# Presentation: 936716

## ILC cryomodule design task list

- Tom Peterson, Fermilab
- ILC Cryomodule Meeting
- CERN, 16 - 17 January 2006

## ILC cryomodule design task list introduction and tasks 1-3 (start 3-D CAD model, consider pipe sizes and segmentation) 

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Introduction:  TTF cryomodule is our reference 

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## TTF Module end

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## CERN meeting goals

- Technical
- Definition of what a T4CM is
- Identification of a comprehensive list of tasks to be accomplished in working toward the T4CM design
- Review the definition of the BCD module
- Organizational
- Formation of an international T4CM design team
- Identify who will do what
- Establish a timeline for T4CM design completion
- Future meetings---discuss when, where, frequency, etc.

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Module design tasks  

- Module design issues were collected by working groups at meetings, including but not limited to
- SLAC (14 - 16 Oct 2004)
- KEK (13 - 15 Nov 2004)
- DESY (6 - 8 Dec 2004)
- Snowmass (August 2005)
- SMTF collaboration meeting (5 - 7 Oct 2005)
- These issues were assembled into a draft list for this meeting

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Draft list of technical issues and tasks for discussion at CERN

- See MS Word document task summary
- This is just an attempt to organize the ILC module design effort into separate tasks which we can fairly independently pursue
- The list already includes a few names of people who have expressed interest in those topics
- The list is not intended to be in any way exclusive in terms of what we do or who does what!

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Draft list of technical issues and tasks for discussion at CERN, tasks 1 - 3 

- Task 1:  Begin a type IV 3-D model and drawing set by importing those features that will remain the same as type III+.
- Task 2:  Decide on pressure drop criteria and pipe sizes for the modules
- Task 3:  Design of a segmentation “spool” piece and other cryogenic boxes (included here to mention that a designs are needed and will interface with modules)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 9

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 1:  Type III ---> Type IV

- We have a general consensus regarding what needs changing
- Based largely on TTF experience, but also Jlab and others
- Consensus collected by working groups at meetings, including but not limited to
- SLAC (14 - 16 Oct 2004)
- KEK (13 - 15 Nov 2004)
- DESY (6 - 8 Dec 2004)
- Snowmass (August 2005)
- SMTF collaboration meeting (5 - 7 Oct 2005)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Features of type III cryomodule

- Allows for fixed couplers
- Invar rod and roller bearings allow cavities to remain axially fixed while the 300 mm tube shrinks
- Smaller cross section results in standard pipe size for outer vessel
- Axial position of last support changed to stiffen structure near quadrupole

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Type IV cryomodule will include the following features from Type III+

- 8 cavities per module
- Same cooling scheme and cryogenic system concept
- Same vacuum vessel diameter and 300 mm pipe diameter
- Nearly the same pipe locations and arrangement
- Same cavity centerline location relative to vacuum vessel
- Same support posts
- Same thermal shields concept, although coupler port locations move
- Same cavity support detail (300 mm header as structural backbone with cavities held by roller bearings and invar rods)
- Same input coupler (at least in terms of mounting and interface to vacuum vessel, cavity, and thermal shields)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cryomodule III model -- helium vessels in the vacuum vessel

- CAD model
- based on DESY design
- imported and modified
- by Don Mitchell, Fermilab

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cryomodule III model -- helium vessels in the vacuum vessel with input couplers and quadrupole

- CAD model
- based on DESY design
- imported and modified
- by Don Mitchell, Fermilab

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Helium vessel supports

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Support posts

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Thermal shield installation

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 18

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 2:  Module pipe sizes

- Compared to TESLA 500, heat loads for ILC are larger
- Larger flow rates
- Pressure drops and pipe sizes need review
- The review should include pressure drop criteria -- what pressure drops to allow

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## ILC cryogenic system overview

- Saturated He II cooled cavities @ 2 K
- Helium gas thermal shield @ 5 - 8 K
- Helium gas thermal shield @ 40 - 80 K
- Two-phase line (liquid helium supply and concurrent vapor return) connects to each helium vessel
- Two-phase line connects to gas return once per module
- A small diameter warm-up/cool-down line connects the bottoms of the He vessels (primarily for warm-up)
- Subcooled helium supply line connects to two-phase line via JT valve once per “string” (~12 modules)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cryo-unit (bcd:main_linac:ilc_bcd_cryogenic_chapter_v3.doc)

- Cryo-unit (bcd:main_linac:ilc_bcd_cryogenic_chapter_v3.doc)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cryo-string

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Module predicted heat loads

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## ILC cryogenic system much larger than TESLA 500

- 8 cryogenic plant locations
- Approximately 5 km spacing
- Each location with 2 cryogenic plants of about the maximum size -- each plant equivalent to about 24 kW at 4.5 K
- Each plant about 6 MW “wall plug” power
- ILC cryogenics about 100 MW total

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Module pipe sizes increase

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## (Increase

- diameter
- beyond
- X-FEL)

- diameter
- beyond
- X-FEL)

- (Review
- 2-phase pipe
- size and
- effect of slope)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 3:  Cryogenic unit segmentation and other cryogenic boxes 

- Segmentation issue is ultimately tied to reliability
- To be conservative, BCD should include features for cryogenic unit and vacuum segmentation
- Arbitrarily assume 5 segments per 2.5 km cryogenic unit, so about 500 m long on average
- Cryogenic string supply and end boxes, which may be separate from modules, are also required within the ILC lattice
- These all must be integrated with the module design

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Segmentation concept

- A box of slot length equal to one module
- Can pass through cryogens or act as “turnaround” box from either side
- Does not pass through 2-phase flow, so must act as a supply and/or end of a cryogenic string
- Includes vacuum break for insulating vacuum
- Includes fast-acting isolation valve for beam vac
- May contain bayonet/U-tube connections between upstream and downstream for positive isolation
- May also want external transfer line for 4 K “standby” operation (4 K only, no pumping line)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Segmentation box concept

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## ILC cryomodule design task list tasks 4 - 6 (cavity interconnect and tuners) 

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Draft list of technical issues and tasks for discussion at CERN, tasks 4 - 6 

- See MS Word document task summary
- Task 4:  Design the intercavity connecting flange and bolting arrangement, detail the new spacing
- Task 5:  Modify the slow tuner design to allow closer cavity-to-cavity spacing
- Task 6:  Modify the fast tuner design for proper piezo function

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 32

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 4:  cavity interconnect 

- Shorten cavity slot length
- Cavity beam pipe length change
- Bellows section -- minimum necessary
- Flange bolt installation is a problem
- Analyze slotted bellows flanges
- Consider cleanliness of bolt installation
- Consider effect on tuner (blade tuner ok?)
- 283 mm iris-to-iris (from TDR) is baseline (chosen for BCD and type IV)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Flange/Bellows Design Specs:
• Bolted flange (12 bolts/flange)
• Convoluted SS Bellows (10 waves, 54mm free length, ±25mm)
	-Length of bellows dictated by bolt length, old elastic parameters
• Bellows elastic requirements: ±4mm (~1mm thermal + ~3mm tuning)
• Aluminum Alloy 5052-H32 Diamond Hex Seal
• 7 Ton (~15,000 lbs) clamping force, 35 N-m torque/bolt
• Mechanical analysis done @ Desy, INFN 
	(Cornelius Martens, Roberto Paulon)

**Flange/Bellows Design Specs:**
- • Bolted flange (12 bolts/flange)
- • Convoluted SS Bellows (10 waves, 54mm free length, ±25mm)
- 	-Length of bellows dictated by bolt length, old elastic parameters
- • Bellows elastic requirements: ±4mm (~1mm thermal + ~3mm tuning)
- • Aluminum Alloy 5052-H32 Diamond Hex Seal
- • 7 Ton (~15,000 lbs) clamping force, 35 N-m torque/bolt
- • Mechanical analysis done @ Desy, INFN
- 	(Cornelius Martens, Roberto Paulon)

- _Interconnect:_
- Tesla TDR: 283mm
- Currently 344mm

- Need to be
- verified

- Salman Tariq

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## TDR:  344 mm reduced to 283 mm (110 63 110)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cavity iris-to-iris length 1036 mm. Cavity flange-to-flange now 1283 mm, TDR 1256 mm due to shorter ends

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cavity slot length

- Now 1036.2 +105.6 + 97 + 141.6 = 1380.4
- Suggest (from Helen Edwards) 1036.2 + 105.6 + 77 + 105.6 = 1324.4
- Gain ~4%, which may not seem like much, but gain ~ 1km for 20000 cav
- But also, the lambda/2 or not question
- Latest dimensions from Don Mitchell -- 1036.2 + 105.6 + 71.8 + 105.6 = 1319.2
- Note that 105.6 + 71.8 + 105.6 = 283 mm

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Cavity Interconnect

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Salman Tariq

**Propose a parallel effort here in trying to minimize cavity interconnect length:**

**A.  **_**Optimize existing Desy design**_ (shorter time frame- SMTF ’06 Mod #1?)
**	**We know this design works, lets try to see if we can further refine it:
- 	- Develop a comprehensive nonlinear (contact) FEA model using Ansys
- 	- Understand stresses, deflections, and most importantly contact pressure 	on sealing surfaces @ cryogenic temperatures
- 	- Use these results as a benchmark to evaluate future modified designs
- Possible design changes being looked at:
- 	1. Completely slotting bolt holes
- 	    (could reduce length by 20-30mm)
- 	2. Reducing flange thickness
- 	3. ... (open to suggestions)	    New Saclay Tuner(s) compatability?

**B.  **_**Evaluate alternative clamp systems & seal design **_(longer time frame)
**	**- Quick disconnect type (ILC industrialization)
- 		(e.g. JLab Radial Wedge Flange Clamp)
- 	  Issues of concern: cleanliness (friction=particulates)
- 			        difficult to get off once clamped
- 	- Niobium bellows?  Welded connections eventually...?
** **

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 5:  Modify slow tuner design

- Present lever tuner design takes cavity interconnect space.  Need modification for closer cavity-to-cavity spacing.
- Could modify lever tuner design
- Or go to blade tuner for type IV.  There appear to be some interferences.
- Reliability.  Are cold stepping motors a problem?  Feature like a port on module for access?  (Not for BCD; this is a longer term issue.)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 41

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Blade tuner concept 

- Blade tuner concept

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Invar rod interference with blade tuner (Don Mitchell)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Other slow tuner options 

- Modified Saclay lever tuner
- KEK slide jack tuner
- KEK coaxial ball screw tuner
- TJNAF Renascence tuner modified for ILC cryostat (“Renascence” is the Jlab 12 Gev upgrade module)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Stiffness measurements:
• FEA of 9-cell cavity reveals stiffness of:
	3,438N/mm (warm); 3,883 N/mm (cold) [Desy ~3KN/mm)
• Cavity shrinks 1.857mm from RT to 2K  (need to verify this with Desy?)
• Tuner mechanism/support stiffness to be measured experimentally using load cell and applied displacement
• Plan to develop FEA model of cavity–helium vessel assembly and simulate cryogenic/thermal loads from RT down to 1.8K. Apply tuning loads.  
	Study the effects of bellows and Ti vessel, plus evaluate integrity of end cone (flange) design.  Determine ‘equivalent’ stiffness of cavity assembly.

**Stiffness measurements:**
- • FEA of 9-cell cavity reveals stiffness of:
- 	3,438N/mm (warm); 3,883 N/mm (cold) [Desy ~3KN/mm)
- • Cavity shrinks 1.857mm from RT to 2K  (need to verify this with Desy?)
- • Tuner mechanism/support stiffness to be measured experimentally using load cell and applied displacement
- • Plan to develop FEA model of cavity–helium vessel assembly and simulate cryogenic/thermal loads from RT down to 1.8K. Apply tuning loads.
- 	Study the effects of bellows and Ti vessel, plus evaluate integrity of end cone (flange) design.  Determine ‘equivalent’ stiffness of cavity assembly.

**CC2 Tuner Analysis Work**

**Kinematics & Mechanics of Tuner:**
- • Properly understand kinematics of Saclay Lateral Tuner
- • Geometric modeling in IDEAS
- • Actual measurements using digital dial indicators

- Salman Tariq

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 6:  Modify fast tuner design

- Modify the fast tuner design for proper piezo-electric actuator function
- Support structure
- Tuning range
- Also consider modifications to the design for magnetostrictive fast tuner
- Fermilab has a fairly large effort on fast tuner designs

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 47

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## • Part of ongoing work on Capture Cavity 2
• Using Saclay Lateral Tuner 1 (below) with Piezoelectric fast tuning (below right)

- • Part of ongoing work on Capture Cavity 2
- • Using Saclay Lateral Tuner 1 (below) with Piezoelectric fast tuning (below right)

**Problems/Issues:**
- • Piezo preload not clearly defined
- • Large coarse tuning parameters
- 	(cavity in compression)
- • Cryo/vacuum loads during cool down not clearly understood
- • Results in large tensile loads on piezo bracket = loss in preload
- • Also side loads on Piezo bracket an issue with this tuner design

- Salman Tariq

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Piezoelectric Fast Tuner

**Piezoelectric Fast Tuner**

- Piezo-Actuator:
- l=39mm
- Umax=150V
-  l=3m at 2K
- fmax,static=500Hz

- Courtesy: Lutz Lilje, Desy (5-10-2005)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## We have developed an instrumented Piezo Bracket to understand force loads:
• Design is an instrumented version of the Desy single Piezo fixture
• Addition of “bullet” piece (instrumented with strain gages) in line with piezo
• Strain gages also mounted on tie rods and top bracket at clevis end
• Warm testing starting this week

- • Design is an instrumented version of the Desy single Piezo fixture
- • Addition of “bullet” piece (instrumented with strain gages) in line with piezo
- • Strain gages also mounted on tie rods and top bracket at clevis end
- • Warm testing starting this week

- Salman Tariq
- Ruben Carcagno
- And others

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Instrumented Piezo Bracket Drawing (FNAL)

**Instrumented Piezo Bracket Drawing (FNAL)**

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Piezo Kinematics

**Piezo Kinematics**

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## ILC cryomodule design task list tasks 7 - 12 (quad package and support scheme)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Draft list of technical issues and tasks for discussion at CERN, tasks 7-12

- See MS Word document task summary
- Item 7:  Quad support details for hanging from 300 mm tube in module center
- Item 8:  Quad current leads
- Item 9:  Vibrational analysis of support structure
- Item 10:  Shipping loads, stability, and restraints
- Item 11:  Active quad movers for remote realignment
- Item 12:  Separate quad cryostat (alternative design)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 55

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 7:  Quad package and support 

- Quad “package” includes quad, steering dipole(s) and beam position monitor (BPM)
- In type IV design, mount at center post for best stability, alignment and vibration
- Quad package is still a major unknown; we can only estimate an “envelope” size now
- Evaluate and further develop BPM for resolution and clean room compatibility

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## What Tolerances are Important? (Nick Walker)

- When beam dynamics people talk about cavity (or quadrupole) alignment, they refer to the EM centre of the field of interest:
- Cavities: electrical centres of the HOM (transverse dipole modes  wakefields)
- Quadrupoles: magnetic centre of field(null-point  no dipole field)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Quad (from TDR table 3.3.3)

- Quad (from TDR table 3.3.3)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Dipoles (from TDR table 3.3.3)

- Dipoles (from TDR table 3.3.3)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Quad package (from TDR table 3.3.3)

- Quad package (from TDR table 3.3.3)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## TDR Quad/steerer-BPM package

- We should clarify what is necessary for beam based alignment -- positional stability, vibration, BPM resolution.

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## QBPM TESLA and option 2 (Helen)

- Option 2 has the same spaces for QBPM elements and additional 335 for steerer  separate, for overall length of 1222 instead of TESLA 887

- 887

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## BPM length

- BPM (e.g. reentrant Saclay): 170mm (Lutz Lilje in 11 January e-mail and also described at http://www-user.slac.stanford.edu/star/images/ILC%20Linac%20Issues.htm#packing_fraction)
- 1222 mm quad package on previous slide assumed 66 mm BPM

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Possible resulting quad package length for BCD:  1326 mm

- Avoid nesting of quad and steering magnets
- Need to be conservative in selecting length without knowing details
- 77 (end) + 170 (BPM) + 666 (quad) + 335 (steerer) + 78 (end) = 1326 mm (quad + BPM + steerer package)
- Perhaps 170 mm less if can nest BPM and steerer magnets
- But there may be additional space needed for magnetic shielding of the quad stray field from adjacent cavities

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 8:  Quad current leads 

- Quad at 2 K in subatmospheric helium, so no vapor flow from quad
- Leads are conductively cooled, at least at cold end
- TDR quad is 100 amps; HTS may be advantageous
- With steerer magnets, multiple 40 A lead pairs (from TDR)
- Need current lead flexibility for final alignment of quad in cryostat

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 9:  Vibrational analysis   

- Analyze quad supports and module for vibrational stability
- Need vibrational stability requirements (next slide)
- Could build and test a physical model for verification of analytical model
- Flow rates at TTF about factor 100 less than ILC -- flow-induced vibration should be checked
- Perhaps a high flow test at TTF (?)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Vibrations (from Nick Walker)

- Cavities: don’t care
- cavities will not vibrate at the 300 m level
- Quadrupole: somewhat critical
- assume <100 nm RMS
- Generates ~1 *y* oscillation at linac exit
- couple additional nm emittance growth
- beam collision OK (fast feedback) but collimator wakefields may be problematic
- more feedback may help: work to do!
- Bottom line: try and keep quad vibration at or below 100nm level
- “cryomodule” should not add additional vibration above ground motion.

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 10:  Shipping   

- Cavity and quad positions in module need to be stable in shipping from final test location to linac location
- Analyze expected loads
- Design shipping restraints
- Define shipping requirements

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 11:  Active quad mover design   

- The task could start with an attempt to determine the need (or not) for remote-controlled quad alignment and specification for active movers.
- Can equivalent be achieved via corrector magnets?
- Active quad mover design
- Probably not incorporated into Type IV; an alternative for later modules

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 12:  Separate quad cryostat -- a parallel design effort   

- Tom Nicol presentation

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## ILC cryomodule design task list tasks 13 - 15 (module ends, interconnect, length)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Draft list of technical issues and tasks for discussion at CERN, tasks 13-15 

- See MS Word document task summary
- Task 13:  Design module end to accommodate the input coupler at the far end of the cryostat
- Task 14:  Module-to-module interconnect design
- Task 15:  Module slot lengths

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 73

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 13:  Module end configuration

- When quad is at the center or absent, the vacuum flange interferes with input coupler port
- Result is 363 mm extra length needs to be added to make room for the input coupler port
- The module with quad in the center is longer than the TTF module (quad at end) with other factors such as cavity spacing the same

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 14:  Module-to-module interconnect 

- Need layout for automatic end pipe welding
- Minimize space (850 mm vacuum flange to vacuum flange in TTF)
- Two beam vacuum isolation valves (each end of modules)
- HOM absorber in interconnect space
- 2-phase pipe to 300 mm header cross-connect in interconnect space

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 76

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Interconnect HOM absorber

- Broadband HOM: 270mm (Lutz Lilje in 11 January e-mail and also described at http://www-user.slac.stanford.edu/star/images/ILC%20Linac%20Issues.htm#packing_fraction)
- Note that earlier assumptions have included a shorter, 210 mm, HOM absorber

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 15:  Module slot length   

- A slot length results from integration of many of the other tasks
- Current assumptions imply 12565 mm with a quad and 11271 without a quad, for a packing factor of 0.71
- Calculated over three modules with one quad per three modules
- Not including cryogenic boxes and other drift space
- For RDR we need an estimate soon

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Module length choices (some history of previous considerations, next 3 slides from Helen)

- Options
- Make just as long as required for TESLA TDR Quad/BPM design length
- * Make as long as present module 12200
- Make the Quad/BPM slot length same as a cavity
- * Arbitrarily have chosen 12200 mm module slot length for the following slides

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Option 2 measurements from center post

- This was assuming that we wanted to keep the present slot length of 12200 and that the extra space would go toward QBPM package for its development. Its space might become less when its design better understood.

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## 2nd option module layout

- Symmetric posts but are they not out far enough?
- Difficulty at module interconnect??
- What are the interconnect constraints and possibilities?
- This layout has 1473 between vac vessel ext interferences. That would give an interface opening of 735, present opening is nominally 850

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Module lengths & QBPM

- 1st 1256+89, 2nd 1247+77+2

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## ILC cryomodule design task list tasks 16, 17 and conclusions (module instrumentation and tests)

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Draft list of technical issues and tasks for discussion at CERN, tasks 16-17 

- See MS Word document task summary
- Task 16:  Develop module test plans and module component test plans
- Task 17:  Design of instrumentation for installation into the module
- Conclusions

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 85

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 16:  Module test plans 

- What must be done on a module test stand, and what instrumentation and features are required?
- Thermal measurements
- Alignment verification, etc.
-  What earlier (before final cold test) tests of the module and module components should be done for QA, QC, and understanding module performance?
- Tie-in to module test stand design

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Task 17:  Module instrumentation

- What special instrumentation is required to be built into the module for understanding performance both on the test stand and in the test linac?
- Additional temperature sensors
- Wire position monitor or another system (such as optical windows) to verify cavity positional stability with thermal cycles
- Etc.

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Slide 88

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Conclusion:  There remain many critical open design issues

**Quad/corrector/BPM package is a major unknown right now and goes into the heart of the module **
- Tuner details, slow and fast, but especially fast tuner, and tuner reliability** **
- Vibrational analysis, which will be compared to measurements for verification of the model for future design work
- Development of module and module component test plans
- Verification of cavity positional stability with thermal cycles
- Design of test instrumentation for the module
- Robustness for shipping, analysis of shipping restraints and loads, shipping specifications
- Active quad movers(?)  A complication

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Additional goals from Chris Adolphsen-- RDR module and cryosystem definition 

- Length of cryomodules with and without quads
- Answer:  12565 mm with a quad and 11271 without a quad
- External support of cryomodules (e.g. from the floor or ceiling)
- Answer:  from the floor until forced otherwise
- Beamline and insulating vacuum segmentation
- Answer:  segmentation box every 500 meters
- Cryogenic maintenance length and the additional space required between segments
- Asnwer:  segmentation box of one module slot length every 500 m
- Space required to convert from cold to warm sections
- Answer:  1.5 meter transition
- Refrigerator spacing, capacities and space requirements
- Results to come from cryogenic system effort

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## BCD/RDR versus Type IV

- The module design for the RDR should be well-understood and conservative, in order to have confidence in the cost estimate
- Type IV is a new development, requires design effort, consideration of various options, over a time period of a few years
- These efforts diverge at some point -- BCD/RDR is a fixed reference with more risky alternatives (ACD) while we move on with type IV design development
- We should review and confirm the previous slide’s responses to the requests from Chris

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Organization of effort 

- An international effort
- Need division of tasks to make best use of our resources
- Minimize duplication of efforts
- Take advantage of ideas and expertise
- Pursue options with parallel efforts
- Each institution has limited resources
-  Work has begun
- Fermilab has organized a group to do type IV design, other labs have also expressed interest and/or begun

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Type IV probable schedule

- Design module -- 12 - 24 months (2006 - 2007)
- Magnet/BPM package
- Tuners, etc.
- Integrate into module design
- Build and test -- 12 - 18 months (2007 - 2008)
- In addition to module, need module test stand and test facility!
- Total 2 to 3 1/2 years, depending on scope of work and availability of resources.

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## X-FEL Modules

- 100+ modules will be industrially produced
- Brings us to the level of manufacturing quantities
- Some differences from ILC, but much of module design and manufacturing is the same
- Cavity supports, thermal shields, MLI, vacuum vessel assembly, internal piping, etc.
- X-FEL experience will be important and valuable part of ILC module development
- X-FEL module effort will stay ahead of ILC effort
- Remain in close contact and take advantage of similar designs, experience, and industrial input to design

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## After Type IV--> increasing quantities

- Experience with large quantities of SC magnets follows an old engineering “rule” (factors of 10)
- 1 prototype
- 10 pre-production prototypes
- 100 first production run (X-FEL!)
- Not “throw-aways” but slower production, still making adjustments, relatively large fraction of reject/rework
- 1000 full production run
- There are design changes and manufacturing method changes at each stage

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Industrialization, impact on design

- Economy of materials and labor will always be considerations in our designs
- But right now the emphasis is still on viability
- As we move to production of quantities of modules in industry, the design will continue to change
- Reduction of required labor
- Less costly materials
- Less costly manufacturing of components
- Design for more efficient assembly

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Type IV is not the (final) ILC design

- Test results of types III and IV will teach us a lot
- There will be some choices beyond type IV from parallel development efforts
- Industrialization will have a significant impact on the design
- Type IV is the next step in module design for ILC

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Acknowledgements 

- Throughout these presentations, I have included slides from various other people
- Especially Carlo Pagani and Helen Edwards provided summaries of module features and design direction
- But, of course, most information came ultimately from the TTF collaboration

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## TESLA-style module information . . .

- _[http://ilc.desy.de/e627/e634/e730/e745/index_eng.html](http://ilc.desy.de/e627/e634/e730/e745/index_eng.html)_
- Links to talks presented by Lutz Lilje, Axel Matheisen, W.-D. Mueller, Bernd Petersen, Nick Walker, and others at our December 6 - 7, 2004, module meeting at DESY
- _[http://lcdev.kek.jp/ILCWS/](http://lcdev.kek.jp/ILCWS/)_
- “First ILC workshop,” November 13 - 15, 2004 at KEK
- _[http://tesla-new.desy.de/content/index_eng.html](http://tesla-new.desy.de/content/index_eng.html)_
- DESY TESLA page with link to the TESLA Design Report and other information including talks and posters from the March 2004 ITRP visit

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting

## Sources of Information

- Bernd Petersen, Lutz Lilje, Axel Matheisen, Nick Walker, Hans Weise, and others (DESY)
- Carlo Pagani (INFN)
- Terry Garvey (LAL-Orsay)
- Helen Edwards, Tom Nicol, Don Mitchell, Harry Carter, Salman Tariq, and others (Fermilab)
- John Weisend (SLAC)
- TESLA TDR (March 2001)
- And others!

- Tom Peterson

- 16-17 January 2006       Cryomodule Meeting