplant components should be moved to compressor building this week

Remaining components due late Feb 2017

In collaboration with STFC

Modular cleanroom concept

20

Modular cleanroom for UHV cavity connections

Two options under test / evaluation

1. Glovebox

− reduced cleandown

2. Walk-in area

− simpler ergonomics

Dummy cavity manufactured from SS316

Ultrasonic clean & degrease

Particle counting just downstream of UHV valve area

Good initial results in large walk-in volume

Also now developing ‘glove box’ solution to test ergonomics.

← To cryostat & bunker

In collaboration with STFC

Modular cleanroom / CSI stand

21

Concept design for VTF assembly area

• Support 2x cryostat inserts

• Access to UHV & cryo instrumentation on top flanges

• Access to cavity connections on lower section

• Flexible / modular options for integration particulate control systems

– Fan filter units

– Laminar flow units

– Screens

– Glovebox

In collaboration with STFC

Cleanroom & HPR

22

In collaboration with STFC

RF System

23

High level design complete LLRF detailed design ongoing

• based on JLab / T Powers LLRF • Adapted by STFC (K Dumbell, P Smith, F

Palade) Rack design near-complete Validation with coaxial resonators ongoing

• Cu resonators for basic system functionality • LLRF validation tests planned using 704.42

MHz Nb SRF coax resonator

In collaboration with STFC

ESS: STFC (H)VTF

24

• Bespoke vertical test

cryostat for ESS HB

cavities

• 3 cavities in cryostat

– Horizontal test

configuration

– 1500L LHe per test

– <4g/s He(g) HVTF

– Conventional config:

• 7500L He(l)

• 20g/s He(g)

• 2 week test cycle

– 1 week potential

In collaboration with STFC

STFC (H)VTF Cavity Interfaces

25

1. Helium diphase outlet CF/ISO flange welded to extended pipe

2. Helium inlet port CF to flexible pipe

3. Beam Pipe Vacuum Coupler Port (ISO flange + DN40 angle valve (not shown))

4. RF input coupler Antenna mounted on flange on main input port

5. RF pick up Pick up point 5 (pickup will remain with cavity in CM)

6. Mounts for T-sensors Custom instrumentation belt in design, 3 temp sensors

7. Film Heater 50 W

Items 3,4 and 5 factory mounted on the cavity

Cavity transported in Vacuum

2 4

3

5

Modification

6

7

1