CryoModule Test Stand Development of CryoModule Test Stand

Cryo-Module Test Stand Development of Cryo-Module Test Stand (CMTS) for Fermi Lab (R. L. Suthar, Head, CDM, BARC) Cryo-Module Test stand (CMTS) is a very sophisticated equipment. The stand is required for supporting and aligning a Cryo-Module, and also for providing the necessary facilities for maintaining the 2 K temp around the SCRF Cavities, which are held in particle free UHV condition, for testing the performance of the Cryo-module.

Cryo-Module Test Stand CMTS consists of following four sub-assemblies: (a) Feed box with transfer lines. (b) Feed Cap with transfer lines. (c) End cap with transfer lines. (d) Mechanical structure with alignment facility for supporting & aligning the Cryo-Module. These sub-assemblies have their corresponding instrumentation, and get connected to Cryogenic Supply Systems.

Cryo-Module Test Stand Fermi-Lab is planning to build a Cryo-Module Test Facilty to test 2 CMTS at the same time: CMTS 1 for 1. 3 GHz Cryo-Module and CMTS 2 for 650 MHz Cryo-Module. End Views of a CMTS, with a Cryo-Module

Cryo-Module Test Stand Parts of a Cryo-module 1. 3 GHz Elliptical Cavity without Helium vessel

Cryo-Module Test Stand Parts of a Cryo-module 1. 3 GHz Elliptical Cavity inside the Helium vessel

Cryo-Module Test Stand Cryo-Module Assembly

Cryo-Module Test Stand Cross section of a Typical Cryo-Module

Cryo-Module Test Stand CMTS will be used for • -- Testing of all Cryo-Modules • • • -- Carrying out Mechanical Checks -- Alignment of tubes, flanges etc. -- Leak check of all volumes -- Conditioning of main RF-Couplers -- Cryo-load measurement, Q etc -- SC magnet power test

Cryo-Module Test Stand CMTS at DESY Outer Bellows pulled back to access piping

Cryo-Module Test Stand Following stages need be followed for development of CMTS: 1 st Stage: Understanding and familiarization with Cryo-Module for which the CMTS is to be developed, and study of existing CMTS at Fermi Lab by a team of BARC Design / Manufacturing engineers. This includes understanding the detail requirements, salient features, critical aspects and functions of all related sub-systems. Study of detailed mechanical and cryogenic design inputs. 2 nd Stage: Finalization of design specifications and functional requirements of CMTS jointly by Fermi lab and BARC scientists. This includes study of requirements of all Mechanical, Cryogenic, Instrumentation systems etc. Finalization of functional testing stages and acceptance criterion before dispatch from BARC. 3 rd Stage: Conceptual design, design layout and assembly drawings of CMTS and it’s related systems (Mechanical, Cryogenic, heat shields and instrumentation etc). Finalization of Cryogenic circuits and Cryogenic joints.

Cryo-Module Test Stand 4 th Stage: Design calculations, Solid modeling and Analysis of all Mechanical systems, Cryogenic systems (Thermal analysis and temperature distribution etc), piping, joints, heat shield and instrumentation. Design calculations for cryogenic liquid flow rates to different sub-systems, Selection of cryogenic pumps, valves and instruments. Preparation of Design report. 5 th Stage: Finalization of General Assembly drawing (including all systems, sub-systems and instrumentation) including bill of materials. 6 th Stage: Procurement of raw materials and standard items including instrumentation. Fermi Lab need to provide support, as and when needed, for imported (difficult to procure) items. 7 th Stage: Detailed manufacturing drawings of all sub-assemblies and components for their manufacturing. 8 th Stage: Finalization of inspection and testing stages (weld tests, vacuum tests etc. at BARC and at Fermi Lab. ).

Cryo-Module Test Stand 9 th Stage: Manufacturing and Assembly of sub-systems. Functional testing of each sub-system. (If any sub-system does not meet the requirements, necessary modifications are to be done to meet the final requirements). It is to be ascertained as to what additional facilities / support systems are feasible to be procured and installed at BARC for the purpose. 10 th Stage: Assembly of complete system, inspection and final functional testing of the complete system. 11 th Stage: Dismantling, packing and shipment to Fermi Lab. Installation of CMTS at Fermi-Lab. 12 th Stage: Installation of Cryo-Module on CMTS at Fermi-Lab for further testing. Final Stage: Final functional testing, with Cryo-Module, at Fermi-Lab.

Cryo-Module Test Stand Design Requirements 1. Mechanical Requirements (Full details are awaited from Fermi Lab) 2. Cryogenic Requirements (a)The system shall support controlled cool down of Cryo-Modules. The design of the SCRF Cryo-Module limits the rate at which these components can be cooled down from room temperature to approximately 150 K. (b) The system is expected to operate for 20 years with an estimated 12 tests per year per CMTS. (c) The system shall be equipped with an appropriate control system. (d)The system shall be able to accommodate connections to a particle free cavity vacuum system.

Cryo-Module Test Stand Cryogenic Requirements (contd): (e)The system shall utilize J-T heat exchangers. The J-T heat exchanger shall provide high-efficiency heat exchange with a minimal pressure drop. (f) The system and its components are subject to comply with Fermi. Lab ES&H Manual (FESHM), in particular, FESHM chapters 5031, 5031. 3, 5032, 5033, 5064. (Copies of these standards are awaited from Fermi-Lab) (g)The test cave’s ODH (Oxygen Deficiency Hazard) classification shall not exceed ODH class 1 as defined in the FESHM 5064. (h) The system shall provide for protection of Cryo-Modules from over pressure. (i) System shall be manufactured using industry accepted QA procedures and standards. ISO accepted testing procedures and standards shall be used for system and component tests.

Cryo-Module Test Stand Cryogenic Requirements (Contd): (j) Insulating vacuum and thermal shield system shall provide for reasonable static heat load. (k) System shall provide for proper protection of process fluids from contaminations. (l) System shall be designed for flexibility to allow thermal contraction while maintaining proper restraint for all over pressure conditions. (m)The CMTF (Cryo-Module Test Facility) shall provide for independent operation of the two test stands, including transient modes, e. g. warm-up, cool-down, etc. (n) The system shall support heat load measurements of components under testing within 20% of accuracy. -----

Cryo-Module Test Stand THANKS