121 04 03 Test Infrastructure TI SC 2

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121. 04. 03 Test Infrastructure (TI) SC 2: Accelerator Complex Upgrades, Linac, Install. and

121. 04. 03 Test Infrastructure (TI) SC 2: Accelerator Complex Upgrades, Linac, Install. and Comm. Jerry Leibfritz PIP-II IPR 4 -6 December 2018 In partnership with: India/DAE Italy/INFN UK/STFC France/CEA/Irfu, CNRS/IN 2 P 3

Outline • Scope/Deliverables • Requirements • Interfaces • Preliminary Design, Maturity • Technical Progress

Outline • Scope/Deliverables • Requirements • Interfaces • Preliminary Design, Maturity • Technical Progress • ESH&Q • Risks • Summary 2 12/4/2018

About Me: • PIP-II Level-3 Manager for Test Infrastructure (TI) • Senior Principal Engineer,

About Me: • PIP-II Level-3 Manager for Test Infrastructure (TI) • Senior Principal Engineer, joined FNAL in 1992 • Current Responsibilities/Roles – Project Leader for Accelerator Division SRF Test Facilities • CMTF – Cryomodule Test Facility – Cryomodule Test Stand #1 (CMTS 1) – PIP-II Injector Test (PIP 2 IT) • FAST - Fermilab Accelerator Science and Technology Facility – FAST Accelerator – Integrable Optics Test Accelerator (IOTA) – LCLSII Project Manager for cryomodule testing at CMTS 1 – SRF Systems Group Leader (Accelerator Division) 3 12/4/2018

Charge #2 Scope and Deliverables • Scope - design, procurement, fabrication, installation and commissioning

Charge #2 Scope and Deliverables • Scope - design, procurement, fabrication, installation and commissioning of the test infrastructure to facilitate PIP-II cavity and cryomodule testing – Note: operation of the test stands and testing of cavities/cryomodules is not covered by this WBS • Test Infrastructure deliverables include: – – Test caves - (shield blocks, lighting, access gates) Utilities - (electrical power, racks, tray, cables, water, air, nitrogen) Cryogenics - (distribution and controls) Supports - (cryomodule/cavity stands, transport/installation carts, RF distribution supports) – Misc. infrastructure - (ODH fans, portable cleanrooms) – Labor for the above - (electricians, contractors, engineers and technicians) 4 12/4/2018

Charge #2 Scope and Deliverables • There are 3 separate test facilities that comprise

Charge #2 Scope and Deliverables • There are 3 separate test facilities that comprise the PIP-II Test Infrastructure: – STC (Spoke Test Cryostat): • horizontal cryostat located at the Meson Detector Building (MDB) • currently used for testing 325 MHz (SSR 1) cavities • modifications will accommodate 650 MHz and SSR 2 cavity testing – HTS-2 (Horizontal Test Stand #2): • new horizontal cryostat being built at RRCAT in India • will be installed in a new test stand located at MDB • capable of testing two 650 MHz dressed cavities at a time – PIP 2 IT (PIP-II Injector Test): • test stand that contains a nearly full-scale test of the PIP-II front-end • initially will test the HWR and proto. SSR 1 cryomodules with beam • will then be re-configured for 650 MHz and SSR 1/SSR 2 cryomodule testing 5 12/4/2018

Charge #2 WBS L 3 System Requirements • Test Infrastructure requirements are captured in

Charge #2 WBS L 3 System Requirements • Test Infrastructure requirements are captured in Functional Requirement Specification (FRS) and Technical Requirement Specification (TRS) documentation, controlled in Teamcenter: – Test Infrastructure FRS • ED 0008064, (pip 2 -docdb #2495) – STC specific FRS/TRS • ED 0006117, ED 0006064 – HTS-2 specific FRS/TRS • ED 0001735, ED 0002154, ED 0007478 – PIP 2 IT specific FRS/TRS • ED 0004145, ED 0007996, ED 0007997 • Test Infrastructure contributes to achieving KPP#1 (achieving the required SRF Linac beam energy) 6 12/4/2018

Charge #2 Interfaces • The Test Infrastructure facilities must interface with all the sub-systems

Charge #2 Interfaces • The Test Infrastructure facilities must interface with all the sub-systems necessary for testing: – – – Cryogenics High Power RF (HPRF) Low Level RF (LLRF) Controls Safety systems (interlocks, ODH) Vacuum systems • An Interface Control Document (ICD) has been developed that defines each of the direct interfaces between TI and the various sub-systems, and establishes the boundaries of responsibility of each (TC#ED 0007505, pip 2 -docdb #2495) 7 12/4/2018

Preliminary Design, Design Maturity and Progress to date Charge #1 & #2 • The

Preliminary Design, Design Maturity and Progress to date Charge #1 & #2 • The design maturity of much of the Test Infrastructure is at an advanced stage (STC, PIP 2 IT-HWR/proto. SSR 1) with the fabrication and installation of the infrastructure for these facilities already in progress • The future conversion of PIP 2 IT into a cryomodule test stand for 650 MHz and SSR 1/SSR 2 cryomodules, and the construction of the HTS-2 facility are at a conceptual stage of design maturity, as the preliminary design has not started • A description of each facility, along with its current design and/or installation status will be described in the next several slides 8 12/4/2018

Charge #1 Cryomodule Test Facility (CMTF) The CMTF Building contains two test stands (CMTS

Charge #1 Cryomodule Test Facility (CMTF) The CMTF Building contains two test stands (CMTS 1 and PIP 2 IT) and a large Cryoplant (you will see this on the tour) CMTF Building CMTS 1 LCLSII Test Cave PIP 2 IT Test Cave 9 Cryogenic Plant 12/4/2018

Charge #1 CMTS 1 • CMTS 1 (Cryomodule Test Stand #1) – Not part

Charge #1 CMTS 1 • CMTS 1 (Cryomodule Test Stand #1) – Not part of PIP-II scope, but demonstrates similar experience – Fully operational test stand for cold RF testing of cryomodules (without beam) – Currently testing LCLS-II cryomodules (1. 3 & 3. 9 GHz, CW) CMTS 1 Test Stand CMTS 1 3 -D model of CMTS 1 10 12/4/2018

Charge #1 PIP 2 IT - HWR/proto. SSR 1 (121. 04. 03) • PIP

Charge #1 PIP 2 IT - HWR/proto. SSR 1 (121. 04. 03) • PIP 2 IT (PIP-II Injector Test) SC 2 -Prost – Nearly full scale test of PIP-II front-end with beam – Half Wave Resonator (HWR) and proto. SSR 1 cryomodules will be tested in PIP 2 IT as part of front-end test – Infrastructure plan design maturity is at an advanced stage – WBS Deliverable: PIP 2 IT ready to run beam through HWR and proto. SSR 1 in FY 20 HWR Cryomodule proto. SSR 1 Cryomodule PIP 2 IT Test Cave PIP 2 Injector Test 11 12/4/2018

Charge #1 PIP 2 IT - HWR/proto. SSR 1 (3 -D Model) proto. SSR

Charge #1 PIP 2 IT - HWR/proto. SSR 1 (3 -D Model) proto. SSR 1 Cryomodule PIP 2 IT WFE (existing) CM TS 1 SC 3 -Conway Tes t St HWR Cryomodule and SC 3 -Passarelli HWR RF Racks (existing) SSR 1/SSR 2 RF Amplifiers (Future ) SC 1 -Steimel 12 12/4/2018

Charge #1 PIP 2 IT - HWR/proto. SSR 1 (Progress) • Recent progress and

Charge #1 PIP 2 IT - HWR/proto. SSR 1 (Progress) • Recent progress and near-term plans – – – PIP 2 IT cave extension and outfitting Cryogenic transfer line (CTL) installation Water/air system installation Cryomodule stand fabrication SC 2 -Baffes Safety system installation (interlocks, gates, ODH system) PIP 2 IT Cave Extension 13 Cave Interlocks & Gate Cryogenic Transfer Line (CTL) 12/4/2018

PIP 2 IT – 650 MHz/SSR 2 Cryomodule Test Stands Charge #1 (121. 04.

PIP 2 IT – 650 MHz/SSR 2 Cryomodule Test Stands Charge #1 (121. 04. 03. 04 & 121. 04. 03. 05) • After HWR & proto. SSR 1 cryomodule testing is complete (FY 21), PIP 2 IT infrastructure will be modified to accommodate testing 650 MHz & SSR 1/SSR 2 cryomodules – Cryogenic distribution, mechanical & electrical infrastructure, RF power • The design maturity is at a conceptual stage (high-level 3 -D planning models) • Scope of work is similar to configuring CMTS 1 for LCLS-II testing, and current estimates are based on previous experience/costs from constructing and commissioning CMTS 1 • There is an experienced team already in place that developed, operates and maintains all systems associated with CMTS 1 and PIP 2 IT, and this same team of experts will be involved in the modifications of PIP 2 IT 14 12/4/2018

PIP 2 IT – 650 MHz/SSR 2 CM Test Stands (3 -D) Charge #1

PIP 2 IT – 650 MHz/SSR 2 CM Test Stands (3 -D) Charge #1 Conceptual plan showing HB 650 and SSR 1/SSR 2 Cryomodule overlaid in PIP 2 IT 3 -D Models of 650 MHz and SSR 1/SSR 2 cryomodules with conceptual secondary cryogenic distribution system (shown in orange) 15 12/4/2018

Charge #1 STC – Spoke Test Cryostat (121. 04. 03. 02) • STC –

Charge #1 STC – Spoke Test Cryostat (121. 04. 03. 02) • STC – Horizontal cavity test stand located at the Meson Detector Building – Used for cold testing 325 MHz SSR 1 cavities • comprehensive “system-level” tests of cavity+coupler+tuner – STC modifications will accommodate testing HB 650 elliptical and SSR 2 cavities • Status – Cavity testing for proto. SSR 1 cryomodule was recently completed – Infrastructure modifications underway • cryostat modifications – lengthening cryostat, modifying support structure – all components received, inspected and being assembled • no changes to cryogenics, instrumentation, or vacuum systems • Infrastructure plan is at an advanced level of design maturity • WBS Deliverable: a modified STC ready for testing dressed HB 650 MHz elliptical cavities in FY 19 16 12/4/2018

Charge #1 STC – (3 -D Models/Pictures) STC cryostat modified with extension to accommodate

Charge #1 STC – (3 -D Models/Pictures) STC cryostat modified with extension to accommodate 650 MHz cavities. Existing STC cryostat as used for SSR 1 cavity testing Cryostat extension SSR 1 cavity 17 12/4/2018

HTS-2 – Horizontal Test Stand #2 (121. 04. 03. 06) Charge #1 • A

HTS-2 – Horizontal Test Stand #2 (121. 04. 03. 06) Charge #1 • A third horizontal cavity test facility being constructed at the MDB building that will be used to test 650 MHz cavities for the PIP-II Project – HTS-1 (1. 3 GHz cavities) - not used for PIP-II – STC (325 MHz and 650 MHz cavities) - see previous slides – HTS-2 (650 MHz cavities) • HTS-2 is a collaborative effort between Fermilab and the Indian Institutes Collaboration for PIP-II • This WBS does not include the fabrication of the cryostat, RF amplifiers or LLRF system, which are part of the India Collaboration • This WBS includes the infrastructure necessary to install and commission the HTS-2 test stand (test cave, electrical and cryo distribution, utilities, racks, cables, stands, etc. ) • Infrastructure plan is at a conceptual level of design maturity (prelim. design begins in FY 20) • WBS Deliverable: HTS-2 ready for testing dressed 650 MHz Elliptical cavities in FY 22 18 12/4/2018

Charge #1 HTS-2 – (3 -D Models/Pictures) 3 -D model of HTS-2 test cave

Charge #1 HTS-2 – (3 -D Models/Pictures) 3 -D model of HTS-2 test cave 3 -D models of HTS-2 cryostat Photo of HTS-2 Cryostat/Feedcan at vendor (Courtesy of RRCAT) 19 AC power distribution and lighting installed in cave 12/4/2018

Charge #6 Environment, Safety and Health (ESH) • Project team is committed to construct

Charge #6 Environment, Safety and Health (ESH) • Project team is committed to construct PIP-II in a safe, environmentally respectful, and cost efficient manner that meets our stakeholder’s needs • The construction, installation and operation of the Test Infrastructure facilities will be in full compliance with all appropriate requirements – – PIP-II Integrated ESH Management Plan (pip 2 -docdb #141) Fermilab ES&H Manual (FESHM) Hazard Analyses Safety by Design and Work Planning processes • Prior to commissioning any new systems/facilities, a series of reviews and approvals take place, culminating in an official Operational Readiness Clearance (ORC) approval, which covers: – – – 20 Oxygen deficiency hazards (ODH) Radiation shielding/radiation safety Personnel protection systems (PPS) Machine (device) protection systems Mechanical & electrical safety Cryogenic safety SC 7 -Anderson 12/4/2018

Charge #6 Quality Management • Quality Assurance and Control for procurement, fabrication and acceptance

Charge #6 Quality Management • Quality Assurance and Control for procurement, fabrication and acceptance of components will follow the Project’s QA Plan (pip 2 -docdb #142) utilizing established Project/Division mechanisms • QC Plan for TI will include – – – • inspections acceptance testing operational verification of sub-systems vendor feedback and control of non-conformances lessons learned Designs will go through the formal review cycle SC 7 -Adetunji – Preliminary Design Review (PDR) • plans and specifications • feedback from other L 3’s – Final Design Review (FDR) • verification of system designs – Production/Procurement Readiness Review (PRR) • vendor visits • hardware acceptance 21 12/4/2018

Risk Management – Test Infrastructure Charge #2, 7 • There are no Project Risks

Risk Management – Test Infrastructure Charge #2, 7 • There are no Project Risks directly “owned” by the TI WBS • Project Risks associated with TI, but owned by others – High Risk = 0 – Medium Risk • • RT-121 -04 -006 Late subsystem delivery makes installation less efficient RT-121 -04 -019 Vacuum incident during beam commissioning RT-121 -04 -012 Subsystem or component problem discovered after installation RT-121 -04 -013 MEBT kickers performance unsatisfactory – Low Risk • RT-121 -04 -003 Unable to maintain proper vacuum between MEBT absorber and SRF • RT-121 -04 -021 Critical component damaged during installation or checkout • RT-121 -04 -020 Mis-steered beam during commissioning • In nearly all cases, the Test Infrastructure facilities serve as a source of mitigation of these risks prior to installation into PIP-II 22 12/4/2018

Summary • Fermilab currently operates an array of world-class SRF test facilities, many of

Summary • Fermilab currently operates an array of world-class SRF test facilities, many of which are critical to the success of the PIP-II project • Several of the existing test facilities will require various modifications to accommodate PIP-II components • The design maturity of the infrastructure modifications range from conceptual to advanced, depending on the specific facility and schedule • Fermilab has similar experience from LCLS-II and SRF R&D Program – All cost and schedule estimates are based on historical data from initial construction or recent modifications of similar facilities and are well understood – Experienced personnel, many of whom have been involved in the original development, construction, and operation of these facilities, are in place and available to carry out this work – Activities are planned so that modifications are completed and infrastructure can be commissioned before cavities and cryomodules arrive for testing • Thank you for your attention! 23 12/4/2018

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