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All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Cryogenic System for the Cryomodule Test Facility at Fermilab

This paper provides an overview of the current progress and near-future plans for the cryogenic system at the new Cryomodule Test Facility (CMTF) at Fermilab, which includes the helium compressors, refrigerators, warm vacuum compressors, gas and liquid storage, and a distribution system. CMTF will house the Project X Injector Experiment (PXIE), which is the front end of the proposed Project X. PXIE includes one 162.5 MHz half wave resonator (HWR) cryomodule and one 325 MHz single spoke resonator (SSR) cryomodule. Both cryomodules contain superconducting radio-frequency (SRF) cavities and superconducting magnets operated at 2.0 K. CMTF will also support the Advanced Superconducting Test Accelerator (ASTA), which is located in the adjacent New Muon Lab (NML) building. A cryomodule test stand (CMTS1) located at CMTF will be used to test 1.3 GHz cryomodules before they are installed in the ASTA cryomodule string. A liquid helium pump and transfer line will be used to provide supplemental liquid helium to ASTA.

White, Michael↗
DOE OSTI2024

Operational Experience of a Cryomodule Test Stand for LCLS-II Cryomodules

CMTS1 (cryomodule test stand 1) at Fermilab was built to test cryomodules built for the LCLS-II beamline at SLAC and is currently testing cryomodules for LCLS-II-HE, the high energy upgrade to LCLS-II. The first cryomodule test was in 2016 and to date over 30 cryomodules have been tested here. This talk will highlight operational experience of the vacuum systems including insulating, coupler, and a low particulate beamline vacuum system. It will focus on the problems that have come up over the years, their solutions, and mitigations put in place to prevent further issues.

43 PARTICLE ACCELERATORS↗
DOE OSTI2015

Nitrogen-doped 9-cell cavity performance in a test cryomodule for LCLS-II

The superconducting RF linac for Linac Coherent Light Source-II calls for 1.3 GHz 9-cell cavities with an average intrinsic quality factor Q{sub 0} of 2.7 × 10{sup 10} at 2.0 K and 16 MV/m accelerating gradient. Two niobium 9 cell cavities, prepared with nitrogen-doping at Fermilab, were assembled into the Cornell Horizontal Test Cryomodule (HTC) to test cavity performance in a cryomodule that is very similar to a full LCLS-II cryomodule. The cavities met LCLS-II specifications with an average quench field of 17 MV/m and an average Q{sub 0} of 3 × 10{sup 10}. The sensitivity of the cavities' residual resistance to ambient magnetic field was determined to be 0.5 nΩ/mG during fast cool down. In two cool downs, a heater attached to one of the cavity beam tubes was used to induce large horizontal temperature gradients. Here, we report on the results of these first tests of nitrogen-doped cavities in a cryomodule, which provide critical information for the LCLS-II project.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Optimization of static heat loads of the PIP-II cryomodules based on prototype HB650 cryomodule test results

During the first cool down of the prototype HB650 cryomodule (pHB650 CM), high static heat loads have been measured compared to the estimation. Several analysis and calculations have been performed to explain this difference which led to cool down this cryomodule two additional times. Before each cool down, repairs and upgrades have been done, and instrumentations were added to identify the issues and quantify their impact on the heat loads. Based on these findings, the production cryomodule design and assembly process have been updated to align the future heat loads measurements with the estimations.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

BEAM ACCELERATION WITH A Nb3Sn CRYOMODULE AT JLAB

We report on the electron beam acceleration experiment with a Nb3Sn cryomodule at Thomas Jefferson National Laboratory (JLAB). Two CEBAF-style 5-cell 1.5 GHz Nb3Sn cavities operated at 4 K, accelerating a 100 nA continuous-wave (CW) electron beam from 200 keV to 4 MeV at JLAB’s Upgraded Injector Test Facility (UITF). The acceleration gradients in each cavity reached 11 MV/m and 7 MV/m, respectively. No field emission was observed. The unloaded quality factors reached 2¿109 at low fields at 4 K.

Geng, R. [Thomas Jefferson National Accelerator Fa↗
DOE OSTI2014

Helium refrigeration considerations for cryomodule design

Many of the present day accelerators are based on superconducting radio frequency (SRF) cavities, packaged in cryo-modules (CM), which depend on helium refrigeration at sub-atmospheric pressures, nominally 2 K. These specialized helium refrigeration systems are quite cost intensive to produce and operate. Particularly as there is typically no work extraction below the 4.5-K supply, it is important that the exergy loss between this temperature level and the CM load temperature(s) be minimized by the process configuration choices. This paper will present, compare and discuss several possible helium distribution process arrangements to support the CM loads.

43 PARTICLE ACCELERATORS↗
DOE OSTI2017

LCLS-II Cryomodules Production at Fermilab

LCLS-II is an upgrade project for the linear coherent light source (LCLS) at SLAC. The LCLS-II linac will consist of thirty-five 1.3 GHz and two 3.9 GHz superconducting RF continuous wave (CW) cryomodules that Fermilab and Jefferson Lab (JLab) will assemble in collaboration with SLAC. The LCLS-II 1.3 GHz cryomodule design is based on the European XFEL pulsed-mode cryomodule design with modifications needed for CW operation. Fermilab and JLab will each assemble and test a prototype 1.3 GHz cryomodule to assess the results of the CW modifications, in advance of 16 and 17 production 1.3 GHz cryomodules, respectively. Fermilab is solely responsible for the 3.9 GHz cryomodules. After the prototype cryomodule tests are complete and lessons learned incorporated, both laboratories will increase their cryomodule production rates to meet the challenging LCLS-II project requirement of approximately one cryomodule per month per laboratory. This paper presents the Fermilab Cryomodule Assembly Facility (CAF) infrastructure for LCLS-II cryomodule production, the Fermilab prototype 1.3 GHz CW cryomodule (pCM) assembly and readiness for production assembly.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

MICROPHONICS TESTING OF LCLS II CRYOMODULES AT JLAB

Jefferson Lab is partnering with Fermilab to build 40 cryomodules for the LCLS II accelerator that will be installed at the Stanford Linear Accelerator (SLAC). The LCLS II cryomodule is an 8-seat CW cryomodule which operates at 1300 MHz and is based on the XFEL design. The cavities have design loaded-Q of 4×107, which means that it has a control bandwidth of 16 Hz. The JLab prototype cryomodule was instrumented with a series of 10 accelerometers, and impulse hammer response measurements were made while the cryomodule was being built and after it was installed in the JLAB cryomodule test facility. This was done so that we could better understand the shapes of the modes of the structure. These results were compared to impulse hammer testing from the outside of the cryomodule to individual cavity frequency shifts when the cryomodule was cold. Additionally, background microphonics and transfer function measurements were made on several other LCLS II cryomodules in the JLab cryomodule test facility (CMTF). The prototype cryomodule had excessive microphonics up to 100 Hz peak due to a thermo-acoustic oscillation in the cryogenic supply circuit. Design modifications were implemented and subsequently the cryomodules had microphonics on the order of 10 to 20 Hz.

Powers, Thomas↗
DOE OSTI2019

LCLS-II Cryomodules Production Experience and Lessons Learned at Fermilab

LCLS-II is a planned upgrade project for the linear co-herent light source (LCLS) at SLAC. The LCLS-II Linac will consist of thirty-five 1.3 GHz and two 3.9 GHz super-conducting RF continuous wave (CW) cryomodules that Fermilab and Jefferson Lab are currently producing in collaboration with SLAC. The LCLS-II 1.3 GHz cryomodule design is based on the European XFEL pulsed-mode cryomodule design with modifications needed for CW opera-tion. Two prototype cryomodules had been assembled and tested. After prototype cryomodule tests, both laboratories have increased their cryomodule production rate to meet the challenging LCLS-II project installation schedule requirements of approximately one cryomodule per month per laboratory. To date, Fermilab has completed the assembly and testing of eighteen 1.3GHz cryomodules. Fermilab has successfully shipped nine cryomodules to SLAC and will continue to ship approximately every two weeks. The first 3.9 GHz cryomodule assembly is scheduled to start in June 2019. Production readiness verifications are currently in process. This paper presents LCLS-II 1.3GHz cryomodule assembly and production experience, emphasizing the challenges, mitigations, and lessons learned.

43 PARTICLE ACCELERATORS↗
DOE OSTI2018

LCLS-II Cryomodules Production at Fermilab

LCLS-II is a planned upgrade project for the linear coherent light source (LCLS) at SLAC. The LCLS-II linac will consist of thirty-five 1.3 GHz and two 3.9 GHz superconducting RF continuous wave (CW) cryomodules that Fermilab and Jefferson Lab are currently producing in collaboration with SLAC. The LCLS-II 1.3 GHz cryomodule design is based on the European XFEL pulsed-mode cryomodule design with modifications needed for CW operation. Two prototype cryomodules had been assembled and tested. After prototype cryomodule tests, both laboratories have increased cryomodule production rate to meet the challenging LCLS-II project installation schedule requirements of approximately one cryomodule per month per laboratory. Fermilab is at half point for the production, meaning that 6 cryomodules are fully assembled and tested. This paper presents Fermilab Cryomodule Assembly Facility (CAF) infrastructure for the LCLS-II cryomodules assembly, production experience at the half point emphasizing the challenges and mitigations.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Standardization and First Lessons Learned of the Prototype HB650 Cryomodule for PIP-II at Fermilab

The prototype High Beta 650 MHz cryomodule (pHB650 CM) has been designed by an integrated design team, consisting of Fermilab (USA), CEA (France), STFC UKRI (UK), and RRCAT (India). The manufacturing and assembly of this prototype cryomodule is being done at Fermilab, whereas the production cryomodules will be manufactured and assembled by STFC-UKRI. As the first PIP-II cryomodule for which standardization was applied, the design, manufacturing and assembly of this cryomodule led to significant lessons being learnt and experiences gathered. These were incorporated into the design of the pre-production Single Spoke Resonator Type 2 cryomodule (ppSSR2 CM) and the pre-production Low Beta 650 MHz cryomodule (ppLB650 CM). This paper presents the pHB650 CM lessons learned and experiences gathered from the design to the lower coldmass assembly and how this cryomodule has a positive impact on all the next Proton Improvement Plan-II (PIP-II) cryomodules due to the standardization set up among SSR and 650 cryomodules.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

LCLS-II-HE Cryomodule Testing at Fermilab

22 Linac Coherent Light Source II (LCLS-II) cryomodules were successfully tested at the Cryomodule Test Facility (CMTF) at Fermilab. Following the completion of the LCLS-II testing program, CMTF has shifted to testing cryomodules for the LCLS-II High Energy upgrade (LCLS-II-HE). The first LCLS-II-HE cryomodule, the verification cryomodule (vCM), was successfully tested and verified the readiness of LCLS-II-HE cryomodule testing at CMTF, and production cryomodule testing has begun. Presented here are the production cryomodule test acceptance criteria, testing plan, and cryomodule test results so far.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Design Strategy of the PIP-II Cryomodules

The Proton Improvement Plan II (PIP-II) is the first U.S. accelerator project that will have significant contributions from international partners. Research institutions in India, Italy, UK and France will build major components of the particle accelerator. The High Beta 650 MHz (HB650) prototype cryomodule is being designed jointly between Fermilab (USA), CEA (France), STFC (UK) and RRCAT (India). The assembly of this prototype cryomodule will be done at Fermilab whereas the production cryomodules will be assembled in UK. Concerning the Low Beta 650 MHz (LB650) cryomodules, they will be designed and assembled at CEA. To reduce the cost of the project and to increase the quality it is essential to define a design strategy for each cryomodule which includes a degree of standardization. In this way, the lessons learned of each prototype cryomodule will have a great impact not only on one cryomodule type but on all cryomodules. An international joint design brings also additional challenges to the project: which unit system should be used? Should a common project lifecycle management system be used for all partners? How to transport the cryomodules overseas.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Heat load measurements for the PIP-II pHB650 cryomodule

This study presents a brief overview of the 1st and 2nd phases and an in-depth analysis of the 3rd phase heat load testing performed on the pHB650 (prototype High Beta 650 MHz) cryomodule at PIP2IT (PIP-II Injector Test Facility), with a focus on both the results and the methodological advancements that have improved testing efficiency and accuracy. A key challenge identified in the testing campaign is the higher-than-expected heat loads observed in the first PIP-II (Proton Improvement Plan II) prototype cryomodules (pSSR1 and pHB650) tested at PIP2IT. Elevated heat loads are concerning given the fixed capacity of the PIP-II cryoplant that is currently being installed at Fermilab. However, understanding the sources of these elevated heat loads offers a critical opportunity to implement effective heat load mitigations on upcoming PIP-II cryomodules to stay within the available capacity of the PIP-II cryoplant. The study includes a summary of test results, descriptions of measurement procedures, and key observations on parameters directly and indirectly related to heat load measurements. Direct observations include measured heat loads and the effectiveness of JT heat exchanger under varying conditions, while indirect observation analyze factors such as the temperature distribution on the two-phase pipe and relief piping under varying conditions. Thermal acoustic oscillations (TAO) were identified during testing, which was mitigated by replacing the original G10 stem with a stainless steel stem equipped with wipers for the cryomodule cooldown valve. A major innovation during pHB650 Phase 3 testing was the development of an automated Python script to streamline data acquisition, analysis, and reporting of heat load results. This script automatically retrieved data from ACNET (Accelerator Control Network), performed heat load calculations, and generated detailed reports featuring plots and tables. This advancement significantly reduced manual labor and enhanced the thoroughness of data analysis compared to earlier campaigns. The heat load test reports were promptly uploaded to the electronic logbook shortly after each test, enabling rapid feedback and collaboration between the SRF and cryogenic teams. The heat load measurements included various components: HTTS (high-temperature thermal shield), LTTS (low-temperature thermal shield), 2K isothermal and non-isothermal heat loads. Results were recorded both within the cryomodule and between the bayonet can supply and return. Measurements were conducted under different operating conditions such as "standard", "linac", and "simulated dynamic". Additionally, HTTS and LTTS heat loads were calculated in real time, allowing for the tracking of thermal stability and identification of changes during testing, both in steady-state and transient conditions. The results of this testing campaign not only provide valuable insights into the performance of the pHB650 cryomodule but also highlight best practices and lessons learned that will inform future cryomodule testing at PIP2IT. These include adopting automated tools for data analysis, refining real-time measurement capabilities, and emphasizing detailed pre-test planning. The framework established in this campaign aims to set an improved standard for cryomodule testing and heat load reporting in future cryomodule test campaigns.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
DOE OSTI2014

CEBAF Upgrade: Cryomodule Performance And Lessons Learned

The Thomas Jefferson National Accelerator Facility is currently engaged in the 12 GeV Upgrade Project. The goal of the 12 GeV Upgrade is a doubling of the available beam energy of the Continuous Electron Beam Accelerator Facility (CEBAF) from 6 GeV to 12 GeV. This increase in beam energy will be due in large part to the addition of ten C100 cryomodules plus associated new RF in the CEBAF linacs. The C100 cryomodules are designed to deliver 100 MeV per installed cryomodule. Each C100 cryomodule is built around a string of eight seven-cell, electro-polished, superconducting RF cavities. While an average performance of 100MV per cryomodule is needed to achieve the overall 12 GeV beam energy goal, the actual performance goal for the cryomodules is an average energy gain of 108 MV to provide operational headroom. Cryomodule production started in December 2010. All ten of the C100 cryomodules are installed in the linac tunnels and are on schedule to complete commissioning by September 2013. Performance during Commissioning has ranged from 104 MV to 118 MV. In May, 2012 a test of an early C100 achieved 108 MV with full beam loading. This paper will discuss the performance of the C100 cryomodules along with operational challenges and lessons learned for future designs.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

200 MV Record Voltage Of vCM And LCLS-II-HE Cryomodules Production Start At Fermilab

The Linac Coherent Light Source (LCLS) is an X-ray science facility at SLAC National Accelerator Laboratory. The LCLS-II project (an upgrade to LCLS) is in the commissioning phase; the LCLS-II-HE (High Energy) project is another upgrade to the facility, enabling higher energy operation. An electron beam is accelerated using superconducting radio frequency (SRF) cavities built into cryomodules. It is planned to build 24 1.3 GHz standard cryomodules and one 1.3 GHz single-cavity Buncher Capture Cavity (BCC) cryomodule for the LCLS-II-HE project. Fourteen of these standard cryomodules and the BCC are planned to be assembled and tested at Fermilab. Procurements for standard cryomodule components are nearing completion. The first LCLS-II-HE cryomodule, referred to as the verification cryomodule (vCM) was assembled and tested at Fermilab. Fermilab has completed the assembly of the second cryomodule. This paper presents LCLS-II-HE cryomodule production status at Fermilab, emphasizing the changes done based on the successes, challenges, mitigations, and lessons learned from LCLS-II; validation of the changes with the excellent vCM results.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Study of Microphonic Effects on the C100 Cryomodule for High Energy Electron Beam Accelerators

The Continuous Electron Beam Accelerator Facility (CEBAF) at Thomas Jefferson National Laboratory (JLab) is a particle accelerator which can accelerate an electron beam to relativistic speeds and apply the beam onto target samples. The C100 superconducting radio frequency (SRF) cavity is the primary accelerating structure of the C100 cryomodule, one of the many cryomodules which compose the CEBAF linear accelerator. SRF cavities are particularly sensitive to internal and external vibrations that can result in a phenomenon called microphonics which degrade the operational stability of a cryomodule. The purpose of this thesis is to investigate the significance of mechanical disturbances on the electromagnetic resonant frequency of a C100 SRF cavity. Knowledge of the mechanical resonance of the cavities and cryomodule sheds light into how these disturbances are most easily realized as deformation which causes radio frequency (RF) detuning. Three studies were conducted: the development and hammer test calibration of a Finite Element Analysis (FEA) model of a C100 cavity, the development and hammer test calibration of an FEA model of a C100 cavity string, and the hammer test of the C100-10R cryomodule at the Cryomodule Test Facility (CMTF). The cavity FEA model was found to accurately predict two modes found in two real cavities in a simply supported configuration. The cavity string FEA model leveraged the calibrated cavity FEA model but was not found to accurately predict the modal behavior of a real cavity string. Even so, the modal behavior of the cavity string inside the C100-10R cryomodule was captured during a hammer test while it was partially assembled. Finally, the C100-10R cryomodule was placed in the CMTF to study RF detuning. The RF detuning spectra during hammer hits and background noise was captured. The results of the hammer testing indicate two strong peaks at low frequencies (9-10 Hz and 22-23 Hz). These two frequencies were found to be nearly coincident to four instances of mechanical resonance found during the hammer testing done on the partially-assembled C100-10R. Because of this, these two modes are believed to contribute to RF detuning of the cryomodule. This test event also included the testing of the effectiveness of a configuration of BNNT canisters designed to act as dampers. While these tests show promising results, the lurking variables render these tests somewhat inconclusive.

Hull, Caleb James↗
DOE OSTI2018

LCLS-II Cryomodule Production at JLAB

The LCLS-II cryomodule construction program leverages the mature XFEL cryomodule design to produce technologically sophisticated cryomodules with a minimum of R&D according to an accelerated manufacturing schedule. Jlab, as one of the partner labs, is producing 18 cryomodules for LCLS-II. To meet the quality and schedule demands of LCLS-II, many upgrades to the JLAB cryomodule assembly infrastructure and techniques have been made. JLab has installed a new cleanroom for string assembly and instituted new protocols to minimize particulate transfer into the cavities during the cryomodule construction process. JLab has also instituted a set of magnetic hygiene protocols to be used during the assembly process to minimize magnetic field impingement on the finished cavity structure. The goal has been to have gradients, both maximum and field emission onset, that do not degrade between the cavity vertical test and final cryomodule qualification, while maximizing the Q0 of each finished cavity. Results from the prototype and first production cryomodule assembly are presented.

Davis, Giles↗