Operating Experience and Reliability Improvements on the 5 kw CW Klystron at Jefferson Lab
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1 Operating Experience and Reliability Improvements on the 5 kw CW Klystron at Jefferson Lab Richard Walker & Richard Nelson Jefferson Lab, Newport News VA
2 Jefferson Lab is a $600M Department of Energy facility for nuclear physics research to explain the quark structure of matter and the forces that hold the nucleus together. Managed by the Southeastern Universities Research Association (SURA) under a performance based contract, Jefferson Lab was constructed within JLab cost and on Background schedule and is currently performing above design specification. The heart of Jefferson Lab is its 4 GeV (design specification) electron accelerator delivering beams of unprecedented quality to 3 experimental halls simultaneously. Scientific purpose of Jefferson Lab (Jefferson Lab) Jefferson Lab acts as a microscope to allow us to look into the inner structure of the nucleus. The purpose of the research done at Jefferson Lab is to help us understand how quarks and gluons make up the nucleus and the forces that hold matter together.
3 CEBAF s Scientific Purpose
4 Jefferson Lab Site
5 Machine Configuration
6 JLab FEL Upgrade
7 RF Zone Configuration 3 control racks 5 racks for klystrons Single shared HV power supply 42 systems in CEBAF 3 more in FEL
8 Klystron Configuration 8 klystrons per zone Powered from single beam power supply Circulators, couplers, etc. 4 waveguides per penetration to tunnel
9 Varian VKL7811W Purchased through competitive bid Order of year delivery period
10 Litton L491 Replacement from competitive bid Multi-year order Purchase in lots of 10 or received to date
11 VKL7811W Specifications (voltage, current, gain, power, etc) 5 kw CW A 32.4% efficiency (min) 38 db gain 4 cavity design Coaxial output PM focusing Potted gun Size limitations (to fit our application)
12 Klystrons Arrive Testing Begin by testing all incoming klystrons - Tuning problems - Gain problems (related to tuning) - High body current: added magnetic shunts Reduce sampling when results are good - End result was to test all tubes
13 Failure Types External arcing Internal arcing Potting failure High leakage Ceramic fracture
14 Gun Treatment Gun is potted with RTV Provides electrical insulation against humidity Adds breakdown resistance Protects against dust & dirt - Minimize maintenance & cleaning Constrains connecting leads Mechanical protection from damage
15 Potting Problems Liquefied, dried, & decomposed
16 Locating Bad Potting Try to find potential bad potting Visual inspection Tactile (Charmin test) Ultrasound examination All methods found some pending failures; no test proved 100% reliable All surviving tubes were repotted
17 Potting and Ceramic Failure Due to excessive heating from Heater power - ~30 watts - Found 60 watts met rated RTV temperature Intercept currents on modulating anode Leakage across gun ceramic insulators
18 Internal Barium Deposition Tubes exhibit linear and non-linear leakage Non-linear: field emission Conditioned out by hipotting or controlled operation Linear: leakage across ceramic, internal to tube Thermal runaway can occur resulting in ceramic breakage Catastrophic runaway can occur in hours if left unchecked
19 Failures When We Increase operating cathode voltage Lower mod anode voltage This increases voltage across the ceramic Demand higher RF power Additional mod anode intercept with RF Fail to observe the onset of problems and take action before catastrophic failure
20 Other Failures Emission failure from cathode depletion Open heater element RF output connector Damage to HV lead insulation (silicone) from rough handling Vacuum leaks from tuner diaphragm failure LCW (cooling water) interlock failure Resulted in collector copper melting into drift tubes
21 Temperature & Space Charge Limits Cathode Voltage 11 kv
22 Operational Changes Minimize heater power Voltage is remotely monitored & settable Monitor mod anode current Increase mod anode voltage to reduce mod anode current & ceramic leakage current Minimize beam voltage Adjust tap settings on cathode power supply for each RF zone for power required Lowers the power from leakage on ceramic
23 Mechanical Changes Lengthen mod anode to cathode ceramic Reduce mod anode to body ceramic length Allows existing gun design to otherwise remain unchanged Provides more surface area to receive barium boil off Results in longer time to develop serious leakage Relocate gun stem vent holes (holes are between gun interior, heat shield, and exterior)
24 Klystron Reliability Graph 100,000,000 10,000,000 1,000,000 Hours & Failures 100,000 10,000 1, Klystron Filament Hrs Cum Klystron Filament Hrs Klystron Failures Cum Klystron Failures Avg Klystron Filament Hrs / Failure Cum Avg Klystron Filament Hrs / Failure Year
25 Klystron Reliability Table Year Klystron Cum Klystron Klystron Cum Klystron Avg Klystron Cum Avg Klystron Filament Hrs Filament Hrs Failures Failures Filament Hrs / Failure Filament Hrs / Failure ,000 40, , , ,636 17, , , ,211 18, , , ,500 22, ,000 1,645, ,778 32, ,268,000 3,913, ,706 46, ,187,000 6,100, ,214 61, ,546,000 8,646, ,167 77, ,626,000 11,272, ,333 98, ,277,000 13,549, , , ,424,000 15,973, , , ,538,000 18,511, , , ,032,000 20,543, ,032, , ,309,600 22,852, , ,829
26 Summary Several failure modes have been addressed Reduced failure rate though - Operating mode changes Lowered heater voltage Reduced cathode voltage - Constant monitoring and adjustment of Mod Anode - Potting changes Used better material (higher temperature & conductivity) - Mechanical design changes But final results won t be available for years Present average life is 138,800 hours
27 Ion Burn Tube has no separate ion pump Cathode shows ion burn
28 Pictures of Problems Crystal growth behind cathode heater View inside gun stalk showing heater potting with cracks
29 Pictures of Problems Mod anode arc tracks
30 Pictures of Problems Gun stem arc tracks
31 Output Connector
32 Gun Externals Gun with potting removed Connections for Heater Heater/Cathode Mod Anode
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