IFJ PAN - ESS meeting

Lund, 25th June 2013

D. Bocian,

A. Kotarba, J. Ludwin, M. Stodulski, J. Świerblewski, M. Wiencek

IFJ PAN contribution

to international projects

Dariusz Bocian IFJ PAN-ESS meeting 2

• 700,000 inhabitants

• ~880 km away from Lund

• former capital of Poland

(between the 11th and the 16th century)

• cultural capital of Poland

• Student city

23 universties/colleges,

~200,000 students

- Jagiellonian University

- AGH University of Science and Technology

- Tadeusz Kosciuszko University of Technology

- Jan Matejko Academy of Fine Arts

- Krakow University of Economics,

- Pedagogical University of Krakow,

- Agricultural University of Krakow,

- Pontifical University of John Paul II,

Kraków (Cracow)

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• General information

• Accelerator activities at IFJ

• IFJ PAN and selected projects

• European XFEL

• LHC consolidation and upgrade

• Wendelstein 7X

• Scientific equipment construction

• Summary

Outline

Dariusz Bocian IFJ PAN-ESS meeting 4

• 492 personnel

• Prof. 37, Assoc. Prof. 49, Ph.D. 106

• PhD studies – 70 students

• Interdisciplinary PhD studies

• 6 divisions: 28 departments

• centre of excellence

• centre of advanced technology

• 4 accredited laboratories

• Equipment and Scientific Infrastructure Construction Division (DAI)

General information

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Main Research Fields

Particle physics and astrophysics

Nuclear and strong interactions physics

Condensed matter physics

Interdisciplinary and applied research

Theoretical physics

General information

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Accelerator activities at IFJ

• cyclotron AIC-144 - proton beam energy: 60 MeV

- Proton Radiotherapy of Eye Melanoma

• Cyclotron Proteus C-235 – National Centre for Hadron Radiotherapy

– under construction (2013)

• neutron generator – 14 MeV

• VdG high stability – 2.5 MeV

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Completed projects

– LHC, CERN Geneva, 2005 – 2012

– Wendelstein 7X, IPP Greifswald, 2007 – 2012

– ATLAS, CERN Geneva, 2004 - 2012

– T2K, J-PARC Tokai, Krakow/J-PARC, 2007 – 2009

Running projects:

– XFEL, DESY, Hamburg, 2009 – 2015

– LHC, CERN, Geneva, 2013 – 2014

– ITER, Cadarache, 2010-2015

– Cherenkov Telescope Array (CTA), 2008 – 2013

IFJ PAN and international projects

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IFJ PAN in-kind contribution to XFEL construction (2009 - 2015)

840 x

103 x

103 x

103 x

In December 2010 IFJ PAN signed the

agreements with European XFEL GmbH and

National Centre for Nuclear Research, Świerk –

Poland for performance of qualification tests of

RF cavities, magnets and cryomodules as a

Polish in-kind contribution for the European

XFEL:

cavities magnets

current leads

cryomodules

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IFJ PAN in-kind contribution to XFEL construction (2009 - 2015)

1) Performance of acceptance tests of cavities for a series of 840 units

on DESY infrastructure and delivering the corresponding test reports

2) Performance of acceptance tests of cryomodules for a series of 103 units on DESY

infrastructure and delivering the corresponding test reports

3) Performance of acceptance tests of cold magnets for a series of 103 units on DESY

infrastructure and delivering the corresponding tests reports – common effort with

DESY

XFEL quadrupole magnets tests XFEL cryomodules tests XFEL RF cavities tests

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IFJ PAN in-kind contribution to XFEL construction IFJ PAN tasks

Each IFJ PAN task is split in two phases:

Tests of cavities and cryomodules in the AMTF Hall

Tests of cold magnets

Serial tests phase

Performance of serial tests:

Cold magnets – 100

Current leads – 100

Cavities – 816

Cryomodules – 100

Data analysis and reporting;

Software upgrade.

Preparatory phase

Knowledge acquiring

(learning, trainings, meetings

with DESY experts);

Procedures writing;

Software preparation;

Performance of preseries tests:

(3 cold magnets and 3 CL,

24 cavities and 3 cryomodules).

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IFJ PAN in-kind contribution to XFEL construction IFJ PAN team structure

IFJ PAN Team (Management)

Teams of cold magnets tests (Technical Coordinator)

Measurement

Data Base and Software Development

Teams of cavities and cryomodules tests (Technical Coordinator)

Safety officer

Mechanic

Vacuum

Cryogenic

RF Measurement

Software Development

Team:

Dr Engineers – 4

Engineers – 23

Technicians – 23

(currently at DESY

30 people)

Expertise:

Mechanics

Electronics / Electrics

Automatics / Robotics

Software engineering

Physics

Computer science

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IFJ PAN in-kind contribution to XFEL construction Cavity Test Flow chart

We create 3 reports from each test and

upload them to the EDMS:

Incoming inspection report

Final test report

Outgoing inspection report

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IFJ PAN in-kind contribution to XFEL construction Cavity test: Incoming inspection & preparation for test

Main tasks: Incoming Report

Mechanical check of the cavity

Vaccum check

Electrical check

Cavity spectrum check & HOM

tuning

Assembling cavity to the insert

Connecting cavity to the vacuum line

(in cleanroom conditions)

Cables connection with TDR

Leak check of the cavity

Transport of the insert to the cryostat

Connecting of the insert to the vacuum

line

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IFJ PAN in-kind contribution to XFEL construction Cavity test: Cryogenic operation

Cryogenic activities at AMTF:

Cool down

Maintenance during the test

Warm up

Cool down process from 300 K to 2 K

Cryogenics operator’s control panel for test cryostat (left) and subcooler box (right) at AMTF. Cavity cryostat at AMTF

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IFJ PAN in-kind contribution to XFEL construction Cavity test in vertical cryostat at 2K

Part of software written

by IFJ PAN engineers

Q vs E measurement

Cavity test-stand, cryostat (left) and electronic racks (right) Cable calibration application

Vertical measurements application

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IFJ PAN in-kind contribution to XFEL construction Cavity test in vertical cryostat at 2K

Maximal Eacc (> 26 MV/m)

Q0 factor vs. Eacc (>1010)

Radiation vs. Eacc (<10-2 mGy/min)

Example of series cavities test results Results overview from IFJ PAN cavitiy database

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IFJ PAN in-kind contribution to XFEL construction Cavity test: Disassembling and outgoing

Main tasks Disconnecting of the insert from the vacuum

line

Transport of the insert to the preparation

area

Leak check of the cavity

Disconnecting cavity from the vacuum line

(in cleanroom conditions)

Disassembling cavity from the insert

Outgoing check

Mechanical check of the cavity

Vacuum check

Electrical check

Cavity spectrum check

Preparation for shipment

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IFJ PAN in-kind contribution to XFEL construction Cavity test: Summary

Insertion of the cavity into the vertical cryostat

Results of RF cavity measurement

60 prototype and pre-series cavities – tested

800 production cavities to be tested

Measurement of the cavity fundamental mode spectra

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test flow chart

We create 3 reports from each test:

Incoming inspection report

Final test report

Outgoing inspection report

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Incoming inspection and preparation for cold test

Incoming checks

Mechanical check

Vacuum check

Check of the cavities fundamental mode

spectra

Electrical check

Cavities tuner check

Shock loggers readout

Load the cryomodule to the movable support

Assembling cryomodule at the test stand

Connecting cryomodule beam line to the test

stand under clean room conditions

Leak check of beam line interconnections and

mass spectroscopy of the beam line

Connecting of the waveguides and electrical

cables

Connect of all cryomodule process pipes to the

test stands

Leak check of cryomodule vessel (ISO-VAC)

and cryogenic valves

Assembly and isolating thermal shields

Pumping down of vacuum insulation

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Coupler conditioning and cool down

Module cool down

Keeping stable cryogenic conditions

during test

Tools developments

Warm coupler conditioning, coupler

conditioning during cool down (couplers

are required to be cleaned before start of

cold test with klystron).

Temperature regions during automatic module cool down process

Automatic module cool down process from 300 K to 4 K:

inlet and outlet temperature

Warm coupler conditioning

application

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Low Power RF measurements at 2K

Cold cables calibration

Spectra measurement

Cavities tuning

Coupler tuning

HOM spectra measurements

Spectrum

measurement

application (left)

Cold cable calibration application

Cavity tuning application

Measurement of

HOM spectra and

Qload (right)

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test : High Power RF measurements at 2K

Cavities calibration

Cavities flat-top

measurement

Heat loads

measurements

Cavity flat – top application

Cavities calibration application

Heat loads application

Example of Flat – top

masurement results

Example of cryomodule RF test results

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Warm – up with flooding of the insulation vacuum

Module warm up

Tools development

During warm-up at

100K insulation vacuum

of cryomodule is flooded

with nitrogen to speed

up the warm-up process

Automatic module warm up from 2 K to 300 K process: inlet and outlet

temperature

Temperature regions during automatic module warm up process

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Disassembling and outgoing inspection

Mass spectroscopy of the beamline

Disassembly of thermal shields

Disconnecting of the beamline (under clean room

conditions) and all other cryomodule process pipes from

the test stand

Disconnecting of the waveguides and electrical cables

Disassembling cryomodule from the test stand

Outgoing checks

Mechanical check

Checking of the cavities fundamental mode spectra

Electrical check

Vacuum check

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IFJ PAN in-kind contribution to XFEL construction Cryomodule test: Summary

Calibration coefficient and check quality factors

of the couplers during cryomodule RF test Leak test of vacuum pipes

3 prototype cryomodules – tested

3 pre-series cryomodules - to be tested

100 series cryomodules – to be tested

Prototype module on existing test bench

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IFJ PAN in-kind contribution to XFEL construction Cold magnet test: Test-stand

Test stand for magnet tests at warm

(top) and electronic rack (left).

Test stand for magnet tests at cold

(top) and electronic racks (right) CL electrical check test-stand

Hall 55 with cryogenic infrastructure for magnet

tests

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IFJ PAN in-kind contribution to XFEL construction Cold magnet test: Preparation and test at warm

Installation of the magnet at

warm test-stand

Preparation for warm tests:

Incoming and visual inspections.

Check of the quantity and quality

components.

Tightness check of magnet using helium

leak detector.

Polarity check of coils

Insulation test using HV insulation meter.

Put the magnet on special Al support and

adjust it on an alignment frame in x,y,z

axes.

Magnet installation in warm test-stand

Magnet test at warm (Quadrupole - harmonics

measurement)

Magnet at warm test stand

with harmonic coil

Harmonic coil in the magnet

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IFJ PAN in-kind contribution to XFEL construction Cold magnet test: Preparation and cold test

Magnet with CL

installation in cryostat

XMTS

Electrical check of current

leads connections

Thermal insulation CL

and magnet

Results of stretched wire test at 2K Stretched wire test at 2K

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IFJ PAN in-kind contribution to XFEL construction Current Leads tests: Incoming and visual check

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Current leads visual inspection

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IFJ PAN in-kind contribution to XFEL construction Current leads tests: Tightness, insulation and resistance

Current leads test stand

and insulation test

Current leads tightness check

Current leads resistance test

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IFJ PAN in-kind contribution to XFEL construction Cold magnets and current leads test: Field analysis

32

Field parameters: GL/BL

Magnet Transfer Function

(MTF)

BL/I [Tm/A] for a dipole

GL/I [T/A] for a

guadrupole

Angle & offset

Re & img part of multipoles

Correction parameters

Quadrupole transfer function (TF) Quadrupole deviation straight line from TF Dipole deviation straight line from TF

Magnetic multipoles for quadrupole (left) and dipole(right)

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IFJ PAN effort to XFEL construction

Total number of FTE’s over 7 years ~150

Total number of trained IFJ PAN staff ~ 60

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IFJ PAN and LHC

(2005-2014)

1) design & construction of measuring/testing devices

2) preparation of necessary software and data bases

3) manufacturing of superconducting N-lines

4) development of measuring/testing methods

5) organization, performance & documentation of electrical measurements /tests

6) organization, performance & documentation of interconnection inspection

Mobil test stations in LHC tunnel Damaged PIM (Plug-In Module) User interface

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IFJ PAN and LHC Motivation

Each of those elements has to be checked after every thermal cycle of the machine

1600 superconducting circuits

1700 magnet cryomodules

(with their instrumentation)

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IFJ PAN and LHC Measurements of the superconducting circuits

For each superconducting circuit check of:

• Electrical insulation,

• Continuity and resistance,

• Continuity and resistance of voltage taps used for quench protection

• Distribution of signal from voltage taps along the circuit.

• Inductive and capacitive properties of the circuit.

Courtesy of Mateusz Bednarek

All measurements are performed

both in the room temperature

and in the cryogenic conditions

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IFJ PAN and LHC Measurements of the cryomodules

For each LHC magnet cryomodule check of:

• Electrical insulation of quench heaters,

• Continuity and resistance of quench heaters,

• Continuity and resistance of voltage taps used for quench protection

Courtesy of Mateusz Bednarek

Those measurements are

performed in room temperature

and in cryogenic conditions

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IFJ PAN and LHC Measurements of superconducting circuits

In total for the qualification of all

superconducting circuits of the LHC at

warm and at cold we have to perform:

• >180 000 voltage measurements

• >140 000 resistance measurements

• > 9600 high voltage insulation tests

• > 3800 transfer function measurements

This are the actual numbers of measurements

which were performed during last 4 monts.

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IFJ PAN and LHC Measurement system

Large variety of tests to be performed on many different types of circuits called for design of universal mobile test benches coupled with advanced software and database system.

Our measurement system is called TP4, what stands for Test Procedure 4.

(Procedures 1-3 were performed on LHC components before assembly.)

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IFJ PAN and LHC Measurement system

• Recently the measurement system

(hardware and software) was

upgraded in the IFJ-PAN

• Each of 8 trolleys is equipped with:

– Gain/phase analyser,

– 36 V/ 6 A power supply.

– PXI computer with two DMM cards,

– Specially designed electronics with

thermally controlled reference resistors,

4 channel current demultiplexer

and 4 1-of-84 signal multiplexers,

– 80 channel high voltage insulation tester.

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IFJ PAN and LHC Electrical measurements and tests

2005 – 2010 Thousands of electrical measurements/tests performed in terms of continuity,

resistance and HV qualification of superconducting circuits in warm and cold states.

The team, as the first, performed measurements of very low resistance of main bus bar

connections at cold (without necessity of opening interconnections between

magnets). The measurement results were essential for CERN groups developing a new

Quench Protection System.

2011 – 2012 Upgrade of the measuring/testing devices

2013 – 2014 Campaign of measurements/tests has started

Measurements in the LHC tunnel (2005-2010) Upgraded hardware and software (2011-2012)

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IFJ PAN and LHC Measurement system

• Measurement results, test

parameters and signal

mappings are stored in the

central database.

• The trolleys are wireless

synchronising their local

database with the central one.

• Most part of the system works

under control of the NI

LabView software.

• Set of web applications is

available for follow-up and

results viewing.

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IFJ PAN and LHC Software and hardware tools development

• For the cool-down and warm-up phase we have developed a measurement system for the insulation monitoring. The device applies periodically DC voltage of 48 V to the selected circuits and measures the leakage current. In case the limit is reached, alert messages are sent via e-mail and SMS.

• Our engineers are working on data mining software used for analysis of the measurement results produced during standard measurement campaigns over the years.

• Recently we cooperate with CERN on development of the current transformer tester that is going to be shipped later to the industry where it will be used to qualify transformers which are going to be installed in the LHC quench protection system.

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IFJ PAN and LHC Inspection of interconnections

Scope of inspection:

• Pre-inspection of a single magnet

(visual inspection of all magnet components, checking of beam lines by means of endoscopy

and microwave reflectometry methods)

• Visual inspection of interconnections (after orbital and ultra-sonic welding)

• Microwave reflectometry measurements of the beam lines in series of connected magnets

• Final visual inspection just before the closure of each interconnection

In collaboration with CERN staff, the team developed a method for the localization of

damaged PIMs

• method is two times more precise than that employed before.

• method could be used without opening the interconnections between magnets.

Dariusz Bocian IFJ PAN-ESS meeting 45

IFJ PAN and LHC Summary

• Just recently group of 25 people (engineers and technicians) from the IFJ-PAN was performing the reference measurements before consolidation of the LHC superconducting circuits during Long Shutdown 1. The measurements are now completed.

• Exactly the same tests will be performed before machine start-up.

• Currently we are monitoring to the circuits’ health during the consolidation.

• Part of the team is working on investigation and solving of the nonconformities revealed during standard measurements: short circuits caused by thermal cycle, abnormal resistances, etc.

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Total number of FTEs over 8 years: ~160

Total number of trained IFJ PAN staff: ~50

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IFJ PAN contribution to W7-X construction (2007 – 2012)

• IFJ PAN was responsible for the assembly of the bus bar system

powering 70 superconducting coils on five modules of the stellarator.

• The bus bars are made of the NbTi superconductors in an aluminium jacket.

• There are 24 bus bars on each module.

Example of bus bars routing on one module

Total number of FTE over 6 years > 160

Total number of trained IFJ PAN staff > 50

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Bus bar cross section

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IFJ PAN contribution to W7-X construction Joints assembly

Mechanical and electrical connection of the superconductors

Electrical connection of 81 triplets

Connected triplets squizzed with clamps

and covered by stainless steel caps

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IFJ PAN contribution to W7-X construction Electrical insulation of joints (wet wrapping)

Electrical insulation of the assembled joints (divided into three steps)

All joints (184) passed successfully tightness and HV tests

Installation of 24 bus bars on the module

and final shaping of the bus bar ends

Module Separation Plane

set of six joints painted and clamped

Dariusz Bocian IFJ PAN-ESS meeting 49

Scientific equipment construction Cherenkov Telescope Array (CTA)

1) Small Size Telescope Structure - prototype to be built by end 2013

dish diameter 4 m; focal length 9.6 m; weight 8.8 t

3-D model based on the technical documentation

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Scientific equipment construction Cherenkov Telescope Array (CTA)

Front (left) and rear (right) view of the prototype mirrors

2) Open structure mirrors for Medium Size Telescope – 10 prototypes under tests

hexagonal shape 1.2 m f-t-f, curvature radius 32 m, weight 35 kg

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Medical equipment construction Proton radiotherapy at IFJ PAN

Components of eye melanoma setup – to be finished in 2013

Device for immediate proton

beam cut-off, so called shutter

Supports for the end of beam line

Adjustable supports for x-ray lamps

Holders for digital x-ray recorders

range discriminators and beam

collimators

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Scientific equipment construction Finger detector at GSI Darmstadt

Mechanics for one detector – completed in 2012

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Scientific equipment construction Stellarator W7 - X

Mechanics for 30 sets of polychromators – completed in 2011

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Scientific equipment construction ATLAS Assembly

Aluminium frame to install Muon Chambers – completed in 2006

The frame at IFJ PAN

The frame used during installation in the ATLAS cavern

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IFJ PAN groups contribute to major world experiments

in particle physics, astrophysics and nuclear physics.

IFJ PAN contributes to XFEL and LHC

IFJ PAN is involved in fusion projects (W7X, ITER)

Conclusions

Expertise:

→ XFEL (construction)

→ LHC (construction, consolidation, upgrade)

→ W7-X (construction)

→ AIC-144 (construction, medical applications)

→ Proteus C235 (medical applications, research)

Team:

→ Scientists: 5

→ Engineers: 34

→ Technicians: 65