SRF2013 - List of Authors (Iversen, J.)

Paper

Title

Page

The Challenge and Realization of the Cavity Production and Treatment in Industry for the European XFEL

18

W. Singer, J. Iversen, A. Matheisen, H. Weise
DESY, Hamburg, Germany
P. Michelato
INFN/LASA, Segrate (MI), Italy

The main effort in production of 1.3 GHz cavities for the EXFEL was dedicated to transfer the superconducting technology to the industry. These know how transfer is executed by DESY and INFN/LASA team. The preparation phase based on prototype cavities covered: qualification of potential vendors for material and cavity fabrication; work out recipe and strategy for qualification of the infrastructure for cavity surface treatment at industry; definition of the quality management strategy, documentation and electronically data exchange. Production of 800 series cavities on the principle “build to print” is contracted to companies Research Instruments and Ettore Zanon. High purity niobium and NbTi for resonators provides DESY. The principles of the material and cavities production in conformity with European Pressure Equipment Directive are developed together with the notified body. New or upgraded infrastructure has been established at both companies. The first several tens of series cavities have been produced and treated. Most of the cavities handed over to DESY up to now fulfill immediately the EXFEL specifications. The cavity production for EXFEL will be finished mid of 2015.

Slides MOIOA03 [7.394 MB]

MOP032

Statistic to Eddy-Current Scanning of Niobium Sheets for European XFEL

171

A. Brinkmann, S. Arnold, A. Ermakov, J. Iversen, M. Lengkeit, A. Poerschmann, L. Schaefer, W. Singer, X. Singer
DESY, Hamburg, Germany

The fabrication experiences of superconducting cavities for FLASH have shown that eddy-current scanning of the Nb-sheets foreseen for half-cells reduces the cavity failures. New eddy current devices have been developed and build together with the industry for the production of 800 pieces 1.3 GHz superconducting niobium cavities for European XFEL. More than 15.000 Nb-sheets provided by three companies have been tested by eddy-current scanning. The sheets that demonstrated local deviations of the signal have been subsequently non-destructively examined by 3d-microscope and X-Ray element analysis. The surface defects (dents, holes, scratches) are the mainly detected flaws. In addition several types of foreign material inclusions observed. Statistic concerning eddy-current signal deviation and rejection rates for each supplier will be presented.

MOP035

Using an Engineering Data Management System for Series Cavity Production for the European XFEL

183

J. Iversen, A. Brinkmann, J.A. Dammann, A. Poerschmann, W. Singer, J.H. Thie
DESY, Hamburg, Germany

For series production of 800 superconducting cavities for the European XFEL an Engineering Data Management System (EDMS) is in use as a tool for quality control and quality assurance. DESY is responsible for “in-time” supply of more than 24000 semi-finished products of niobium and niobium-titanium alloy. The EDMS as a main repository was set up to fulfill logistic requirements and to guarantee traceability and documentation issues according to the European pressure equipment directive (PED 97/23 EC). The main aspects consist of complete paperless documentation, fully automated transfer of quality management documents and data from vendor system to DESY’s EDMS, providing to industry an access to relevant documentation and processing of release procedures for acceptance levels and non-conformity reporting. A summary of documentation methods, procedures and first experiences will be presented.

MOP039

Strategy of Technology Transfer of EXFEL Preparation Technology to Industry

197

A. Matheisen, J. Iversen, A. Schmidt, W. Singer
DESY, Hamburg, Germany
P. Michelato, L. Monaco
INFN/LASA, Segrate (MI), Italy

For the EXFEL a specification for the cavitiy preparation procedures (R1)was set up and handed to the industrial companies. Basing on this specification companies hard ware as well as process flows were set up. Beside this specified part of the preparation technique the companies personal needed to be educated and the processes ramped up. To check the quality of the infrastructure, status of education of personal and correct set up of process flows, so called Dummy (DCV) - , Reference (RCV ) and Pre-series (PCV) cavities were assigned. We report on the general strategy applied for the EXFEL technology transfer on cavity preparation and the results obtained on the qualification cavities.
R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

MOP041

A Database for the European XFEL

205

S. Yasar, P.D. Gall, V. Gubarev, J. Iversen, A.A. Sulimov
DESY, Hamburg, Germany

The database takes over more and more an effective part of the quality control system for the whole cavity production and preparation process for European XFEL on a very detailed level. Currently we try to find out the most effective and safe way to get the production data from the different companies to the database and to control the quality of the cavity production from the Niobium sheets to the complete modules in the linac. At the moment the database contains information about 250 9-cell cavities, 7000 half cells, 2200 dumb bells and 500 end groups.

MOP043

ILC-HiGrade Cavities as a Tool of Quality Control for European XFEL

212

A. Navitski, E. Elsen, B. Foster, J. Iversen, A. Matheisen, D. Reschke, W. Singer, X. Singer, L. Steder, M. Wenskat
DESY, Hamburg, Germany
R. Laasch, Y. Tamashevich
University of Hamburg, Hamburg, Germany

Funding: BMBF, Helmholtz Association, ILC-HiGrade, FP7 (CRISP), Alexander von Humboldt Stiftung/Foundation
The EXFEL order for SRF cavities includes 24 cavities, which are part of the ILC-HiGrade program. Initially, these cavities serve as quality control (QC) sample extracted from the EXFEL cavities series production on a regular basis. The QC and quality assurance (QA) include all processing steps of the EXFEL cavities. To maximize the information from these so-called QC cavities, a surface mapping technique is applied in a second cold RF test. There the cavities delivered have experienced identical treatment of the inner surface with the exception of mounting of the Helium vessel. After the normal acceptance test at the cavity RF measurement facility, the cavities are removed from the production flow. Further quality assurance steps beginning with a detailed RF test with surface mapping followed by a high resolution optical inspection (OBACHT) are carried out to improve the understanding of defects in close collaboration with the standing experts engaged in the EXFEL production. Results of the first QC cavities tests as well as planned further R&D will be presented and discussed.

MOP048

PED Requirements Applied to the Cavity and Helium Tank Manufacturing

227

A. Schmidt, J. Iversen, A. Matheisen, W. Singer
DESY, Hamburg, Germany

For the European XFEL more than 800 Cavities are manufactured by industrial partners. Each cavity is housed in an individual cryo vessel, the so called helium tank. All vessels are made from titanium and manufactured by industry as well. The cavity, welded into its helium tank, is a pressure loaded part and has to follow the pressure equipment directive - PED (97/23/EC). Setting up a series production of cavities and helium tanks by different vendors according given standards, was the task of the EXFEL WPG-1 LINAC-WP04. In cooperation with the TUEV-Nord as the notified body, DESY is responsible for the qualification of design, material in use and reasonable tests to get a certificate for pressure bearing parts.

MOP050

Strategy and Experiences on Procurement of Material for European XFEL Cavities

X. Singer, J. Iversen, W. Singer
DESY, Hamburg, Germany
F. Gaus, K-H. Marrek
TÜV NORD Systems GmbH & Co. KG, Hamburg, Germany

Analysis of the strategy for material procurement and quality management is done on base of the European XFEL experiences. In the preparation phase the requirements to material has been defined and the qualification of various companies as potential supplier for European XFEL executed. Estimation of the material for production of pressure bearing parts, creation of PMAs (particular material appraisal) acc. the European Pressure Equipment Directive and certification of the companies as producer of the material for pressure bearing parts has been done together with the notified body (TÜV NORD Systems). The procurement of material, QC, documentation, shipment and supervising the material workflow at cavity-producers has been carried out by DESY. Four companies produced ca. 25.000 semi-finished parts of high purity niobium and NbTi within of three years. Analysis of the main flaws and foreign material inclusions in niobium sheets is presented.

Poster MOP050 [1.609 MB]

Paper	Title	Page
MOIOA03	The Challenge and Realization of the Cavity Production and Treatment in Industry for the European XFEL	18
	W. Singer, J. Iversen, A. Matheisen, H. Weise DESY, Hamburg, Germany P. Michelato INFN/LASA, Segrate (MI), Italy
	The main effort in production of 1.3 GHz cavities for the EXFEL was dedicated to transfer the superconducting technology to the industry. These know how transfer is executed by DESY and INFN/LASA team. The preparation phase based on prototype cavities covered: qualification of potential vendors for material and cavity fabrication; work out recipe and strategy for qualification of the infrastructure for cavity surface treatment at industry; definition of the quality management strategy, documentation and electronically data exchange. Production of 800 series cavities on the principle “build to print” is contracted to companies Research Instruments and Ettore Zanon. High purity niobium and NbTi for resonators provides DESY. The principles of the material and cavities production in conformity with European Pressure Equipment Directive are developed together with the notified body. New or upgraded infrastructure has been established at both companies. The first several tens of series cavities have been produced and treated. Most of the cavities handed over to DESY up to now fulfill immediately the EXFEL specifications. The cavity production for EXFEL will be finished mid of 2015.
	Slides MOIOA03 [7.394 MB]

MOP032	Statistic to Eddy-Current Scanning of Niobium Sheets for European XFEL	171
	A. Brinkmann, S. Arnold, A. Ermakov, J. Iversen, M. Lengkeit, A. Poerschmann, L. Schaefer, W. Singer, X. Singer DESY, Hamburg, Germany
	The fabrication experiences of superconducting cavities for FLASH have shown that eddy-current scanning of the Nb-sheets foreseen for half-cells reduces the cavity failures. New eddy current devices have been developed and build together with the industry for the production of 800 pieces 1.3 GHz superconducting niobium cavities for European XFEL. More than 15.000 Nb-sheets provided by three companies have been tested by eddy-current scanning. The sheets that demonstrated local deviations of the signal have been subsequently non-destructively examined by 3d-microscope and X-Ray element analysis. The surface defects (dents, holes, scratches) are the mainly detected flaws. In addition several types of foreign material inclusions observed. Statistic concerning eddy-current signal deviation and rejection rates for each supplier will be presented.

MOP035	Using an Engineering Data Management System for Series Cavity Production for the European XFEL	183
	J. Iversen, A. Brinkmann, J.A. Dammann, A. Poerschmann, W. Singer, J.H. Thie DESY, Hamburg, Germany
	For series production of 800 superconducting cavities for the European XFEL an Engineering Data Management System (EDMS) is in use as a tool for quality control and quality assurance. DESY is responsible for “in-time” supply of more than 24000 semi-finished products of niobium and niobium-titanium alloy. The EDMS as a main repository was set up to fulfill logistic requirements and to guarantee traceability and documentation issues according to the European pressure equipment directive (PED 97/23 EC). The main aspects consist of complete paperless documentation, fully automated transfer of quality management documents and data from vendor system to DESY’s EDMS, providing to industry an access to relevant documentation and processing of release procedures for acceptance levels and non-conformity reporting. A summary of documentation methods, procedures and first experiences will be presented.

MOP039	Strategy of Technology Transfer of EXFEL Preparation Technology to Industry	197
	A. Matheisen, J. Iversen, A. Schmidt, W. Singer DESY, Hamburg, Germany P. Michelato, L. Monaco INFN/LASA, Segrate (MI), Italy
	For the EXFEL a specification for the cavitiy preparation procedures (R1)was set up and handed to the industrial companies. Basing on this specification companies hard ware as well as process flows were set up. Beside this specified part of the preparation technique the companies personal needed to be educated and the processes ramped up. To check the quality of the infrastructure, status of education of personal and correct set up of process flows, so called Dummy (DCV) - , Reference (RCV ) and Pre-series (PCV) cavities were assigned. We report on the general strategy applied for the EXFEL technology transfer on cavity preparation and the results obtained on the qualification cavities. R1) Series Surface and acceptance test preparation of superconducting cavities for the European Xfel (XFEL/A - D) JUNE 30, 2009

MOP041	A Database for the European XFEL	205
	S. Yasar, P.D. Gall, V. Gubarev, J. Iversen, A.A. Sulimov DESY, Hamburg, Germany
	The database takes over more and more an effective part of the quality control system for the whole cavity production and preparation process for European XFEL on a very detailed level. Currently we try to find out the most effective and safe way to get the production data from the different companies to the database and to control the quality of the cavity production from the Niobium sheets to the complete modules in the linac. At the moment the database contains information about 250 9-cell cavities, 7000 half cells, 2200 dumb bells and 500 end groups.

MOP043	ILC-HiGrade Cavities as a Tool of Quality Control for European XFEL	212
	A. Navitski, E. Elsen, B. Foster, J. Iversen, A. Matheisen, D. Reschke, W. Singer, X. Singer, L. Steder, M. Wenskat DESY, Hamburg, Germany R. Laasch, Y. Tamashevich University of Hamburg, Hamburg, Germany
	Funding: BMBF, Helmholtz Association, ILC-HiGrade, FP7 (CRISP), Alexander von Humboldt Stiftung/Foundation The EXFEL order for SRF cavities includes 24 cavities, which are part of the ILC-HiGrade program. Initially, these cavities serve as quality control (QC) sample extracted from the EXFEL cavities series production on a regular basis. The QC and quality assurance (QA) include all processing steps of the EXFEL cavities. To maximize the information from these so-called QC cavities, a surface mapping technique is applied in a second cold RF test. There the cavities delivered have experienced identical treatment of the inner surface with the exception of mounting of the Helium vessel. After the normal acceptance test at the cavity RF measurement facility, the cavities are removed from the production flow. Further quality assurance steps beginning with a detailed RF test with surface mapping followed by a high resolution optical inspection (OBACHT) are carried out to improve the understanding of defects in close collaboration with the standing experts engaged in the EXFEL production. Results of the first QC cavities tests as well as planned further R&D will be presented and discussed.

MOP048	PED Requirements Applied to the Cavity and Helium Tank Manufacturing	227
	A. Schmidt, J. Iversen, A. Matheisen, W. Singer DESY, Hamburg, Germany
	For the European XFEL more than 800 Cavities are manufactured by industrial partners. Each cavity is housed in an individual cryo vessel, the so called helium tank. All vessels are made from titanium and manufactured by industry as well. The cavity, welded into its helium tank, is a pressure loaded part and has to follow the pressure equipment directive - PED (97/23/EC). Setting up a series production of cavities and helium tanks by different vendors according given standards, was the task of the EXFEL WPG-1 LINAC-WP04. In cooperation with the TUEV-Nord as the notified body, DESY is responsible for the qualification of design, material in use and reasonable tests to get a certificate for pressure bearing parts.

MOP050	Strategy and Experiences on Procurement of Material for European XFEL Cavities
	X. Singer, J. Iversen, W. Singer DESY, Hamburg, Germany F. Gaus, K-H. Marrek TÜV NORD Systems GmbH & Co. KG, Hamburg, Germany
	Analysis of the strategy for material procurement and quality management is done on base of the European XFEL experiences. In the preparation phase the requirements to material has been defined and the qualification of various companies as potential supplier for European XFEL executed. Estimation of the material for production of pressure bearing parts, creation of PMAs (particular material appraisal) acc. the European Pressure Equipment Directive and certification of the companies as producer of the material for pressure bearing parts has been done together with the notified body (TÜV NORD Systems). The procurement of material, QC, documentation, shipment and supervising the material workflow at cavity-producers has been carried out by DESY. Four companies produced ca. 25.000 semi-finished parts of high purity niobium and NbTi within of three years. Analysis of the main flaws and foreign material inclusions in niobium sheets is presented.
	Poster MOP050 [1.609 MB]