302 3 RFD Dressed Crab Cavities Fabrication Leonardo
302. 3 - RFD Dressed Crab Cavities Fabrication Leonardo Ristori – Fermilab L 2 Manager – RFD Dressed Crab Cavities Fabrication HL-LHC AUP IPR DOE/SC Review – Jan. 14 th– 16 th 2020
Outline § § § § Scope, Deliverables Requirements and Design Iteration Interfaces and External Dependencies Organization Production Plan Technical Progress Procurement Status QA/QC Schedule Cost Risks ES&H Open recommendations Plans for CD-3 c Summary HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 2
Scope and Deliverables • Dressed RFD Crab Cavity • • • Project Scope includes 2 Prototypes + 2 Pre-Series + 10 Series Bare Cavities: Intermediate Qualification at FNAL at 2 K Integration: Bare Cavity + Magnetic Shields + Helium Tank + RF Ancillaries Dressed Cavities: Final Qualification at FNAL at 2 K + RF Ancillaries Delivery: 10 qualified dressed cavities (mix of pre-series + series) § Yield assumptions: Bare 92% (1 of 12 fail), Dressed 91% (1 of 11 fail) HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 3
WBS Dictionary US-Hi. Lumi-doc-39 HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 4
Functional Requirements Specification RFD Dressed Crab Cavity US-Hi. Lumi-doc-294 § § Charge 1 Hi. Lumi LHC approval (v. 1. 0) Accepted by AUP (#294) FRS Revision in progress to include requirements for magnetic shielding and transportation. Approval ~ Feb 2020. Current design (right) meets revision. Current Design HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 5
Z. Li (SLAC) Recent RF design change (SLAC) Charge 1 (1 a) RF design change was necessary to address two issues: § (1) Excessive beam-induced voltage observed at CERN in SPS tests of similar crab cavity (DQW) § § § New requirement by CERN on beam coupling voltage Vb < 0. 3 V/n. C (1 a) Port rotated by 90 deg, (1 b) implemented a hook design (2) Structural integrity of ceramic window subjected to transportation loads § § (a) Increased inner diameter of ceramic 50 Ohm 25 Ohm (b) Adjusted overall length (1 b) 50 ohm 35 mm 30 mm 37. 879 5 mm 16. 469 26 mm 71. 0 mm (1) 5. 94 mm (1+2) +/-0. 3 V/n. C (1 b+2) 25 ohm 35 mm 30 mm 37. 879 5 mm 24. 970 26 mm 68. 8 mm 5. 94 mm Vb: 0. 123 V/n. C HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 6
Charge 3 Interfaces Talk: S. Verdu - Interfaces § Project integration plan (#1166): US-Hi. Lumi-doc-219 § T. Page System Integration Engineer § RFD Interfaces AUP-CERN (#647): US-Hi. Lumi-doc-647 § Monthly meetings with WP 4 § RFD Interfaces inside AUP (#1702): US-Hi. Lumi-doc-1702 § Interfaces at level 4 § Weekly meetings HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 7
Charge 3 External Dependencies § § RF design of bare cavity and RF ancillaries is responsibility of AUP. Design is uploaded in EDMS at CERN. Mechanical design is responsibility of CERN. Specification/functional drawings provided to AUP. All external dependencies are captured in milestones dictionary Risks associated with external dependencies § CERN specification drawings of deliverables are delayed or changed. External Milestones A 231304 EX: Design Freeze – Prototype RF Ancillaries 01 -Jul-19 Accomplished A 231301 EX: Design Freeze – Prototype Mag. Shields 03 -Sep-19 Accomplished A 231302 EX: Design Freeze – Prototype Helium Tank 01 -Oct-19 Accomplished A 231303 EX: CERN Design Complete – Bare Cavities 02 -Jan-20 Accomplished A 231300 EX: CERN Design Complete – RF Ancillaries 30 -Jun-20 A 205980 EX: Cavities Final Design Review (FDR) 02 -Jul-20 A 229800 EX: CERN Design Complete – Helium Tank 24 -Sep-20 A 205690 EX: CERN Crab Cavity Acceptance Completed 30 -Jan-23 HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 8
Acceptance of RFD cavities US-Hi. Lumi-doc-1744 § Acceptance Plan (#1744) § § Acceptance Criteria (#1154): § § Describes the process for acceptance between AUP and CERN, including OK to ship from CERN, and final checks at CERN after receiving All requirements from FRS will be verified with a test or a set of measurements during cavity production or during final tests at FNAL. Electronic travelers (VECTOR): § Already in place for several activities (see below) US-Hi. Lumi-doc-1154 HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 9
AUP Crab Cavity Organization US-Hi. Lumi-doc-104 § 2 Control Accounts (1 LOE, 1 Discrete) § L 2, L 3, CAM & Deputy positions filled § CAM Training completed & refreshed for CAM & deputy HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 10
U. S. RFD Team US-Hi. Lumi-doc-1055 Institutions in alphabetical order (See #1055) § Argonne National Laboratory (Brazing and Cavity Processing): § § Brookaven National Laboratory (Coordination, Interfaces and MIPs): § § Naeem Huque Old Dominium University (General Oversight and RF measurements): § § Paolo Berrutti, Manuele Narduzzi, Alex Melnichuk, Damon Bice Jefferson Lab (HOM Dampers Fabrication): § § Silvia Verdu Andres Fermilab (RF/Mech Design, Procurements, Cold Tests): § § Mike Kelly, Mark Kedzie, Tom Reid, Bill Toter Jean Delayen, Subashini De Silva SLAC National Accelerator Laboratory (RF Design, Coordination): § Alessandro Ratti, Zenghai Li Quarterly Reports from BNL, ODU, SLAC (#1680) Roles & Responsibilities Response to CD-1/3 a recommendation US-Hi. Lumi-doc-1680 Comment from Preliminary Design Review (2018) Quarterly Reports HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 11
RFD Production Plan § § Large procurements in industry, Processing/Testing in laboratories Centralized management at Fermilab (Issue PO’s, Perform QC) Yield assumptions: 1/12 bare cavity failure, 1/11 dressed cavity failure Niobium material increased to 14 (CD-3 b recommendation) 302. 3. 02. 02 Cavity Materials Procurement RF Ancill. Materials Procurement For 14 cavities* For 17 sets 302. 3. 02 Bare Cavity Procurement (Industry) 302. 3. 02. 04 Magnetic Shields Procurement (Industry) 302. 3. 02. 04 RF Ancillaries Procurement (JLab) 12 12 14 302. 3. 02. 03 Bare Cavities Process + Test (ANL+FNAL) 302. 3. 02. 04 Helium Vessel Welding (Industry) 302. 3. 02. 05 Dressed Cavities Process + Test (ANL+FNAL) 12 (1 fail) 11 11 (1 fail) Shipment to CERN 10 * Added material for 2 additional cavities to address recommendation HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 12
Charge 1 Technical Progress: Cold Tests Summary A B § § § 2 available LARP prototypes (RFD#1, RFD#2) exceeded Voltage and Q 0 requirements All 14 tests (with and w/o dampers) exceeded nominal voltage of 3. 4 MV Highest Q 0 achieved at 4. 1 MV with dampers = 7. 3 109 (~2 x requirement) (A): Solved issues with RF losses in dampers (B): Removed surface defect causing early quench HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 13
J. Delayen, S. De. Silva (ODU) Charge 1 (A) RFD cavity + HHOM and VHOM validation § § LARP RFD 2 cavity has been successfully tested with all RF ancillaries. Initially observed RF leakage causing losses, has been understood and resolved employing special RF gasket. HHOM and VHOM dampers design has been successfully tested. HOM qualification/acceptance (#2581) in response to recommendation ODU-JLAB Non-negligible currents causing losses Regular gasket on HHOM coupler US-Hi. Lumi-doc-2581 Improved RF gasket HOM Qualification Document (Recommendation) HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 14
Status of key procurements Charge 4 § Raw Materials Procurements (CD-3 b scope) § All materials for prototypes available and being used at E. Zanon S. p. A for prototypes § Niobium Sheets for pre-series & series cavities § Received 15 of 98, all accepted, option for balance imminent Niobium Sheets § Other Raw Materials for Cavity § PO imminent for pre-series + series § Raw Materials for RF Ancillaries § POs placed for prototypes § Bare Cavity Procurement § 2 x AUP Prototypes at E. Zanon S. p. A. – ETA Mar 2020 § RF Ancillaries Procurement FNAL inspection of Nb Sheets § 3 x AUP Prototypes at Jlab – ETA Jul 2020 § Dressed Cavity Procurements § Mag. Shields – REQ in progress § He Tanks – REQ imminent JLAB RF Ancillaries HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 15
Fabrication at E. Zanon S. p. A. 1 st Nb Pole formed (June 2019) Charge 4 Key components formed + welded (Sep 2019) § PO Placed with E. Zanon S. p. A. on Sep 2018 for 2 Prototype Cavities § Heavy FNAL oversight, weekly meetings, ~monthly visits § Prototypes on track for delivery to FNAL on 3/2020 & 4/2020 § 12 additional cavities are in contract as options § 2 pre-series (must launch April 2020) § 10 series (must launch October 2020) HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 16
Charge 4 Fabrication Status FPC Waveguide End Cap As of Dec 5 th H-HOM Waveguide Beam Axis Pole Corner FPC End Group RFD Crab Cavity Pick Up End Group Main Body Half Main Body Racetrack & Tuning Pin Pick Up V-HOM Waveguide Beam Axis HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 17
QA Documentation for Pre-Series: Actual Status Description Procedure N. Revision Status 3326. 1. 000 0 Update Ongoing (for Pre-Series) Manufacturing Drawing Tooling Not Available 0 Update Ongoing (for Pre-Series) Welding Book – section 1 Welding Map 3326. W. 001 0 Update Ongoing (for Pre-Series) Welding Book - section 3 Test Coupon (WPQR) 3326. W. 001 0 Update Ongoing (for Pre-Series) Welding Book - section 2 (WPS) 3326. W. 001 Update Ongoing (for Pre-Series) Welding Book - section 4 Welding Operators (WOPQ) 3326. W. 001 0 0 Welding Book – section 1 -4 3326. W. 001 0 Update Ongoing (for Pre-Series) Quality Control Plan – RFD Prototypes (MIP) 3326. F. 001 2 Update Ongoing (for Pre-Series) Quality Control Plan – Deep Drawing of Cu Test 3326. F. 002 0 Approved Cleaning & Chemical Etching 3326. S. 004 1 Approved Identification, Marking, Traceability 3326. S. 001 1 Approved Radiographic Examination (RT) 3326. S. 005 1 Approved Radiographic Test Extent Radiographic Tests Extent 1 Update Ongoing (for Pre-Series) Manufacturing Sequence 3326. S. 008 0 Update Ongoing (for Pre-Series) Helium Leak (LT) 3326. S. 006 0 Waiting for comments (CERN) Dimensional Control 3326. S. 002 0 Waiting for comments (CERN) Visual Inspection 3326. S. 003 1 Approved Packing Procedure 3326. P. 001 0 Ongoing (Zanon) RFD Crab Cavity Drawing Package Update Ongoing (for Pre-Series) NOTA: The Eng. Spec. (EDMS 1389669) requires CERN approval for all procedures concerning Pre-series and Series production HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 18
Summary Schedule § CD-3 c ESAAB assumed in end of Oct 2020 § Achieving CD-3 c is critical to maintain schedule § Series cavities (fabrication and testing) are on critical path HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 19
302. 3 Cost & Schedule Performance CPI Charge 2 SPI § Slight underspending in LOE activities § Slightly ahead of schedule with Nb sheet procurements HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 20
Estimate at Completion Charge 2 § Variance at Completion for 302. 3 is +$138 k (underspending) § VAC driven by underspending in LOE compared to original estimates. § EAC automatically calculated and also manually adjusted if necessary (e. g. to account for upcoming BCRs) on a monthly basis as part of monthly status sheet updates. HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 21
Charge 6 Risk Register 302. 3 Open Risks § § § High Medium Low Total Threats 0 8 1 9 Opportunities 0 2 0 Total 0 10 1 Closed Risks (Managed or Retired) US-Hi. Lumi-doc-79 High Medium Low Total Threats 0 0 2 Opportunities 0 0 11 Total 0 0 Since CD-2 Baseline, we have retired/closed no risks and introduced/opened 2 new risks Total of 11 risks: 9 threats, 2 opportunities have been identified Threats include: vendor default on contract, cavity delivery delays, infrastructure breakdown, and cavity damaging due to mishandling. HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 22
ES&H for RFD Crab Cavities § We are working closely with ES&H coordinator (A. Pavnica) § FNAL crab cavity hazards have been included in AUP Hazard Analysis Report (#1121) Charge 5 US-Hi. Lumi-doc-1121 § All operations at Vertical Test Stand Facility, are regulated by operating procedures, checklists and safety documents § Hazards at ANL (chemical processing), fall under ANL/Phys. Division Super-Conducting Surface Processing Facility (SCSPF) ES&H § § SCSPF Hazard Analysis SCSPF Safety Analysis SCSPF Chemical Procedures … HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 23
Charge 7 Recommendations from Previous Review Recommendations Closed Open Anticipated Closure CD-1/3 a (Aug 2017) 4 4 0 Design Freeze (Mar 2018) 4 4 0 PDR/FDR (Jun 2018) 3 2 1 Jul 20201 Dir CD-2/3 b (Jul 2018) 5 4 1 Feb 20202 CD-2/3 b (Dec 2018) 6 4 2 Jul 20203, Dec 20214 TOTALS 22 18 4 Open recommendations: 1. “Hold a FDR” – planned 2. “Revision of FRS to include mag. shields" – draft under approval 3. “Finalize calculations and documents prior to FDR” – planned 4. “Perform cryostat test” – in CERN’s plan HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 24
Plans for CD-3 c Charge 2 § Process and Cold-Test AUP cavity prototypes § Conduct a Procurement Readiness Review for Pre-Series Bare Cavities – planned Mar 2020 § Conduct a Final Design Review of entire RFD scope by an external team (413. 3 b requirement) - planned June 2020 § Finalize and approve all necessary documentation § Acceptance Criteria, Interface Documents, Technical Specifications, Drawings, Manufacturing Plans, . . § Address open recommendations HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 25
Summary § In general work is proceeding well and in accordance to baseline for the RFD scope. § SPS tests at CERN uncovered an issue with beam-loading. Design iteration complete. § LARP prototypes continued to provide key validations for the design, processing and performance of crab cavities. § Procurement of raw materials (CD-3 b scope) is on schedule. Fabrication of cavity prototypes is progressing well. § Quality assurance is in accordance with HL-LHC and HL-LHC AUP requirements. It is integrated in all activities. § FDR and PRR are planned for 2020. Several documents need to be finalized together with CERN to maintain schedule for pre-series and series. § Dressed RFD crab cavities are on track for CD-3 c in July 2020 with the assumption that key documents are approved on time. HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 26
Backup Slides HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 27
302. 3 Resource Type Breakdown Money data is displayed in thousands of dollars HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 28
302. 3 Estimate Quality § Describe drivers … § Conceptual is for new activities on dressed cavities § The quality of estimate has been updated for CD-2/3 b HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 29
302. 3 FTE Breakdown HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 30
CD-3 b Scope Estimated Cost US-Hi. Lumi-doc-1341 HL-LHC AUP IPR DOE/SC Review– Jan 14 -16, 2020 31
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