Some

Fundamentals of Cryogenic and Module Engineering

with regard to SRF Technology
Bernd Petersen DESY Cryogenic Group MKS Hamburg, Germany

Overview
First part: Some theory Second part: More practical aspects (cryomodule design considerations)
Too much items.. and still incomplete.. But lets see how far we can proceed

My sources:
LINDEKRYOTECHNIK AG Switzerland, H.Herzog AERZEN Compressors Germany AIR LIQUIDE France WEKA Valves Switzerland VDI-Seminars Germany AD-Pressure-Vessel-Code ASME Code My colleagues from INFN, FNAL, Cornell-University, JLAB, KEK, BESSY, DESY and Steve van Sciver others

First part: tutorial objectives

after this part, we should remember: The meaning of cryogenic Carnot refrigerator efficiency COP of a refrigerator Some Helium refrigerator cycles Some quantum properties of matter at low temperatures Some useful Helium II properties Some typical cooling cycles Some fundamentals of thermal insulation

Cryogenic Fundamentals
Why is Cryogenic separated from usual cooling engineering ? Use of conventional superconductors like Nb requires cooling at liquid helium temperatures Due to basic thermodynamic laws, the efficiency of refrigerators is quite low at these temperatures (Carnot cycle) the cooling is very expensive ! -> excellent thermal insulation is required -> refrigerators should work very efficient to come closer to the Carnot cycle -> we have to deal with quantum properties of matter at these temperatures: decrease of specific heat, heat transfer, superconductivity, superfluidity -> helium is the only coolant ( low heat of vaporization, leak tightness, purification techniques.) -> careful engineering is needed: choice of materials, welding procedures, quality control, pressure vessel code requirements..

Definition: CRYOGENIC
Traditional (you can find in textbooks) : T < 120 K

[My personal view: T < 77 K ( LN2 cooling is no real cryogenic)]

Physicist view : temperatures were characteristic quantum states of matter dominate ( Cp -> 0, Helium II, conventional superconductivity..)

HERE: The engineering, which is required to specify, design, construct and operate cooling systems and cryostats for superconducting RF cavities at liquid Helium temperatures.

Basic laws of thermodynamics

1. Energy conservation 2. Entropy can never decrease spontaneously in a closed system: 0 S - corresponds to The Carnot Cycle is the most efficient cycle that exist 3. S -> 0 for T -> 0 for an ideal crystal corresponds to Cp -> 0 (Engineers forget zero-point energy)

Carnot Refrigeration Cycle

Q HIGH =T 2 ( S 2 S 1 ) T W OUT
HEX 3 Cryo Load 4 2 1

T2 W IN T1

3 W = W IN W OUT 4

2 1

Q LOW S1
Entropy

S2 S

Q LOW = T 1 ( S 2 S 1 )

Carnot =

Useful Refrigeration = Work Input

Q LOW
=

T1 T2T1

Q HIGH - Q LOW

COP = Coefficient of Performance = 1/ Carnot

Sources of Irreversibility
(B.Ziegler, LINDE) Carnot Cycle

Some Refrigerator COPs

1 W useful refrigeration at 2 K = 870 W Primary Power !!!
Refrigeration Carnot 1/ Temperature IDEAL
WORLD

XFEL-Spec REAL WORLD

% Carnot

2K 5K 40 K

149 79 7

870 220 20

17 36 33

Coefficient of Performance
COP vs T 1200 1000 800 600 400 200 0 0 10 20 30 40
1200 1000 800 600 400 200 0 1.5

COPreal=1/( K * CARNOT)
CARNOT = T/(300 -T) K= 0.176 ( from latest LHC measurements at 1.8 K)
COP at Low T

COP

Temperature [K]
COP

JLab

measured LHC value at 1.8 K 1.7 1.9

TMR
2.1

Temperature [K]

Why do we care about COPs ?

Cooling at liquid helium temperatures T < 5 K is very expensive ! Large SRF facilities (JLAB,SNS, ERLs, XFEL,ILC..) need Megawatts of primary power supply. Excellent thermal insulation is mandatory ! Already at about T> 40 K the situation is much more relaxed ! -> Direct heat loads as much as possible to temperature levels above 40 K ( Radiation, HOMloads, solid state thermal conduction..)

Some Helium Refrigerator Cycles

Compressor

Simple LINDE cycle

H

Will this work for Helium ?

S Ideal Joule-Thomson Expansion = Isenthalpic Expansion H=0

HEX

Heat Exchanger Joule-Thomson JT Valve

load

Joule-Thomson Expansion: Inversion Curve

H = const cooling

= 40 K for HELIUM

Some Helium Refrigerator Cycles

Simple Claudet Cycle
H HEX Expansion HEX Machine (Turbine) S Ideal Turbine Expansion = Isentropic Expansion S=0 HEX

JT

load

Some Helium Refrigerator Cycles

Simple Collins Cycle
LN2 HEX Expansion HEX Machine (Turbine) HEX

JT

load

Some Helium Refrigerator Cycles

Simplified 4.5 K Helium Refrigerator + Shield Cooling

HEX HEX

HEX

JT

4.5 K load 40/80 K load

EXAMPLE: HERA Cryo Plant

T-s Diagramm Source: of cryogenic process

Example: HERA Cryo Plant

Inside HERA Cold Boxes

Cryogenic Turboexpander

Source: LINDEKRYOTECHNIK AG

Screw-Compressors

Source: AERZEN

HERA-Screw Compressors

LP + MP

HP

Choice of operation temperature for a sc cavity

Module 6 CMTB
Meas Qo/Eacc average gradient 10Hz 500/800us
Status:13-Mar-07 Esch/Kos/Lil/Lan MKS

3.00E+10

2.50E+10

Qo

1.6 K 1.8 K 2.0 K

Qo

2.00E+10

1.50E+10

1.00E+10 0 5 10

Eacc[MV/m]
(Courtesy of R.Lange et al. DESY MKS)

15 20 Eacc [MV/m]

25

30

35

Qo versus Eacc measurement for a complete TTF-cryomodule type III (similar to XFEL-prototype)

Simplified 2 K Helium Refrigerator + Shield Cooling

Primary Power HEX P cc out T cc out Cold Compressors P cc in T cc in HEX JT P bath T bath = f ( P bath ) 2 K load 4.5 K load 40/80 K load JT HEX

HEX

subcooler JT

The 20-year old HERA cryogenic plant will be up-graded to the 2 K- XFEL-cryogenic plant
2K Box incl. Cold compressors added

2 HERA Cold-Boxes modified and operated in parallel

Source: LINDE KRYOTECHNIK AG

Options to Produce Temperatures below 4.4 K, i. e. Evaporation of Helium at Reduced Pressures

Efficiency -> -> ->

A
Only the heat of evaporation of the helium is utilized.

D
The precompression is realized by several stages of cold compression.

The low pressure stream The cold low pressure is warmed up in a heat stream is precompressed exchanger inside the by a coldcompressor. refrigerator cold box.

Option A example: warm helium compressors for FLASHlinac/TTF supply at DESY

4 rotary vane pumps + 3 stages of roots blowers 10 g/s helium flow compression: 10 mbar -> 1.05 bar ( two identical sets of compressors for linac and TTF)

Option B: use of heat exchanger Example: FLASH linac at DESY

External low pressure heat exchanger ( IHEP,Russia) counter-flow heat exchanger: 3,5 K / 31 mbar -> 280 K / 29 mbar 7,5 K / 12 bar <- 300 K / 12 bar

Option C/D Example: TESLA Model Refrigerator

layout by TU-Dresden advice from CERN discussion with industry component number and size, flow rates, power consumption flow scheme 8 screw compressors 9 turbines 3 cold compressors

40 - 80 K Shield

5-8K Shield

2 K Load

Example of a cold compressor with active magnetic bearings used at Tore Supra, CEBAF and Oak Ridge

Source: Air Liquide

Cold Compressor Cartridges of 2.4 kW @ 1.8 K Refrigeration Units

Cold compressor impeller IHI-Linde

1st stage

The four-stage LHC cold compressors

Development of the Efficiency of Cold Compressors

Temperature (T)

P2

2 2'

80 Isentropic efficiency [%]

P1

LHC CEBAF Tore Supra

70 60 50 40 30 20 10 0

Entropy (s)

H 2' H1 is = H 2 H1

1985 1993 2000 Year of construction

Quantum Properties of Matter at low T

Many physical effects can be characterized by a typical Excitation Energy E The probability of excitation is about ~ EXP ( - E / kB T) For T ->

all states are excited.

For T -> 0 condensation in the ground state E = binding energy -> condensation of matter , liquifaction of gases E = h phonons in solids -> specific heat, thermal conductivity E = superconducting energy gap -> superconductivity E = band gap of semiconductors -> electrical resistance Other effects are not disturbed by thermal energy at low T like: Helium II phenomena (Bose condensation), Kapitza-Effect,

Thats why we have this SRF workshop..

Measurement of the superconducting surface resistance at 3 GHz

Nb/Cu : reduction of Rs by nearly 6 orders of magnitude

Quantum Properties of Matter at Low Temperatures Specific Heat of Solids

Thermal Conductivity of Solids at Cryogenic Temperatures

Thermal conductivity

Thermal conductivity of copper

Glas fiber re-inforced epoxid

Thermal contraction of solids Thermal Stress

L/L

Plastics > 2% Steel 0,3%

77K

Other View: H-S-Diagramm of Helium (Source: HEPAK)

Quantum Properties of Matter at low T Specific Heat of liquid HELIUM

Much larger than specific heat of solids at these temperatures !

Quantum Properties of Matter at low T Latent Heat and Entropy of liquid HELIUM

Phase Transition HE I -> HE II second kind phase transition ( no latent heat )

Helium II parameters = f(T)

Helium Parameters vs. Temperature 25 Heat of Vaporisation [J/g] / JT Qual %
Heat of vaporisation

0.06 Vapor Pressure [bar] 0.05 0.04

20 15 JT-Quality % 10

0.03 0.02

5 0

Vapor pressure

0.01 0.00

1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Temperature [K]

2.1 2.2

Definition of Lambda max in a HEII bath

Heat conductivity in HeII q**m = f(T) * dT/dx T-Temperature, x-length m3 f(T) Germany = f**(-1) (T) USA

T2 q max * L** 1/3 = [ f(T) dT ]**1/3 T1 T1 = F ( P1 ) Temperature function of vapour pressure T2 = F ( P1 + P ) P = *L*g = density of liquid g=9.81 m/s2 L= depth in bath T1, P1 at liquid surface L T2, P2 at depth L in the bath T2 must not be exceeded to avoid bubbles !

Helium II parameters = f(T) (cont.)

Lambda, Cp,Diffusivity,Density of HEII

16000 0.18 0.16 0.14 Lambda max in a saturated bath 0.12 0.1 0.08 0.06
Liquid density=RHO [kg/m3]

Lambda [W/m2], Cp [J/kg]

14000 12000 10000 8000 6000 4000 2000 0 1 1.2 1.4 1.6 1.8 2 2.2 'Diffusivity' = Lambda/(RHO*Cp) [m/s] Cp of liquid

Design

0.04 0.02 0

Temperature [K]

Diffusivity [m/s]

Kapitza Heat Transfer Solid Surface to Helium II

Heat transfer at the surface of one TESLA cavity T = 100 mK
400 350 Dissipated Heat [W] 300 250 200 150 100 50 0 1.5 1.7 1.9 Temperature [K] 2.1 0.1 0 0.4 0.3 0.6 0.5 Kapitza Resistance [W/K*cm2]

For Niobium

Hk=0.043*T**3.18
W/K*cm2

0.2

Some Cooling-Cycles: Forced 1-phase Helium I Cooling

SC Quadrupoles in TTF-Cryomodules + = simple -= large mass flow excess liquid

HERA Accelerator SC Dipoles ++ = homogeneous cooling of sc coils at constant temperature

HERA Accelerator Lumi-up-Grade SC Magnets + = no excess liquid -= large mass flows extra pump

Some Cooling cycles: Bath cooling

Advantages: very simple vapor P/ P = 0.5 mbar/ 31 mbar = 0.016 pressure regulation easy (pressure stability required for TESLA cavities) JT

liquid

T bath = f ( P bath )

Heat Transfer to a Bath of Helium I

Remember: Helium II bath 1 W/cm2 maximum heat flow density INSIDE the bath !

Bubble -boiling Free convection

Film-boiling 1 W / cm2

Over-Heating

Layout of XFEL-linac cryogenic: Helium II bath cooling About 1000 1.3 GHz sc cavities will be cooled in a 2K Helium II bath
support

2.2 K forward 2 K return 80 K return 300 mm 5 K forward 40 K forward

GRT
8 K return cool down/ warmup 2 K 2-phase

Two phase He II flow involved

cavity coupler

Disadvantage: Complex 2-phase flow conditions

Example: Situation at the start of the XFEL-linac (refrigerator side) P 0

Strings 5 - 11
Vapor flow large Gas return tube Two phase tube

JT Vapour Liquid
0.35 0.30 0.25

Beam tube

Vapor velocity [m/s]

Module 1

0.20 0.15 0.10 0.05 0.00 -2.00 0.00 -0.05 -0.10 -0.15 2.00 4.00 6.00 8.00 10.00 12.00 14.00

Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 Module 9 Module 10 Module 11 Module 12

Vapor flow velocity in 2-phase tube String 10

Module length [m]

Disadvantage: 2-phase flow affected by gravitational forces

Laser-straight XFEL-linac
JT
3.9 GHz Cavities

BC

JT

BC

JT

Liquid Helium II supply JT JT

JT
8 Modules

Length [m]

66 141 String 11

208 354 String 10

442 540 String 9

978

1561

5 String 4

1660 String 1

One String = 12 cryomodules each of 12 m length

Deviation from gravity equipotential [mm] 72,7 61,5 52,3 34,7 26,0 Beam

Beam direction

17,7

0,04

26,3

36,3

Gravity equipotential surface

Two phase Helium II flow: for the XFEL-linac we want stratified-smooth flow
Design operation of XFEL: 2 K, 20 GeV, 23.6 MV/m 15 W/cryomodule K = [ (l * g * VGS2 * VLS ) / ( (l g) * g * * cos () )]1/2
Flow Pattern String 10

String 11
10.00

Flow PatternString 11
10.00

String 10

K
1.00 0.00 0.10

K-Parameter

3.9 GHz
0.20 0.30 0.40 0.50

smooth
0.60 0.70 0.80 0.90 1.00 He II level / Tube diameter

K-Parameter 1.00 0.00 0.20 0.40 0.60 He II level / Tube diameter 0.80 1.00

wavy

He level /tube diameter

10.00

String 5

Flow Pattern String 5

10.00

String 1
K-Param eter

Flow PatternString 1

K-Param eter

1.00 0.00 0.20 0.40 0.60 0.80 1.00 He II level / Tube diameter

1.00 0.00 0.20 0.40 0.60 He II level / Tube diameter 0.80 1.00

2-ph-flow conditions for cryomodules in different sections of the XFEL-linac

Some Fundamentals of Thermal Insulation absorb radiation on

heat radiation a thermal shield Multi Layer Insulation reduce heat conduction by design and material

solid state heat conduction

rest gas heat conduction/convection

remove rest gas

heat conductivity

Some Fundamentals of Thermal Insulation: vacuum

viscous

Knudsen

molecular = mean free path of gas molecules S = cryostat dimension

Some Fundamentals of Thermal Insulation: MLI

Multi Layer Insulation = Superinsulation
to limit heat conduction between the MLI-layers: avoid direct contact of layers, make vacuum pumping possible MLI-materials: Aluminum foil Plastic foil : Mylar Al coated ( one or both sides)

vacuum pumping may be enhanced by small holes in foil space between foils required to limit heat conduction: use of wrinkled foils or spacer layers spacer materials: glas-paper, glas fiber net, paper,

Some Fundamentals of Thermal Insulation: MLI impressions

spacer glas fiber net (vitrolan)

Some Fundamentals of Thermal Insulation: TESLA Cryomodule MLI impressions

spacer net MLI covered Cu shield of end-cap

80K shield

8K shield Module connection to end-cap

Some Fundamentals of Thermal Insulation: MLI

heat conduction W/m2 0.7 0.8

Heat conduction of different MLI types

For design: 1 W/m2

0.6

0.5

0.4 number of layers

20

30

40

Some Fundamentals of Thermal Insulation: MLI

Heat conductivity of different MLIs vs. Density of layers
A: AL coated plastic foil B: AL glas-fiber spacer C: AL glas-fiber spacer tissue D: AL glas-fiber paper spacer MLI Layers / cm

Some Fundamentals of Thermal Insulation: MLI

Some Fundamentals of Thermal Insulation: MLI

(see safety section)

Note: All helium process areas inside the cryostat should be covered with about 5-10 layers of MLI to limit the impact of insulation vacuum loss !

Heat input caused by the break down of Insulation vacuum: 40kW / m2 without MLI 6kW/ m2 with MLI

2 K Helium Vessel of TESLA Cavity

 in addition the Helium vessel get their magnetic shielding

Some Fundamentals of Thermal Insulation: cryogenic valves

Thermal intercept
Desy philosophy: NO metal/metal sealings !!! Use of plastic seals like Vespel SP1 (polyimid)

Definition of Kv-value: volume flow of water [m3/h] at P = 1bar and T 278 K -313 K (Cv= 1,17 Kv USA)

First part: tutorial objectives

after this part, we should remember: The meaning of cryogenic Carnot refrigerator efficiency COP of a refrigerator Some Helium refrigerator cycles Some quantum properties of matter at low temperatures Some useful Helium II properties Some typical cooling cycles Some fundamentals of thermal insulation

Second part: tutorial objectives

after this part, we should remember: Measures to increase refrigerator availability Helium management considerations Suited materials for cryogenic temperatures Cryogenic safety aspects Basic cryomodule design considerations Pressure vessel regulations Quality control measures Example: TESLA style cryomodule design

HE RA C r y o P la n t: Av a ila b ility 1 9 9 4 - 2 0 0 3 105 104 103 102 101 100 99 98 97 96 95

average: MTBF = 33 days

Availability

99.6 %
1 9 9 2 1 9 9 3 1 9 9 4 1 9 9 5 1 9 9 6 1 9 9 7 1 9 9 8 1 9 9 9 2 0 0 0 2 0 0 1 2 0 0 2 year 2 0 0 3

(utilities excluded)

HERA Cryo Plant: Interruptions 1992 - 2003 18 16 14 12 10 8 6 4 2 0 1 99 2 1 99 3 1 99 4

average: MTBF = 33 days External Supply Com puter Control Coldbox Com pressors

N u m b e r

1 99 5

1 99 6

1 99 7

1 99 8

1 99 9

2 00 0

2 00 1

2 00 2

year
HERA Cryo Plant: Interruptions over 10 years of operation 1994 - 2003 25 20 N u m b e r 15 10 5 0
C ompressors C omputer C ontrol Main Power Water A ir
average: 6,2 interruptions /year 0,16 interruptions /week 1,04 h / week

2 00 3

200 180 160 140 120 100 80 60 40 20 0

kind of interruption

D o w n tim e(h )

Is there an availability increase by the installation of a complete redundant refrigerator ?

Availability increase by redundant refrigerators? Rating Source of unavailability 1 2 External utility failures Blockage by frozen out gaseous impurities Operational problems Single component failure not leading to total plant shutdown Catastrophic component failure leading to plant shutdown

Example

Electrical power, cooling water, instrument air failure Air and/or water vapor Controls, instrumentation, operators Electrical motor burnout, compressor bearings, leaking oil pump seal, turbine bearing trouble Loss of insulation vacuum, rupture of heat exchanger, oil spill into cold process piping

Multiple refrigerators ... ? would bring no advantage provide somewhat larger tolerance would be detrimental, because of higher complexity of the system would bring no advantage over component redundancy within a single refrigerator would have a positive effect

3 4

Redundant compressors and low temperature adsorbers Easy exchange of turbines and cold compressors

Helium Process Gas Management

Helium gas storage tanks

Liquid Helium storage dewar

Removal of: gravitation separation oil droplets

coalescence filter I

oil fog

Helium process gas purification

coalescence filter II

oil fog

dryer

H2O vapor

adsorber oil vapor

Low temperature purifier

oxygen nitrogen hydrogen

HD Coalescence Filter

Helium Dryer

Suited materials for low temperatures

Low temperature embrittlement Causes overloaded components to fracture spontaneously rather than accommodating the stress by plastic deformation Appropriate steels for low temperature use are listed in the Technical Rules for Pressure Vessels AD-Merkblatt W10 /European harmonized technical rules /ASME-code (USA) . (In general, materials with face-centered cubic (fcc) crystal structure as copper, nickel, certain copper nickel alloys, zircon and titanium are suitable for cryogenic applications.) .

European Harmonized Rules Stainless steels for the use at low temperatures
DIN EN 13445-2 B.2.2.4 Lowest material temperature for austenitic stainless steels Apply also for 2K ! (material spec corresponding to ASTM type AISI may differ ! )
Material spec
X1NiCrMoCu 31-27-4 X1CrNiMoN 25-22-2 X1CrNi 25-21 X2CrNiMoN 17-13-3 X2CrNiMoN 17-11-2 X2CrNiMoN 18-12-4 X2CrNiMo 18-15-4 X2CrNiN 18-10 X2CrNiMo 18-14-3 X2CrNi 19-11

DIN EN number
1.4563 1.4466 1.4335 1.4429 1.4406 1.4434 1.4438 1.4311 1.4435 1.4306

ASTM type AISI

TM (in C)
-270

310 L 316 LN

317 L 304 LN 316 L 304 L

Cryogenic safety aspects: Preventive Measures Against Pressure Build-up

Redundancy i.e. more safety devices than required double safety devices and Diversity i.e. safety devices based on different mechanisms

Cryogenic safety aspects Pressure Build-up by Evaporation Large air leak into the wave guide of an insert -> Evaporation of about 2.6 kg/s mass flow through safety valve

Heat input caused by the break down of Insulation vacuum: 40kW / m2 without MLI 6kW/ m2 with MLI

Bernd Petersen DESY MKS1 Bernd.Petersen@desy.de

Cryogenic safety aspects Preventive Measures against PressureBuild-up Release Flap + Safety Valve

Caution in the Vicinity Of Release devices !

Safety aspects: Calculation of venting conditions

According to ASME Code CGA S.1.3-1995

Q m = v * sqrt ( dh / d v) P
T=T flow Q heat input m mass flow V specific volume H specific enthalpy

sqrt ( v )
= f(T) v * sqrt ( dh / d v) P

Maximum at T=T flow T/Tkrit

Safety aspects: Spec of safety valves

Source: AD pressure vessel code

Safety aspects: procedure

Method used by DESY MKS:

Calculate heat input Q Find T flow (by ASME code) Calculate mass flow at T flow (by ASME code) Calculate sv dimensions ( by AD code)

Safety Valve in action .

Basic cryomodule design considerations (1)

Task : design a cryomodule for SRF accelerator operation
Operation mode : pulsed or cw ??? Fraction of dynamic and static loads ? RF operation frequency -> choice of operation temperature beta = ??? -> general cavity and cryostat design RF main coupler loads -> thermal intercepts HOM loads -> design of couplers and absorbers ERL machines -> active cooling of HOM absorbers may be required Tuners -> warm or cold ( extra feedtroughs required ?) Magnetic shielding of cavities Focusing sc magnets included ? Current leads design. Alignment requirements Environment -> expected radiation level, tunnel ?........... Single individual cryostat or serial production for large accelerator ?

Basic cryomodule design considerations (2)

Task : design a cryomodule for SRF accelerator operation
Some formal aspects: Generate a design concept Concept for cooling and heat load estimate Risk analysis -> choice of technical rules & pressure vessel classification Risk analysis -> safety concept & equipment Pressure vessel code -> design & construction rules Pressure vessel code -> choice and control of materials Pressure vessel code -> welding procedures & management Pressure vessel code -> third party inspection & test procedures Quality control plan ( in addition to pressure vessel code ) Design, construction & prototyping Testing, testing,testing Transfer to industrial construction Testing, testing,testing.-> pre-series -> serial production

Basic cryomodule design considerations (3)

Task : design a cryomodule for SRF accelerator operation
Some formal Rules, laws, regulations which have to be obeyed in the EU INCOMPLETE ! - European Pressure Equipment Directive (Richtlinie 97/23/EG fr Druckgerte) - Richtlinie ber elektrische Betriebsmittel (73/23EWG) - Gerte- und Produktsicherheitsgesetz (GPSG) - Betriebssicherheitsverordnung (BetrSichV) - Qualittsmanagementsysteme DIN EN ISO 9001, August 1994 - European Harmonized Standards like Europische Norm EN 13445, etc.

Basic cryomodule design considerations (4)

Task : design a cryomodule for SRF accelerator operation
Some technical aspects: By the way: the cavities have to work -> include clean room requirements from the start for all related components Quality insurance procedures: helium leak tests of each and every helium process components required (before, during and after assembly ) Helium leak testing at a rate of 10-8 mbar/l*sec (or better) for the individual componets at ambient temperatures will avoid cold-leaks in the order of better than 99% DESY philosophy: no direct feedthroughs from helium process areas to insulation vacuum for accelerator cryostats !!!! Structural tests (like X-raying of welds) can NOT replace helium leak checks ( and vice versa) !!!!! Welding additives must be qualified for low temperatures -> strict certification of welding procedures & welders; strict quality control organization and management

Example: TESLA-style cryomodule design (INFN Milano/Italy)

Designed for large accelerators -> low costs per length accelerator -> easy and cheap assembly -> serves as a generic design for other projects:ERLs,XFEL,ILC..

Example:

TESLA-style cryomodule design

Positions of cavities and Couplers are fixed

longitudinal movement posts during cool down

XFEL module type

-->sliding fixed

Sc magnet package also fixed at invar rod

sliding

Fixpoint Invar rod

C1

C2

C3

C4

C5

C6

C7

C8

Mag/BPM

X-ray of coupler position at 300 K and 2K

HOM-Absorber Between Modules

TESLA-style module design: 3 design steps In use for FLASH-linac user facility at DESY Prototype for XFEL-linac cryomodules ( only minor modifications )

(courtesy of N. Ohuchi et. al KEK)

T4CM Design. The Master Spreadsheet

(courtesy of Don Mitchell and Youri Orlov FNAL)

Hyperlinked to a detailed PDF drawing

Values which can be modified

Shrinkage Calculations

Cornell University ERL Injector Cryostat

(courtesy of Eric Chojnacki)

Design changes for for ERL use (cw-operation, large HOM loads)

HOM absorber

Second part: tutorial objectives

after this part, we should remember: Measures to increase refrigerator availability Helium management considerations Suited materials for cryogenic temperatures Cryogenic safety aspects Basic cryomodule design considerations Pressure vessel regulations Quality control measures Example: TESLA style cryomodule design

Thank You !