1. SRF Cryomodule Assembly Facility Plans Tug Arkan AAC, May 10-12, 2005

2. 2 Outline Introduction Cryomodule Assembly Workflow Infrastructure Plans Procurement Plans Summary

3. 3 Introduction A plan is being developed to assemble 1.3 GHz Elliptical cryomodules at Fermilab. Current plan involves two1.3 GHz (β=1) cryomodules to be assembled in FY06 and FY07. High power RF and Beam testing of these cryomodules will be done on the Fermilab site in the proposed Meson Lab test facility (HPTF) MP9 building will be used to setup the infrastructure to assemble these cryomodules.

4. 4 Cryomodule Assembly Workflow Plans in FY06 & FY07 Assumptions for the assembly of two 1.3 GHz Elliptical cryomodules in FY06 & FY07: (R&D production rate)  SRF bare cavities are fabricated in industry. (Form/machine parts, electron beam welding)  Cavities are processed (tuned for field flatness, baked, chemical etched {BCP and/or electro-polished}, high pressure water rinsed and vertical dewar tested).  Cavities are outfitted with helium vessel and input power coupler and further dressed (tuner, magnetic shielding) for the horizontal dewar test.  It is assumed that these steps (processing & dressing) are carried out elsewhere (collaborating laboratories, universities).  After passing horizontal dewar test, the cavity with helium vessel and cold part of the input coupler is shipped sealed to the MP9 facility.  The sealed cavities with cold input coupler are received at the MP9 facility for incorporation into cryomodules. 8 dressed cavities are assembled into a string at MP9 facility clean rooms. The cavity string is then assembled into cold mass. Cold mass is then inserted into vacuum vessel and the cryomodule assembly is complete.

5. 5 Receive dressed Cavities Receive peripheral (vacuum vessel, cryogenic pipes, super-insulation etc.) Cryomodule Parts Assemble dressed Cavities to form a String in the Cavity String Assembly Area (Clean Room) Work Flow at MP9 Facility Install String Assembly to Cold Mass in the Cold Mass Assembly Area

6. 6 Cryomodule Testing at HPTF Ship completed cryomodules to HPTF Install the String assembly with the cold mass into the Vacuum vessel in the Vacuum Vessel Assembly area Cavity Repair fail Cryomodule Repair (assumes one or more cavities must be replaced) -Disassemble the module -Disassemble the string in the Clean Room -Install a new dressed cavity to the string pass Cyomodule production is successful Send the Cryomodule back for repair Work Flow at MP9 Facility

7. 7 Infrastructure Plans at MP9 1.3 GHz Elliptical Cryomodules Assembly Infrastructure at MP9 in FY06 & FY07

8. 8 Cryomodule Assembly Workflow Model for Small Scale Mass Production Rate Assumptions for a production rate of 1~2 cryomodules per month: (small scale mass production rate)  SRF bare cavities are fabricated in industry. (Form/machine parts, electron beam welding). The bare cavities arrive to FNAL.  Cavities are processed (tuned for field flatness, baked, chemical etched {BCP and/or electro- polished}, high pressure water rinsed and vertical dewar tested) at Fermilab.  Cavities are outfitted with helium vessel and input power coupler and further dressed (tuner, magnetic shielding) for the horizontal dewar test at Fermilab.  After passing the horizontal dewar test, the cavity with helium vessel and cold part of the input coupler is shipped sealed to the MP9 facility.  The sealed cavities with cold input coupler are received at the MP9 facility for incorporation into strings. 8 dressed cavities are assembled into a string at MP9 facility clean rooms.  The cavity string is then transported to another assembly facility to be assembled into cold mass. Cold mass is then inserted into vacuum vessel and the cryomodule assembly will be completed. (1~2 cryomodules per month in two ~ three cold mass and vacuum vessel assembly lines.

9. 9 Receive bare Cavities Receive peripheral parts to dress cavities & assemble a string Chemical Etch Cavity (BCP and/or Electropolish) Dress cavity -Weld Helium vessel -Install input power coupler -Assemble Tuner, -Assemble magnetic shielding Assemble Dressed Cavities to form a String in the Cavity String Assembly Area (Clean Room) Horizontal Dewar Test Dressed Cavity Pass Fail High Pressure Water Rinse (HPWR) Cavity Vertical Dewar Test Processed Cavity Fail Transport String Assembly to another Facility

10. 10 Receive String Assembly Receive peripheral (vacuum vessel, cryogenic pipes, super- insulation etc.) Cryomodule Parts Install String Assembly to Cold Mass in the Cold Mass Assembly Area Ship completed cryomodules to HPTF Install the String assembly with the cold mass to the Vacuum vessel in the Vacuum Vessel Assembly area Cryomodule Testing at HPTF Cryomodule Repair (assumes one or more cavities must be replaced) -Disassemble the module -Disassemble the string in the Clean Room -Install a new dressed cavity to the string Fail Send the Cryomodule back for repair Pass Cyomodule production is successful Cavity Repair

11. 11 MP9 Building & Meson Area

12. 12 MP9 Building inside views Beam Separator work at MP9 will be completed by the end of November 2006

13. 13 Procurement Plans FY05:  Elliptical cavity string assembly clean rooms  1.3 GHz elliptical cryomodules cold mass and vacuum vessel assembly fixtures FY06:  Elliptical cavities string assembly fixtures  Clean room equipment  Portable clean rooms  Miscellaneous fixtures

14. 14 Summary In FY06 and FY07, MP9 building will be used for the infrastructure to assemble two 1.3 GHz (β = 1) elliptical cryomodules. 3~4 FTE’s are needed to assemble the strings in the cavity string assembly clean rooms. 6~8 FTE’s are needed for string to cold mass and vacuum vessel assembly outside of the clean rooms. MP9 has no cryogenics capabilities, testing of cavities and completed cryomodules needs to be done at proposed HPTF areas. To assemble cryomodules with a small scale mass production rate (1~2 cryomodules per month), MP9 facility could be used only for the cavity string assembly infrastructure and another facility could be setup for the string to cold mass and vacuum vessel assembly infrastructure (non clean room, multiple assembly lines). This production rate will require ~50 FTE to work in multiple production assembly lines.