Cryomodule Development and Cryo-Engineering Application Section (CDCAS) is entrusted with responsibility to design and develop 650 MHz Cryomodule for future Indian Facility for Spallation Research (IFSR). CDCAS has also accomplished successfully design and development Horizontal Test Cryostat for qualifying 650 MHz SCRF dressed cavity. It also successfully developed various indigenous technologies. This section has developed expertise in mechanical, cryogenics, instrumentation and electronics.

CDCAS has also successfully developed spin-off of cryogenic technology. The prominent one is the liquid Nitrogen based transportable refrigeration system for fruits and vegetables. This is named as SHIVAY (Sheetal Vahak Yantra). A variant of the system has also been developed for storage and transportation of vaccines called SHIVAY-V. The technology is being developed for commercial use by M/s Tata Motors Ltd. This is being done under incubation agreement between RRCAT and M/s Tata Motors Ltd.

Major Achievements

Design and development of cryomodules for High Beta (Beta= 0.92) 650 MHz Superconducting Radio Frequency (SCRF) cavities is being pursued at RRCAT under auspices of Indian Institute FermiLab Collaboration (IIFC) program. These cryomodules will be a part of high beta section of any of the superconducting proton LINAC projects for DAE’s.

High Beta (HB) 650 MHz cryomodule will be used in high energy section of high intensity super conducting proton LINAC project of DAE. This cryomodule is approximately 1m in diameter and 9.5 m in length. It will house six numbers of 650 MHz SCRF cavities, which have to be supported and maintained at 2 Kelvin temperature environment. HB 650 MHz cryomodule supports cavities and these cavities need to be maintained within alignment of ±0.5 mm of their ideal beam axis even after cool down. The outer envelope of cryomodule consists of vacuum vessel which keeps all internal components in vacuum insulated environment. Design of this cryomodule mainly includes design of Cavity Support System (CSS), internal piping, thermal shields etc.

Design work of major subsystems for HB 650 MHz cryomodule mainly vacuum vessel, 70K thermal shield, cavity support system etc. has been done and will be reviewed jointly by experts from FNAL and DAE. Design of internal piping is underway. Design of assembly tooling for cryomodule has been initiated.

Procurement for cryomodule parts like vacuum vessel, 70K thermal shield, cavity support system, piping components and cryo-instrumentation has been initiated. Tentative procurement specification for components has been prepared and discussions are started with probable vendors.

3 D model of High Beta Cryomodule for 6 SCRF Cavity

Cryomodule Assembly Infrastructure Development - Jacking system (Spreader Bar) for lifting cavity string has been Installed with following features:

• Capacity 6 Ton in Compression with 1 m Stroke
• Translating, inverted type self locking worm gear screw jack
• Speed range 30 to 300 mm/min and any desired intermediate speed with VFD control
• Inductive proximity sensor (non contact type) for both ends of the movement
• Overall Length 10 m with 1.6 m wide clear space between columns
• Minimum Height under the Beam 1.5 m (at lowest position)

Jacking system at the lowest position	Jacking system at the full lift of 1 m

"The very first laser-welded 1.3 GHz SCRF niobium cavity developed at RRCAT using innovative laser welding technique reached an accelerating gradient (E_acc) of 31.6 MV/m with a quality factor (Q₀ ) of 1.0 x 10¹⁰ at 2 Kelvin."

An innovative technique to fabricate superconducting radio-frequency (SCRF) niobium cavities by laser welding has been developed at RRCAT. The first laser-welded 1.3 GHz SCRF cavity developed at RRCAT using this technique was tested at Fermilab, USA, and it reached an acceleration gradient (E_acc) of 31.6 MV/m with a quality factor (Q₀) of 1.0x10¹⁰ at 2 Kelvin. This performance is similar to that of standard cavities fabricated by conventional process involving electron beam welding.

The first laser-welded 1.3 GHz SCRF niobium cavity developed at RRCAT and tested at Fermilab, USA showed Eacc of 31.6 MV/m with a Q0 of 1.0x1010 at 2K.	Dr. R.K.Sinha, Chairman, Atomic Energy Commission & Secretary, Department of Atomic Energy, Government of India, discussing with Dr. P.D.Gupta, Director RRCAT the laser welding of SCRF niobium cavities.

RRCAT have developed laser cutting and welding techniques using in-house developed 10 kW fiber-coupled Nd:YAG lasers. These have been successfully deployed in a number of laser cutting and welding operations such as welding of brachytherapy assemblies for cancer treatment, welding of titanium shells for heart pacemakers, remote cutting of bellow-lips during en-masse coolant channels replacement campaign in three pressurized heavy water reactors (PHWRs) resulting in a substantial cost savings and reduction in radiation exposure to the personnel. In the present instance, the laser welding was applied for development of innovative technology for fabrication of superconducting radio-frequency (SCRF) cavities. The idea was conceptualized for the first time and developed at RRCAT. An international patent was earlier filed with title "Niobium based superconducting radio frequency cavities comprising niobium components joined by laser welding, method and apparatus for manufacturing such cavities" (Application no. 09812469.6-2302 PCT / IN20090621). This technique was granted patent from United States, European, Japanese and Indian Patent office.

In parallel, efforts were launched for practical realization of the above technique. An in-house developed 10 kW fiber-coupled Nd:YAG laser was used for welding and a cavity welding rig was fabricated with the help of Indian industry. The laser welding experiments were carried out on more than 150 samples for parameter optimization, and a single-cell 1.3 GHz SCRF niobium cavity was fabricated. The cavity was processed and tested at Fermilab, USA. The cavity went up to an accelerating gradient of 31.6 MV/m at Q₀ of 1.0x10¹⁰ at 2K.

10 kW fibre-coupled Nd:YAG laser	Superconducting cavity welding setup	The first laser-welded single-cell 1.3 GHz Nb cavity

Traditionally, electron beam welding technique is used for fabrication of SCRF niobium cavities where it is necessary to carry out the welding operation in a vacuum environment. The international experts are quite surprised at the high quality factor achieved in our laser-welded cavity, especially as the welding was carried out in an inert gas atmosphere. The advantages of the laser-welding technique are much lower cost, small heat affected zone, no necessity to have vacuum environment for welding, and enhanced rate of production. It is expected that this development will open up an entirely new R&D path which will be greatly followed by scientists and engineers engaged in accelerator programmes using superconducting cavities world over.

A transportable, standalone system for fruits & vegetables (F&V), under any temperature (appropriate for given perishable good), has been developed at RRCAT. Refrigeration is provided by liquid nitrogen, which is stored in the system itself. The system has been developed keeping in view the socio-economic conditions of Indian farmers. This standalone system is a perfect example of Make in India initiative of Government giving effect to Lab to Land guideline.

Liquid nitrogen is a commodity which is abundantly available in India in every taluka place. In bulk, it is cheap (Rs 10-12/litre) and 100% environment friendly. Air comprises of 78% nitrogen. It is known that large nitrogen liquefaction capacities, to a tune of 50% are idle in the country.

Final Products (SHIVAY & SHIVAY-V)

Liquid Nitrogen Based Transportable Refrigeration System- Sheetal Vahak Yantra (SHIVAY) intended for transportation of fruits vegetables & Pharmaceuticals products caters up-to requirement of minus 40 °C temperatures. This transportation can be carried out in a specially developed refrigerated container that can be mounted on any truck or can be built on the chassis of any vehicle. It is refrigerated by using liquid nitrogen. This technology has been tailor made for Indian conditions and is aimed at solving issues like high maintenance due to rough roads, which are faced by conventional refrigerated trucks (reefers) operators. The system does not use diesel for refrigeration, is 100% eco-friendly as it generates no pollutant gases or sound and is economical to use.

1. The cost of liquid nitrogen consumed is lower than cost of diesel consumed by 20-25%.
2. This standalone system needs no input from vehicle or the driver. Same system can be loaded and transferred on any carrier like train or truck. Thus it is truly multi modal.
3. Only two simple moving parts are used so minimum maintenance is expected.
4. Container can be built to any size.
5. LN2 is 100% eco-friendly. It is a by-product of oxygen plants.
6. Can travel 1200-1300 kms or 40 hrs, without refilling of liquid nitrogen in its tank.

1. Fruits & Vegetable and non vegetarian products up-to minus 40 degree centigrade as desired.
2. Pharmaceuticals Products.

SPECIFICATIONS OF THE SYSTEM

Standalone SHIVAY	Road Trial of the System

Liquid Nitrogen Based Transportable Refrigeration System- Sheetal Vahak Yantra (SHIVAY-V) for transportation pharmaceutical products (including vaccines) at any temperature, up-to minus 70 °C has been developed. The container has a cargo handling volume of 266cubic feet, and can hold 2 standard pallets of vaccines. This transportation can be carried out with this refrigerated container mounted on any truck or it can be built on the chassis of any vehicle. It is refrigerated by using liquid nitrogen. This technology has been tailor made for Indian conditions and is aimed at solving issues like high maintenance when travelling on rough roads. The system does not use diesel or CFC for refrigeration and hence is 100% eco-friendly. It generates no pollutant gases or sound, and is economical to use.

• The system performs the dual job of vaccine storage and transport and thus is a unique product not available in pharmaceutical cold chain.
• It can store and transport vaccines for about 4 days at 2° to 8° C without refilling of liquid nitrogen in its tank. (ambient temperature is 37°C as highest in a day)
• Container can be built to any size.
• During transport system needs no input from vehicle or the driver. Same system can be loaded and transferred on any carrier like train or truck and is thus, a truly multi modal system. It can also be rested outside hospital building and it keeps working.
• Only two simple moving parts are used so minimum maintenance is expected.
• LN2 is highly eco-friendly. It is a by-product of oxygen plants and Spare capacity exists in the country.

• Storage and transport (both) for vaccines up-to minus 70 degree centigrade. Thus it can be used for any vaccine that has been developed for use on mankind so far.

Ten Feet Refrigerated Container for Vaccine Transport

Mr.Aniruddha Kulkarni VP M/s Tata Motors Ltd	Mr Debashis Das Director,RRCAT

A major milestone was accomplished by fabricating and installing a Horizontal Test (HTS) Cryostat at RRCAT. This system will be used to test, two superconducting radio frequency (SCRF) cavities at cryogenic temperature before installing them inside cryomodules of the linear accelerator. (SCRF) cavities are the heart of linear accelerators built with SCRF technology. This is the third such facility in the world which can test two SCRF cavities in a single cycle.

These cryostats were designed and fabricated in India with help of FermiLab USA with twin objectives. Primary objective was to gave rich design experience to DAE engineers, in design of such complicated cryogenic equipment. Second objective was to provide technical experience for fabricating such advanced system to Indian Industry (In this case M/s. INOX India Pvt. Ltd., Vadodara). One of these cryostats has been installed in RRCAT and is under commissioning.The other will be installed in FermiLab. It will showcase technical prowess of DAE and strength of Indian industry.

3-D Model Of HTS Cryostat	Fabricated HTS Cryostat

• Shri Prashant Khare, Head, Cryomodule Development & Cryo-engineering Application Section
  • Sh. S.K. Awasthi
  • Sh. Suresh Chandra Patidar
  • Sh. Ashish Kumar Shukla
  • Sh. Devendra Sinnarkar
  • Sh. Gaurav Agrawal
  • Sh. Lakshminarayanan A.
  • Sh. Rahul
  
  
  • Sh. Rupul Ghosh, Head, Cryo-Module Engg. Application Lab.
    • Sh. Amit Srivastava
    • Sh. Abhishek Jain
    • Sh. Lakshman Singh
    • Sh. Gayadin Yadav
      
      
  • Sh. Shailesh G. Gilankar, Head, Cryo-Module Design Lab.
    • Sh. Hemant Kumar Patel
    • Sh. Ankit Tiwari
    • Sh. Divakar Sharma
    • Sh. Bablesh Meena
      
      
  • Sh. Deepak Kumar Arzare, Head, Cryo-Module Infrastructure Development Lab.
    • Sh. Chintan Gupta
    • Sh. Manoj Kushwaha
    • Sh. Jagdish Thate
    • Sh. Pangothu Prabhakar

List of Publications and patents 2010 onwards

Patents

1. “A liquid nitrogen based portable refrigeration system for carrying refrigerated goods” - Patent Application No. 201821009008 dated 12/3/2018.
   
   
2. “Niobium based superconducting radio frequency (SCRF) cavities comprising niobium components joined by laser welding, method and apparatus for manufacturing such cavities”, Patent: US grant US9352416B2, May 31, 2016

Conference/Symposia Papers 

2018

1. P. Khare, S. G. Gilankar, H. Patel, A. Lakshminarayanan, R. Chaube, R. Ghosh, A. Jain, A Tiwari, D. Arzare, S. C. Joshi, J. P. Ozelis and T. H. Nicol,” Design and Development of 650 MHz Cryomodule and Horizontal Test Stand at RRCAT”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018
   
   
2. R. Ghosh, Abhishek Jain, S.C. Patidar, Rajeev Chaube, Chintan Gupta, Lakshman Singh, Diwakar Sharma, A. Lakshminarayanan, B.N. Upadhyaya, R. Arya, K. S. Bindra, Prashant Khare and S.C. Joshi,” Infrastructure development for 650 MHz SCRF cavity fabrication by laser welding”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018
   
   
3. S. G. Gilankar, P. Khare, H. Patel, A. Lakshminarayanan, R. Chaube, R. Ghosh, A. Jain, A Tiwari, D. Arzare, S. C. Joshi, J. P. Ozelis, A. Hocker, M. G. Geynisman, C. M. Reid, V. V. Poloubotko, D. V. Mitchell , T. J. Peterson and T. H. Nicol,” Status of fabrication of HTS-2 Cryostat for testing two 650 MHz SCRF cavities”, presented at InPAC-2018 , RRCAT, Indore, Jan., 09-12, 2018
   
   
4. H. Patel , P. Khare, S. G. Gilankar, A. Lakshminarayanan, R. Ghosh, A. Tiwari, S. C. Joshi, J. P. Ozelis, A. Hocker, M. G. Geynisman, C. M. Reid, V. V. Poloubotko, D. V. Mitchell, T. J. Peterson and T. H. Nicol, “Design of Helium Relief System of Horizontal Test Cryostat”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018
   
   
5. Abhishek Jain, R. Ghosh, S.C. Patidar, Chintan Gupta, Lakshman Singh, Diwakar Sharma, A. Lakshminarayanan, B. N. Upadhyaya, R. Arya, K. S. Bindra, Prashant Khare, S.C. Joshi, K. K. Mistry, S. S. K. Sonti and P. N. Prakash, “Challenges in fabrication of QWR cavity by laser welding technique”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018
   
   
6. Ankit Tiwari, Shailesh Gilankar, Hemant Kumar Patel, Rupul Ghosh, Deepak Arzare, A. Laxminarayan, Prashant Khare, Satish Chandra Joshi and Mohit Dashore,” Challenges in fabrication of QWR cavity by laser welding technique”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018
   
   
7. Chintan Gupta, Suresh Chandra Patidar, Rupul Ghosh, Abhishek Jain, Prashant Khare and S. C. Joshi,” Target maneuvering system for laser welding of SCRF cavity components”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018
   
   
8. Devendra Sinnarkar, Suresh Chandra Patidar, Chintan Gupta, V.  K. Dubey, Piyush Saxena, Divakar Sharma, Shailesh Gilankar, Rajiv Jain, Prashant Khare and Viraj Bhanage,” Development of Data Acquisition System for Online Temperature Monitoring in Cryomodule Component Test Rig”, presented at InPAC-2018, RRCAT, Indore, Jan., 09-12, 2018

2017

1. S Gilankar, P Khare, R Ghosh, A Jain, A Tiwari, A Lakshminarayanan and P K Kush, "Development of a cryomodule for beta 0.61, 650 MHz SCRF cavities at RRCAT", 26th National Symposium on Cryogenics and Superconductivity (NSC-26), VECC, Kolkata, February 22-24, 2017
   
   
2. A Tiwari, S Gilankar, P Khare, R Ghosh, A Jain, A Lakshminarayanan and P K Kush, "Design of 70 K thermal shield of a cryomodule for beta 0.61, 650 MHz SCRF cavities", 26th National Symposium on Cryogenics and Superconductivity (NSC-26), VECC, Kolkata, February 22-24, 2017
   
   
3. Ashish Kumar Shukla, Hemant K Patel, et al “Safety System Assessment of Cold box for Large Capacity Helium liquefaction system”, 26th National Symposium on Cryogenics & Superconductivity” 22-24 Feb 2017, VECC-Kolkata.
   
   
4. Rekhya Naik, Hemant K Patel, et al “Development of cryostat for calibration of cryogenics temperature sensors”, 26th National Symposium on Cryogenics & Superconductivity” 22-24 Feb 2017, VECC-Kolkata.

2016

1. Khare P, Gilankar S, Kush P K, A. Lakshminarayanan, Choubey R, Ghosh R, Jain A, Patel H, Gupta P D, Hocker A, Ozelis J P, Geynisman M, Reid C, Poloubotko V, Mitchell D, Peterson T J and Nicol T H, “Design of horizontal test cryostat for testing two 650 MHz cavities: cryogenic considerations”, paper presented at 26th International Cryogenic Engineering Conference International Cryogenic Material Conference 2016 (ICEC-26- ICMC 2016), Manekshaw Centre, New Delhi, 07-11 March 2016

2015

1. Khare Prashant,  Gilankar Shailesh, Ghosh Rupul, Saxena Piyush, Chaube Rajeev, Jain A., Gupta C., Sinnarkar D., Tiwari A., Singh L., Sharma D., Kushwaha M., Lakshminarayanan A, Vora H.S., Kush P.K., Roger Vincent, Nicol Tom, “Design of a standalone cryomodule for 650MHz SCRF cavities of ISNS : New Concepts and Experimental results”, Presented at InPAC-2015, TIFR, Mumbai, 21-24 December 2015
   
   
2. Khare P., Upadhyay B., Ghosh R., Arya R., Jain Abhishek, Gilankar S., Gupta C., Singh Laxman, Sharma D., Lakshminarayanan A., Kush P.K., Oak S.M., Gupta P.D., "Successful development of world’s first laser welded SCRF cavity at RRCAT technique and advantages", Presented at InPAC-2015 , TIFR, Mumbai, Dec., 21-24, 2015
   
   
3. P. K. Sahani, Haridas G, Hemant K Patel, et al “Radiation shielding evaluation of Vertical Test Stand facility AT RRCAT”, Indian Particle Accelerator Conference InPAC-2015, 21 - 24 December 2015, Mumbai, India.

2013

1. P. K. Kush, Prashant Khare, S G Gilankar, Rupul Ghosh, Abhishek Jain, R. Chaube, A. Lakshminarayanan, Andy Hocker, Thomas J Peterson, Brian D Degraff, Ronak Patel, “Design of a Horizontal Test Stand at RRCAT for Testing of Two SCRF Cavities ", presented a paper at 24th National Symposium on Cryogenics at IPR, Ahmadabad, January 21-24, 2013"
   
   
2. P. K. Kush, Prashant Khare, S G Gilankar, Rupul Ghosh, Abhishek Jain, R. Chaube, A. Lakshminarayanan, Yuri Orlov, Thomas J Peterson, “Design and Prototyping efforts towards development of a cryomodule for 650MHz SCRF cavities", Presented a paper at 24th National Symposium on Cryogenics at IPR, Ahmedabad, January 21-24, 2013
   
   
3. Prashant Khare, B. N. Upadhyay, Jishnu Dwivedi, Abhishek Jain, Rupul Ghosh, Rajesh Arya, Shailesh Gilankar, Chintan Gupta, R.S. Sandha, G.V. Kane, P. Ramsankar, Girdhar Mundra, Rakesh Kaul, P.Sh.vastava, C.K. Pithawa, V.C. Sahni, P.K. Kush, S.B. Roy, S.C. Joshi, S.M. Oak, P.D. Gupta, Camille Ginsburg, Allan Rowe, Anna Grassillina, Charlie Cooper, Shekhar Mishra, " New Technique and Result of Laser Welded SCRF Cavity Developed at RRCAT”, presented at 16th International Conference on RF Superconductivity, SRF2013, Paris, France, September 23-27, 2013

2011-2012

1. M.Tech Thesis Titled " Development of Cavity Support System for Cryomodule of 650 MHz SCRF Cavities" was submitted to Homi Bhabha National Institute and Recommended for awarding Degree of Master of Technology by Thesis Examining Committee.
   
   
2. Prashant Khare, Pradeep Kush, Shailesh Gilankar, Rupul Ghosh, Abhishek Jain,A. Lakshminarayanan, RRCAT, Indore, "An Approach towards Developing Cryomodule for Indian SNS",  presented at 2nd International Workshop on ADS and Thorium Utilization at BARC, Mumbai during December 11-14, 2011

2010-2011

1. Thomas Peterson, Mike Foley, Camille Ginsburg, Chuck Grimm, James Kerby, Yuriy Orlov, Fermilab, Batavia, IL 60510, USA. Rupul Ghosh, Shailesh Gilankar, Abhishek Jain, Prashant Khare, Pradeep Kumar Kush, A. Laxminarayanan, RRCAT, Indore, India, "650 MHz Cryomodules For Project X At Fermilab – Requirements And Concepts", presented at 15th international conference on RF Superconductivity, SRF 2011, Chicago.
   
   
2. Prashant Khare, Pradeep Kush, Shailesh Gilankar, Vikas Jain, Rupul Ghosh, Abhishek Jain, A.Lakshminarayanan, RRCAT, Indore, India. Camille Ginsburg, Chuck Grimm, Jim Kerby, Yuriy Orlov, Tom Peterson, Fermi Lab, Batavia, IL 60510, USA, "Design Efforts for Cryomodule of 650MHz SCRF Cavities at RRCAT", presented at Indian Particle Accelerator Conference, 2011 (InPAC2011), New Delhi, 15th-18th Feb. 2011 (Manuscript not submitted)
   
   
3. P. K. Kush, P. Khare, S. G. Gilankar, V. Jain, R. Ghosh, A. Jain & A. Lakshminarayanan, RRCAT, Indore, India A. Hocker, V. Poloubotko, Fermilab., Batavia, IL 60510, U.S.A, "Design of Horizontal Test Stand (HTS 2) For SCRF Cavities At RRCAT", presented at Indian Particle Accelerator Conference, 2011 (InPAC2011), New Delhi, 15th-18th Feb. 2011
   
   
4. Prashant Khare, Pradeep Kush, Shailesh Gilankar, Vikas Jain, Rupul Ghosh, Abhishek Jain, A. Lakshminarayanan, RRCAT, Indore, "Technical Challenges in Cryomodule Design", presented at Theme Meeting on Challenges of Mechanical Engineering for Superconducting Accelerators, VECC Kolkata, 25th-26th March 2011