wbs x.8 rf systems

10/16/06 Main Linac RF Systems 1

WBS x.8RF Systems


FY08-09 Overarching Goals

• Demonstrate rf system performance at the level

required for the TDR

– Design approaches finalized

– Industrial versions built

– Reliability measured at few 10 khr level

– Cost and path to mass production understood

– Potential vendors identified.

• Use an ILC-like rf source in a ‘string test’ to power an

rf unit (3 cryomodules).


FY08-09 Program Overview• FY08

– Target 1 = 10 M$

– Target 2 = 12 M$

• FY09

– Target 1 = 12 M$

– Target 2 = 17 M$


Target 1 and Target 2

FY08 FY08 FY08 FY09 FY09 FY09FTE Direct M&S Total FTE Direct M&S Total

Design 2.8.2 Acc components 4 0 745 4 0 745R&D 3.8.1 Modulator 7 2625 4276 3 2025 2795R&D 3.8.2 Klystron 5 975 2053 1 4200 5016R&D 3.8.3 RF Distribution 4 700 1457 4 900 1687R&D 3.8.4 Couplers 4 1116 2029 5 956 2031R&D 3.8.6 RF Source Test 0 0 0 2 0 373Infra 5.8.1 Test Stands 4 900 1780 8 2470 5387

Total 27 6316 12340 26 10551 18033

Target 2

Target 1

FY08 FY08 FY08 FY09 FY09 FY09FTE Direct M&S Total FTE Direct M&S Total

Design 2.8.2 Acc components 3 0 512 3 0 512R&D 3.8.1 Modulator 5 1800 2955 3 1450 2133R&D 3.8.2 Klystron 5 975 2053 1 2800 3406R&D 3.8.3 RF Distribution 4 400 1112 4 750 1515R&D 3.8.4 Couplers 4 384 1094 5 528 1446R&D 3.8.6 RF Source Test 0 0 0 2 0 279Infra 5.8.1 Test Stands 4 650 1400 7 1537 3081

Total 23 4209 9125 23 7065 12372


Target 2 Funding Program

• 2 DFM Marx (started in FY07)

• 6 Modulator Production Units

• 2 Second Generation 10 MW MBKs (started in FY07)

• Sheet Beam Klystron (started in FY07)

• 6 Klystron Production Units

• 4+4 RF Distributions Systems to FNAL (1½ in FY07)

• 32+32 Processed Couplers to FNAL (12 in FY07)

• Coupler Development at FNAL and SLAC

• 1 Production RF Source to FNAL and 5 at SLAC

• RF system for new CM Test Stand in FY09


Target 1 Funding Program

• 2 DFM Marx (started in FY07)

• 4 Modulator Production Units

• 2 Second Generation 10 MW MBKs (started in FY07)

• Sheet Beam Klystron (started in FY07)

• 4 Klystron Production Units

• 1+2 RF Distributions Systems to FNAL (1½ in FY07)

• 8+16 Processed Couplers to FNAL (12 in FY07)

• Coupler Development at FNAL and SLAC

• 1 Production RF Source to FNAL and 3 at SLAC


Modulators• Goal: Down select ILC modulator design by FY07-Q3 and have

industry build six units: five for long term test at ESA and one for use

at FNAL in FY09 for ILCTA.

• Candidates

– Baseline designs at DESY (PPT, ABB, FUG, Poynting), KEK

(Nichicon) and FNAL(FNAL,SLAC)

– SLAC Marx Generator

• First Prototype in early FY07

• Build two DFM versions by early FY08

– DTI Direct Switch Modulator

• Expect delivery to SLAC in early CY07

– DTI Marx Generator

• SBIR funded – expect sometime in CY08 (not factored into program)


Modulators (cont)

• Infrastructure/Testing

– RF Test Stands at FNAL, DESY and KEK

• Generally run at less than max power for cryomodule operation.

– SLAC ESB

• Two new dedicated test stands in FY07 capable of 24/7 operation

– Evaluate Marx and DTI modulators in FY07

– Test two DFM Marx versions in FY08 (if Marx selected).

– SLAC ESA

• Run five new test stands 24/7 in FY09 with industry built modulators

– FNAL ILCTA-NML

• Run three cryomodules with industry built modulator in FY09


Modulator WBS

• 3.8.1.1 - Charging Supply: Build prototype and upgrade to power up

to six modulators at SLAC (Common 8kV SCR + Individual 4kV

Switching Supply design). Supply single-unit switching supply to

FNAL in FY09 for 3-cryomodule test.

– For Target 1 scope, build 3 charging supplies for SLAC, 1 for

FNAL.

• 3.8.1.2 – Interlock/Monitoring System: Develop HA interlock and

monitoring system based on experience with two new stations in

FY07. Build six of them, one of which will need to interface with

FNAL controls system

– For Target 1 scope, build only 4 systems.


Modulator WBS (cont)• 3.8.1.3 – DFM Marx: Complete fabrication of two Marx DFM units and

test at SLAC ESB (half of cost in FY07). DTI modulator or original Marx

to be sent to FNAL for 5 MW TH2104C klystron in NML injector.

• 3.8.1.4 – Production Modulators: Based on performance/cost of Marx

and DTI modulators at SLAC and Pulse Transformer modulators at

DESY, KEK and FNAL, purchase three unit each from two vendors.

Five to be installed in ESA and one shipped to FNAL.

– For Target 1 scope, build 4 production units (3 at ESA, 1 for FNAL)

• 3.8.1.5 – Modulator Evaluation: Participation by modulator experts at

FNAL in performance and cost evaluation of the various modulator

designs at DESY, FNAL, SLAC and KEK.


Klystrons• Goal: Down select klystron design by end of FY08 and have industry

build six units: five for long term test at ESA and one for use at FNAL in FY09 for ILCTA-NML

• Candidates

– Baseline 10 MW MBK• DESY

– Thales: 4 vertical tubes tested (none robust) and 4 in pipeline

– CPI: 1 vertical tube tested at DESY – low efficiency

– Toshiba: 1 vertical tube test at DESY – OK with > 200 hrs operation

– Request for bids by DESY for ~ 3 horizontal tubes

• SLAC

– Buy 2nd generation vertical tubes from Toshiba and CPI in FY07

– SLAC 10 MW Sheet Beam Klystron• Design well along – build two generations of tubes in FY07-08


Klystrons (cont)

• Infrastructure/Testing

– RF Test Stands at FNAL, DESY and KEK

• Generally run at less than max power for cryomodule operation.

– SLAC ESB

• Two new dedicated test stands in FY07 capable of 24/7 operation

– Evaluate Toshiba & CPI MBKs and SLAC SBKs in FY07/08

– SLAC ESA

• Run five new test stands 24/7 starting in FY09 with industry built

klystrons.

– FNAL ILCTA-NML

• Run three cryomodules with industry built klystron in late FY09


Klystron WBS

• 3.8.2.1 – MBK – Evaluate two 10 MW klystrons purchased in FY07 from

Toshiba and CPI in the two test stands in ESB (started in FY07). Includes

cost for solenoid power supplies, moving fixtures and supports.

• 3.8.2.2 – SBK – Complete first full power prototype sheet-beam klystron

(beam stick completed and full power prototype started in FY07). At ESB,

test beam stick before CPI klystron and full prototype after finish Toshiba

klystron.

• 3.8.2.3 – Production Klystrons: Based on performance/cost of vertical MBKs

at SLAC, horizontal MBKs DESY and the SBK at SLAC, purchase three unit

each from two vendors. Five will be installed in ESA and one shipped to

FNAL.

– For Target 1 scope, build 4 production units: 3 for SLAC, 1 for FNAL


RF Distribution• Goal: Develop low cost, efficient and agile distribution system and have

three, 8-cavity systems in operation at FNAL in FY09

• Changes being considered to baseline

– Add adjustable tap-offs to maximize cavity gradients

– Feed cavities in pairs via 3 dB hybrids to eliminate circulators

– Use simpler phase shifters in place of three stub tuners

– Use WR770 in place of WR650 for long waveguide runs

– Weld Al waveguide in-situ instead of using flanges

• Testing

– Evolve design and provide FNAL one per year in FY07, 08 and 09.

– First two will have optional circulators to allow beam operation with

n spacing of the cavities in the cryomodules.


RF Distribution WBS

• 3.8.3.1 – Component R&D – Continue studies to lower cost of

components and develop techniques for mass production (e.g.

welding instead of flanges).

• 3.8.3.2 – Distribution Systems for FNAL – In FY08, complete second

8-cavity system started in FY07 for TTF3 cryomodule, together with

3 more, and in FY09, build 4 ILC prototype 8-cavity systems for

Type-4 cryomodule. These systems, like the first one in FY07, would

be assembled and tested at SLAC and then shipped to FNAL to be

installed at NML and at CM test facility.


Couplers• Goals:

– Understand processing limitations and evaluate surface contamination

– Clean, bake, assemble and rf process coupler pairs for FNAL cavities

– Revaluate TTF3 and other designs to reduce manufacturing cost

• Program (collaboration of SLAC/LLNL/FNAL with Orsay/KEK input )

– FY07

• RF process coupler parts

• Build class 10 clean room in B006 and do surface contamination studies

• Assemble and rf process 12 CPI couplers bought by FNAL

– FY08-09

• Supply up to 32 couplers per year for FNAL cavities

• Revaluate coupler dimensional tolerances and assembly techniques and

produce low cost versions at SLAC. Explore alternative designs at FNAL.


Coupler WBS• 3.8.3.1 – Coupler R&D – Modify TTF3 design to lower cost and improve

performance based on SLAC R&D in FY07, and on continuing R&D at Orsay and KEK. Build two prototypes each in FY08 and FY09.

– For Target 1 scope, this program would be descoped.

• 3.8.3.2 – Coupler Design – Explore alternate coupler designs using rf modeling programs.

• 3.8.3.3 – Supply 32 TTF3 couplers in FY08 and 32 in FY09 to FNAL. SLAC would purchase couplers, assemble and rf process at ESB using the facilities developed in FY07.

– For Target 1 scope, only 8 couplers would be produced in FY08, and 16 in 09, which with those from DESY and those produced at SLAC in FY07, would allow three cryomodules to be operated at NML by the end of FY09.


RF Sources/Unit Test

• At SLAC-ESA, do long-term reliability testing of five production rf sources.

• At FNAL-NML, power three cryomodules with rf system having

– High efficiency, high power factor charging supply

– 120 kV, 130 A, 1.6 ms, 5 Hz modulator

– 10 MW, 65% efficient klystron

– Low loss rf distribution system with adjustable tap-offs

– High power couplers with adjustable Qext

– Control system with interface to HA LLRF system and

modulator/klystron interlocks.

– ILC-like cooling system for klystron and racks

• Operate accelerator with ILC-like bunch trains for few thousand hours.


RF Source Test WBS• 3.8.5.1 – Operation and Evaluation – Starting in FY09, install and

operate five production klystrons and modulators in ESA (high power rf terminated in ferrite loads). Record data on performance to characterize reliability. Run 24/7 into FY10 to integrate at least 30,000 hours in total at full power and repetition rate.

– For Target 1 scope, labor effort is reduced.

• 5.8.1.1 – ESB Test Stand Maintenance - Maintain three L-band test stands in ESB for component, modulator and klystron testing.

• 5.8.1.2 – ESA Test Stand Facilities - Install facilities in ESA in support of six test stands (only five would be used). Includes water, power, charging supply cable distribution, containment tanks, fire suppression and safety systems.

– For Target 1 scope, 4 test stands would be implemented (only 3 would be used).


RF Source Test WBS (cont)

• 5.8.1.3 – ESA Test Stand Controls - High level controls for the ESA test stands.

– For Target 1 scope, this effort would be reduced.

• 5.8.1.4 – ESA Test Stand Maintenance – Starting in FY09, maintain five L-band test stands in ESA for modulator and klystron testing.

– For Target 1 scope, the effort would be reduced to maintain 3 test stands.

• 5.8.1.5 – Send Klystron/Mod to NML - In FY09 send production modulator, klystron and waveguide to connect to existing rf distribution systems at cryomodules for rf-unit test. Send SLAC experts as needed.


RF Source Test WBS (cont)

• 5.8.1.6 – NML RF Station Install/Operate/Maintain – Starting in FY09,

install, operate and maintain SLAC-supplied L-band station at FNAL-

NML. Integrate interlock system with FNAL control system.


RF System Integration• Goal: Complete TDR engineering design of the rf system integrated

with the other systems in the beam and service tunnels

• Interface with CF&S Group to finalize

– Electrical connections and line loading specifications

– Cooling connections and water flow and temperature stability

requirements

– Rack and RF component layouts

• Interface with the Installation Group to

– Design equipment and procedures to install components

– Develop installation schedule and component check out scheme

• Interface with Controls Group to

– Provide high level interface to interlock and LLRF system


Accelerator Design

• 2.8.1 – Accelerator Design – covered in WBS x.7

• 2.8.2 - Accelerator Components

• 2.8.2.1 and 2.8.2.1 - RF Design at SLAC and FNAL: Write

specs and work with other technical systems (civil,

cryomodule, installation, controls) to create an integrated

design for the TDR.

– For Target 1 scope, this effort would be reduced.

wbs x.8 rf systems

Documents

test stands5

test stands465014007173733115

string test

rf systemsfy08

rf unit

target 1fy08

rf system design

rf source test000202793