2. TESLA Cryomodule Design Ratinales
High Performance Cryomodule was central for the TESLA Mission
More then one order of magnitude was to be gained in term of capital and operational cost
High filling factor: to maximize real estate gradient
Long sub-units with many cavities (and quad): cryomodules
Sub-units connected in longer strings
Cooling and return pipes integrated into a unique cryomodule
Low cost per meter: to be compatible with a long TeV Collider
Cryomodule used also for feeding and return pipes
Minimize the number of cold to warm connections for static losses
Minimize the use of special components and materials
Modular design using the simplest possible solution
Easy to be alligned and stable: to fullfil beam requirements
FNAL Module
December 6, 2004
Carlo Pagani

3. Performing Cryomodules
Required plug power for static losses < 5 kW/(12 m module)
Reliable Alignment Strategy
Sliding 2 K
“Finger Welded” Shields
Three cryomodule generations to:
improve simplicity and performances
minimize costs
FNAL Module
December 6, 2004
Carlo Pagani

4. Cryoodules installed in TTF II
RF gun
400 MeV
120 MeV
800 MeV
ACC 1
ACC 2
ACC 3
ACC 4
ACC 5
4 MeV
ACC 4 & ACC 5
ACC 2 & ACC 3
FNAL Module
December 6, 2004
Carlo Pagani

5. Cry2 to Cry3: Diameter Comparison
FNAL Module
December 6, 2004
Carlo Pagani

6. From Prototype to Cry 3
Extensive FEA modeling (ANSYS™) of the entire cryomodule
Transient thermal analysis during cooldown/warmup cycles,
Coupled structural/thermal simulations
Full nonlinear material properties
Detailed sub-modeling of new components and Laboratory tests
Finger-welding tests at ZANON
Cryogenic tests of the sliding supports at INFN-LASA
FNAL Module
December 6, 2004
Carlo Pagani

7. TTF Module Installation
Type
Installation date
Cold time [months]
CryoCap
Oct 96 50 M1
Mar 97 5
M1 rep.
Jan 98 12 M2
Sep 98 44 M3
Jun 99 35
M1*
MSS
Jun 02 21 8
M3* M4 M5
Apr 03 10
M2*
Feb 04 7 1 2 3
FNAL Module
December 6, 2004
Carlo Pagani

8. Wire Position Monitors
On line monitoring of cold mass movements during cool-down, warm-up and operation
2 WPM lines with 2 x 18 sensors
4 sensors per active element
8 mm bore radius
1 WPM lines
1 sensors per active element
25 mm bore radius
1 WPM line
7 sensors/module
Cry 1
Cry 2
Cry 3
Module 1
Module 2 & 3
Module 4 & 5
FNAL Module
December 6, 2004
Carlo Pagani

9. Safe Cooldown of ACC4 and ACC5X Y
FNAL Module
December 6, 2004
Carlo Pagani

10. ACC4 & ACC5 Met Specs Still some work at the module interconnection
Cavity axis to be properly defined
FNAL Module
December 6, 2004
Carlo Pagani

11. TTF Cryomodule Performances
FNAL Module
December 6, 2004
Carlo Pagani

12. Cold Leaks Experience at TTF
FNAL Module
December 6, 2004
Carlo Pagani

13. INFN and ILC
Cold recommendation and new management are both moving INFN in the direction of an important contribution to ILC
Subjects, resources and organization will be defined by Feb 2005
On the basis of the experience and the expertise from TTF cryomodule design, fabrication and assembly, INFN is willing to restart soon this activity, with the required resources
As for the evolution from the prototype to Cry3, all contributions from the experienced labs in the three regions will be integrated
Existing MoU between INFN and: DESY, FNAL, KEK and JLab will be used to start the process
I expect that INFN is willing to review the existing cryomodule design, the so called Cry3, moving soon to a new module generation, similar to the one sketched on the TESLA TDR and closer to the ILC requirements.
FNAL Module
December 6, 2004
Carlo Pagani

14. Cry3 is a proven design, to be cleaned up
Most changes are useful, but not necessary, for X-FEL
Industrialization foreseen for X-FEL good for ILC too
A few examples
Quad Fixture (sliding as for cavities) – planned for X-FEL
Flange connections: Sealing and Fixing to improve reliability
Various braids for heat sinking (all coupler sinking stile)
Cables, Cabling, Connectors and Feed-through: all must be qualified
Composite post diameter and flanges
Warm fixtures of cold mass to Vacuum Vessel (fixed and sliding)
LMI Blankets for the K shield (LHC Style)
Module interconnection: Vacuum Vessel sealing, pipe welds, etc.
Coupler provisional fixtures and assembly
FNAL Module
December 6, 2004
Carlo Pagani

15. Design changes important for ILC
Move quadrupole to the center
Quad/BPM Fiducialization
High pressure rinsing and clean room assembly issues
Movers for beam based alignment? Why not if really beneficial
Short cavity design
Cutoff tubes length by e.m. not ancillaries (coaxial tuner)
Cavity inter-connection: Flanges and bellows (coating?)
Fast locking system for space and reliability (CARE activity)
Bellow waves according to demonstrated tolerances
Coaxial Tuner with integrated piezo-actuators
Parametric “Blade Tuner” successfully operated on superstructures
Piezo fast tuner integration under way. Chechia tests by summer ’05
Longer module design: cavities not urgent
Length to be based on the overall machine cost optimization
FNAL Module
December 6, 2004
Carlo Pagani

16. ILC and Euro-XFEL ILC and XFEL module design should move in parallel
Module length, quad length and inter-cavity spacing can be different
INFN could support a few parallel designs, based on the same baseline to be agreed upon: that include FNAL and KEK modules
To maximize synergy between the two projects is important to maintain a common baseline on a number of points as:
Quadrupole position: central
Fixture design for all the active elements
Pipe layout at the module interconnection for orbital welding
Posts and fixtures for vibration and transportation
MLI blanquettes design
Vacuum sealing
…………….
FNAL Module
December 6, 2004
Carlo Pagani

17. Concluding Remarks INFN is willing to play the role played in the past
TTF Operation Experience shows that Cry 3 Modules are close to meet all the requirements
Improvements where conceived at the time of the TESLA TDR, but never developed because of sake of funding and personnel
X-FEL could use the present design with minor modifications, but, if compatible with the tight schedule, module could be better
ILC should use the TESLA TDR cryomodule design, very close to the so called Cry 3, as the basis for further improvements
An international concentrated effort in this direction would have the advantage to have most of the modifications implemented in time for the X-FEL
Synergy with the X-FEL would be much stronger and the benefit for the ILC really great
INFN is willing to play the role played in the past
FNAL Module
December 6, 2004
Carlo Pagani

18. Additional Material
FNAL Module
December 6, 2004
Carlo Pagani

19. Module assembly picture gallery - 1
String inside the Clean Room
FNAL Module
December 6, 2004
Carlo Pagani

20. Module assembly picture gallery - 2
String in the assembly area
FNAL Module
December 6, 2004
Carlo Pagani

21. Module assembly picture gallery - 3
Cavity interconnection detail
FNAL Module
December 6, 2004
Carlo Pagani

22. Module assembly picture gallery – 3bis
Internal details
FNAL Module
December 6, 2004
Carlo Pagani

23. Module assembly picture gallery - 4
String hanged to he HeGRP
FNAL Module
December 6, 2004
Carlo Pagani

24. Module assembly picture gallery - 5
String on the cantilevers
FNAL Module
December 6, 2004
Carlo Pagani

25. Module assembly picture gallery - 6
Close internal shield MLI
FNAL Module
December 6, 2004
Carlo Pagani

26. Module assembly picture gallery - 7
External shield in place
FNAL Module
December 6, 2004
Carlo Pagani

27. Module assembly picture gallery - 8
Welding “fingers”
FNAL Module
December 6, 2004
Carlo Pagani

28. Module assembly picture gallery - 9
Sliding the Vacuum Vessel
FNAL Module
December 6, 2004
Carlo Pagani

29. Module assembly picture gallery - 10
Complete module moved for storage
FNAL Module
December 6, 2004
Carlo Pagani

30. Composite support posts
FNAL successful design, routinely produced by industry
Size to be reconsidered for lateral stiffness and transportation
FNAL Module
December 6, 2004
Carlo Pagani

31. Supporting Brackets
FNAL Module
December 6, 2004
Carlo Pagani

32. Module Interconnection Detail
FNAL Module
December 6, 2004
Carlo Pagani

33. TESLA Blade Tuner Spring analytical model
KHT KT KC KB
Cavity
Bellow
Tuner
Helium tank
KTA KM
KTB
Tuner axial
bending/axial mixed
Movement mechanism
Spring analytical model
FEA 3D Model
Parametric design fulfilling ILC specs
Successfully tested on Superstructures
Piezo-tuner integration still pending
FNAL Module
December 6, 2004
Carlo Pagani

34. Piezo-assisted Blade Tuner
FNAL Module
December 6, 2004
Carlo Pagani

35. LCH and TESLA Cryomodule Comparison
A number of design details from the LHC/CERN experience will be considered
From an LHC Status Report by Lyndon R. Evans
ACC 4 & ACC 5 in TTF
ACC 2 & ACC 3 in TTF
 = 38”
FNAL Module
December 6, 2004
Carlo Pagani