# Presentation: 431147

## 3rd Harmonic Program Review

_**3**__**rd**__** Harmonic Program Review**_
- Cavity & Coupler Processing and Testing
- + Cold String Assembly

- Allan Rowe
- Fermilab
- AD/MSD
- November 8, 2005

## Overview & Scope

- _Overview & Scope_

- Schedule, Manpower Estimates, and Costs for:
-   Cavity Processing and Testing with Detailed Steps
-   Coupler Processing and Testing
-   Cavity String Assembly

## Cavity Processing and Testing Sequence

- _Cavity Processing and Testing Sequence_

- Preliminary Processing Cycle

- Vertical Performance Processing Cycle

- Titanium Vessel Weld

- Horizontal Performance Processing Cycle

- Cavity Storage

## Preliminary Processing Cycle

| Step | Description | Days | Techs |
| --- | --- | --- | --- |
| 1 | Receive cavity from fabrication | .125 | 1 |
| 2 | RF QC measurements | 1.25 | 1 |
| 3 | Degrease & dry | 1 | 1 |
| 4 | External etch (20um) | 3 | 2 |
| 5 | Degrease & dry | 1 | 1 |
| 6 | Internal etch (80um) | 3 | 2 |
| 7 | Degrease & dry | 1 | 1 |
| 8 | Bake (hydrogen degasification) | 2.5 | 1 |
| 9 | Tune for field flatness | 5 |  |
| 10 | Receive cavity from warm tuning | .125 | 1 |

- = 17.5 Days

## Vertical Perf. Processing Cycle

- = 11.125 Days

| Step | Description | Days | Techs |
| --- | --- | --- | --- |
| 11 | Degrease & dry | 1 | 1 |
| 12 | Internal etch | 3 | 2 |
| 13 | Rinse etching components & cavity | .125 | 2 |
| 14 | HPR & dry | .5 | 1 |
| 15 | Mount cavity to coupler & leak check | .5 | 1 |
| 16 | Mount to vertical test dewar & stage | .5 | 2 |
| 17 | Vertical Test | 4 | 1 |
| 18 | Remove VTD from cave | .375 | 2 |
| 19 | Remove cavity from VTD & coupler | .5 | 2 |

## Titanium Vessel Weld

- = 3.5 Days

| Step | Description | Days | Techs |
| --- | --- | --- | --- |
| 20 | Receive Ti vessel from fabrication | .125 | 1 |
| 21 | Clean Ti vessel and weld comp. | .25 | 1 |
| 22 | Purge and cap cavity | .25 | 1 |
| 23 | Weld Ti vessel to cavity | 2 | 2 |
| 24 | Leak check welds | .25 | 1 |
| 25 | Adjust HOM coupler | .5 | 2 |
| 26 | Receive cavity from RF work | .125 | 1 |

## Horiz. Perf. Processing Cycle

- = 13.625 Days

| Step | Description | Days | Techs |
| --- | --- | --- | --- |
| 27 | Degrease & dry | 1 | 1 |
| 28 | Internal etch (20um) | 3 | 2 |
| 29 | Rinse cavity and processing comp. | .25 | 2 |
| 30 | HPR & dry | .75 | 1 |
| 31 | Mount to side coupler and leak chk. | 1 | 2 |
| 32 | Mount & test tuner | 2 | 1 |
| 33 | Mount cavity to HTV | 1 | 2 |
| 34 | Horizontal test | 4 | 1 |
| 35 | Remove cavity from HTV, coupler | .625 | 2 |

## Cavity Storage

- = 11.125 Days

| Step | Description | Days | Techs |
| --- | --- | --- | --- |
| 36 | HPR & dry | .75 | 1 |
| 37 | Store cavity for cold string assembly | .25 | 1 |

## Cavity Processing  and Testing Schedule 

- _Cavity Processing  and Testing Schedule _
- _(6 cavities total)_

**Assumptions built into schedule:**
- 5 technicians are available 100% of the time for _processing activities_ by the time cavity #2 arrives.
- As many as 4 cavities are processed in parallel.
- Horizontal tests are equivalent to vertical tests in time and manpower requirements.
- All time gaps due to the delay in coupler delivery are removed.

## Cavity Processing and Testing Schedule cont...

- _Cavity Processing and Testing Schedule cont..._

- No cavity re-processing is required.
- Additional technicians are available to assemble and process couplers.
- No systematic problems. (UPW system, HPR, etc. operate 100% of the time).
- Other SCRF related activities (A0, BCP Facility, etc.) are fully supported through FY06.

## Cavity Processing and Testing Schedule cont...

- _Cavity Processing and Testing Schedule cont..._

- Processing six 3rd Harmonic 9-cell cavities concludes:
**Optimistic processing end date -- Middle of Sept. 2006.**

## Cavity Processing and Testing Schedule cont...

- _Cavity Processing and Testing Schedule cont..._

- A realistic schedule adds the following:
-   1 additional processing cycle/cavity = 8 wks
-   Systematic failures/delays = 3 wks
-   Additional time required for horizontal testing = 4 wks
**Realistic processing end date:   January 2007 **

***Shutdown interruption adds 14wks to above schedules!**

## Cavity Processing Manpower Requirements

- _Cavity Processing Manpower Requirements_

- Peak FTE’s:

- 3 Engineers
- 5 Technicians

- Current FTE’s:

- 1 Engineers
- 0 Technicians

## SCRF Mechanical Manpower Requirements

- _SCRF Mechanical Manpower Requirements_

- Peak FTE’s:

- 6 Engineers
- 8 Technicians

- Current FTE’s:

- 2.5 Engineers
- 6.75 Technicians

## SCRF Mechanical Manpower Conclusions

- _SCRF Mechanical Manpower Conclusions_

**Manpower needed going forward**:
-   50% Process Engineer (traveler development)
-   3 full-time technicians
-   1 Mechanical Engineer and 1 Designer for tooling work
-   RF Engineer as needed
-   Current stable of people working on  BCP Facility, A0 operations

## 3rd Harmonic Coupler Processing and Testing

- _3__rd__ Harmonic Coupler Processing and Testing_

**Schedule:**
-   Couplers arrive in bulk at the end of March
-   Coupler QC, Cleaning, Assembly, Baking ends mid April
-   Coupler testing takes 2 weeks/coupler pair
-   Coupler Processing concludes at the end of May

**Manpower Requirements:**

- 1 Technician, .25 Mech. Eng.,
- 0.5 RF Engineer
- April-May

## 3rd Harmonic Cold String Assembly

- _3__rd__ Harmonic Cold String Assembly_

**Schedule:**
-   Assembly fixtures are in A0 in early September.
-   Cavity string is assembled mid. Sept. through mid. Oct.
-   Cavity string is moved from A0 mid. October.

**Manpower Requirements:**

- 1.5 Technicians
- 0.5 Mechanical Engineers
- Mid. Sept. through Mid. Oct.

## 3rd Harmonic Processing Costs (M&S only)

- _3__rd__ Harmonic Processing Costs (M&S only)_

## Summary

- _Summary_

- Optimistic Schedule:
-   Cavity processing and testing begins early December and concludes mid. September.
-   Cold string assembly takes 1 month and concludes mid. October.
- Realistic Schedule:
-   Adds 3.5 months for cavity re-processing, infrastructure downtime, and horizontal testing.

## Summary cont...

- _Summary cont..._

- Manpower requirements:
-   3 Mechanical Techs., 1 Processing Engineer, 1 Mechanical Engineer, and 1 Designer all need to be added to the cavity processing team ASAP.
-   The current stable of people working on all SCRF related mechanical activities must be maintained.
-   At least 5 Technicians are available through the 14wk shutdown to do cavity processing and testing.

## Summary cont...

- _Summary cont..._

- Expected M&S Costs:  < $50k
- *Costs associated with A0, BCP Facility, etc. are not 3rd Harmonic Program specific and are covered by other cost codes.  Assembly fixtures, devices, and other hardware are covered by other cost codes.