Abstract. RF Crab Cavities are an essential part of the HL-LHC upgrade. Two concepts of such systems are being developed: the Double Quarter Wave (DQW) and the RF Dipole (RFD). A cryomodule with two DQW cavities is in advanced fabrication stage for the tests with protons in the SPS. The cavities must be operated at 2 K, without excessive heat loads, in a low magnetic environment and in compliance with CERN safety guidelines on pressure and vacuum systems. A large set of components, such as a thermal shield, a two layers magnetic shield, RF lines, helium tank and tuner are required for the successful and safe operation of the cavities. The sum of all these components with the cavities and their couplers forms the cryomodule. An overview of the design and fabrication strategy of this cryomodule is presented. The main components are described along with the present status of cavity fabrication and processing and cryomodule assembly. The lesson learned from the prototypes and first manufactured systems are also included.

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In the frame of the HL-LHC project, innovative technical solutions are sought to measure accurately the position of the magnet helium vessel inside the cryostat. To this end, a system based on laser-interferometry is being designed to monitor the displacement of the vessel through dedicated openings in the new HL-LHC magnet cryostats. In order to test such a system on a full-scale setup in representative operating conditions, a LHC dipole cryostat was modified to integrate the system optical lines of sight and the reflective mirrors were mounted onto the magnet helium vessel. Upon the first cool down of the magnet to 80 K, severe ice-like condensation started forming on the reflective surface of the mirrors hence making the system unusable at cold. This was attributed to the condensation of the residual gas remaining in the cryostat insulation vacuum on the mirror surface. In this configuration the mirrors acted as local “cold spots” since they were purposefully sticking out of the multi-layer insulation (MLI) that is otherwise covering the magnet helium vessel. In order to cope with this condensation issue, a dedicated study was carried out to design and manufacture a passive temperature regulation system based on a thermal insulating support and a thermal radiation intercept in order to keep the mirrors just above the expected freezing temperature in operational conditions. This paper details the thermal engineering study leading to the design of the insulated mirrors and presents the technical solution retained as well as the latest test results.