Fermilab PIP Booster Accelerator RF Cavity Refurbishment Matt Slabaugh ARW 2015 27 April 2015

Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Matt Slabaugh

ARW 2015

27 April 2015

Topics

• Proton Improvement Plan (PIP)• Booster Radio Frequency (RF) Cavities• Cavity Refurbishment• Tuner Refurbishment• Planning for failure• Testing and Summary

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment2

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Booster RF Cavity

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Circa. 1969bid drawing(obsolete)

Critical advantage: Access to retired personnel with development knowledge

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Cavity Refurbishment- Scope

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Vacuum

Misc.

RF Contact

Cavities are radioactive and fragile!

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Cavity Refurbishment- RF Contact

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Milling improved quality, reduced time and distance (dose). ~ 7 days2 days

Insufficient contact= heat and RF leakage

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Cavity Refurbishment- Vacuum Repair and Upgrade

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Leaking “pie-tin” quick disconnect flange

Removal with Wach’s tool

Replace with solid flange

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Cavity Refurbishment

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Water cooling repair/upgrade

Alignment fiducials installedImprovised repair tooling

Internal sparking and damage

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Tuner Refurbishment

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

Contact surfaces

Cones

Cooling lines

Each tuner:• 500+ pieces • 150ft+ tubing • 50+ water connections• 44in long • 650lbs

Ferrite

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Tuner Refurbishment

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

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Tuner Refurbishment- Risk

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

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Tuner Refurbishment- Procurement and challenges

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

• Difficult procurement– Stock items not stock (tube sizes)– Common processes no longer

common– Unusual materials

• Original drawings not updated– Undocumented revisions– All hand drawings, no CAD

• Little data available for optimizing design changes or benchmarking

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Tuner Refurbishment- Planning for failure

• Have begun building new tuner assemblies• Potentially replace all refurbished tuners with new

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

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Cavity Testing and Summary

• Each assembly tested for two weeks prior to install• Thermal sensors near critical surfaces for real time data• Beginning production of two spare cavities

4/27/2015M. Slabaugh | Fermilab PIP Booster Accelerator RF Cavity Refurbishment

• 17 of 20 cavities installed

• 50 tuners refurbished

• 3 tuners built new