FNAL 3 9 GHz Cryomodule Project Management Camille

FNAL 3. 9 GHz Cryomodule Project Management Camille M Ginsburg LCLS-II 3. 9 GHz CM Delta Final Design Review January 29 -30, 2019

3. 9 GHz CM Delta FDR: Project Management Outline • Delta review • Overview of the work scope • Schedule • Technical status and procurements • Previous reviews • Organization and staffing • Risks Cryogenic Valves 3. 9 GHz cryomodule Instrumentation Flanges • Review outline • Summary Vacuum Bellows Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 Support Stands Coupler Pumping Line 2

Delta Review • 3. 9 GHz cryomodule final design review was Jan 2017 • The cryomodule design is final and approved • Requirements and specifications stable for two years • Some design verification tests and lessons learned drove incremental changes to cryomechanical design and components [Kaluzny, Solyak] • Components are procured • Based on our experience with 1. 3 GHz cryomodule fabrication, test and transport, we are taking a fresh look at the 3. 9 GHz cryomodule design • If necessary, change will be incorporated into the design • We do not anticipate any significant changes required, as judged by 1. 3 GHz CM experience Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 3

Overview of the 3. 9 GHz CM work scope Two 3. 9 GHz cryomodules, plus one spare PL Management & Integration (1. 04. 05. 01) • Oversight and integration of all WBS 1. 04. 05 related activities • Overall CM support in areas that include ES&H, QA/QC, and supporting engineering • CM related travel M&S (including vendor visits) Engineering & Design (1. 04. 05) • Design 3. 9 GHz cryomodules • Produce all necessary calculations, analyses, models, and drawings • Perform design verification tests of cryomodule subcomponents • CA complete/closed since Oct 2018; updates charged to engg integration 1. 04. 05. 01 3. 9 GHz Cryomodule Procurement and Fabrication (1. 04. 05. 12) • Procure CM components, receive/inspect them • Test dressed cavities, re-HPR if necessary • Assemble cryomodules • Test 3. 9 GHz LCLS-II cryomodules assuming Installation Support & Shipping (1. 04. 05. 20) • Ship CM’s from FNAL to SLAC, limited installation support Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 4

3. 9 Cryomodule Assembly Schedule: Need-by Nov’ 18 forecast First string assembly: Jun 2019 First CM test: Oct 2019 First shipment: Nov 2019 Last shipment: Jan 2020 Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 5

3. 9 GHz Cryomodule Technical Status • Cryomodule design complete since Jan 2017 • From FDR presentation: 3 D model and 2 D engineering drawings: 100% Completed; Minor modifications expected during construction phase • Few updates related to 1. 3 GHz lessons learned [Kaluzny] • Component design verification now complete: heat load, magnetic shielding, tuner, cavity and coupler performance [Aderhold, Solyak] • All procurements awarded, >60% received/inspected/ accepted, with nearly everything to arrive by end March • Assembly and test plans well advanced [Arkan, Harms] • Transportation plans substantially updated [Hartsell] • 1. 3 GHz lessons learned being incorporated in all relevant aspects Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 6

3. 9 GHz CM (Design) Reviews prior to FDR • CM PDR & Dressed Cavity FDR November 2015 • Cavity Procurement Readiness Review March 2017 • Coupler Procurement Readiness Review December 2017 Recent major reviews • LCLS-II 3. 9 GHz Cryomodule Final Design Review • https: //indico. fnal. gov/event/13697/ • LCLS-II Director’s Review March 2018 • LCLS-II Facility Advisory Committee Review March 2018 These were for 1. 3 GHz cryomodules but are very relevant • QA/QC and assembly audits for 1. 3 GHz [Blowers] • Transportation investigation (Apr-Dec 2018) • DOE Transportation review for 1. 3 GHz (Aug 2018) • Technical transportation review for 1. 3 GHz (Dec 2018) Ø All 3. 9 GHz CM-related review recommendations are addressed; some additional LLRF and microphonics tests in CMTS are still needed Ø Expect to have a production readiness review once the 3. 9 GHz transportation analysis and tests are complete, summer 2019 Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 7

Procurements >60% received/inspected/accepted Nov’ 18 forecast • • • Cavities and couplers • First several production components received, starting in December; cavities high FE • Will continue to receive these through March [first string assembly June] Vacuum vessels, upper cold masses and interconnect big bellows • One VV/UCM pair received before pausing due to tariff issues for Chinese goods • Remainder shall be shipped in February for receipt in March CM retrofit refers to cryogenic valve modifications, 1. 3 -identical, completed as-needed Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 8

Fermilab Cryomodule Organization Highly experienced staff working on 1. 3 GHz CM continue to work on 3. 9 GHz CM’s (T. Arkan) Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 9

Tom Nicol joined our engineering effort Tom Nicol was brought into our organization Fall 2018 • Serves as technical advisor to an internal working group looking into transportation issues and has been very valuable in this role Ø Translating the 1. 3 GHz transportation lessons learned to the 3. 9 GHz CM • Provides additional senior-level CM expertise and analysis, leads in specific areas of concern, e. g. , thermal management and support post loading Ø Ensure that with the known transportation difficulties solved, there are no other issues waiting to cause problems • Will be involved with any remaining CM related questions or issues arising CM design authority & design changes remain with Y. Orlov and J. Kaluzny • CM design has been stable for several years • • 35 (of 40) 1. 3 GHz CMs are either completed or in progress 100% of 3. 9 GHz CM drawings have been complete for two years • Initiation of any change to the solid model and the subsequent drawings Ø Has worked well in the past and will continue for 3. 9 GHz Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 10

Risks (1/2) • 1. 3 GHz lessons learned are not correctly incorporated, and mistakes are repeated causing schedule delays and/or increased cost • • Project management re-aligns schedule so that some currently noncritical activities or procurements become schedule critical • • Mitigation: Strong involvement of QA/QC team Mitigation: Plan to be ready earlier than the need-by (p. 4) Cavity and/or coupler delivery schedule from vendor could be delayed • Mitigation: Work intensively with vendors with visits and regular meetings - Bi-weekly meetings with cavity vendor, weekly emails with coupler vendor - Delivery schedules are satisfactory for both since December • This risk shall be retired at the end of March • Schedule could be delayed due to cavity performance (field emission), requiring re-HPR in a busy facility • Mitigation: Working with vendor with interactions on processes and equipment to identify weakness in final preparation and assembly Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 11

Risks (2/2) • 3. 9 GHz cryomodule design flaw first observed during testing or transport of first CM, after all are in fabrication process • Shipping of the first CM occurs when the third/final CM is at WS 5 • No prototype • No time allocated in schedule for re-work – success based as for • 1. 3 GHz Mitigation: Fresh look at the design and application of lessons learned, as described at this review • Absence of tuner access ports limits ability to access critical component or install critical diagnostic instrumentation • Recall: For 1. 3 GHz cryomodule, tuner access ports and tuner were • • designed for access to replace potentially risky piezos or tuner motors, without removing the vacuum vessel. They have never once been used for their original purpose. Coupler ports on both sides limits space for such access ports, and tuner design limits value of access Mitigation: More and earlier modeling and testing of items for which we used the access ports for 1. 3 GHz CM [Hartsell] Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 12

Review Charge 1. 2. 3. Have recommendations from previous reviews been addressed? Is the design team organized and staffed to successfully complete the project? Many aspects/components of the 3. 9 GHz CM differ from the 1. 3 GHz CM including cooling/heat load, tuner, end-group, fundamental power coupler. Are these differing designs mature and have they undergone appropriate reviews? 4. Have the risks of not having a tuner access port been adequately evaluated and mitigated? How to verify that HOMs have been tuned? 5. Is the design likely to meet performance expectations? 6. 6. Have there been design modifications since the FDR? Have they undergone adequate peer reviews and approval? Have drawing packages been released? 7. Have transportation requirements for the 3. 9 GHz CM been developed? Have engineering processes and reviews been applied to the shipping system design and implementation of the 3. 9 GHz cryomodules? 8. Have lessons learned from the 1. 3 GHz cryomodule quality assurance, assembly and test been applied? 9. Have lessons learned from the 1. 3 GHz cryomodules transport challenges been applied to the 3. 9 GHz cryomodules? 10. Have handling and installation issues been adequately addressed? Have handling and installation procedures been developed? 11. Have other major risks been identified and managed? Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 13

Outline of the Review 1. Project Management – Ginsburg [Charge questions 1, 2, 3, 11] 2. QA/QC – Blowers [1, 6, 7, 8, 11] 3. Cryomodule Design (Kaluzny) [4, 5, 6] 4. Design verification of components (Solyak) [3, 4, 5] 5. Design verification of cavities (Aderhold) [3, 4, 5] 6. Production readiness (Arkan) [5, 8, 10] 7. Cryomodule testing (Harms) [5, 8] 8. Cryomodule transportation (Hartsell) [5, 7, 9] 9. Cryomodule acceptance, handling, transport, installation at SLAC (Chan) [7, 9, 10] Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 14

Summary • Tremendous progress on the 3. 9 GHz cryomodule since the final design review • The advanced state of the 1. 3 GHz cryomodule means we have lessons learned in all aspects of the 3. 9 GHz CM development • Component design verification was completed and reviewed • Previous review recommendations are addressed • Constant vigilance to ensure lessons learned are incorporated Ø Advances and improvements described in upcoming talks Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 15

Backup Slides Ginsburg-LCLS-II 3. 9 GHz CM Delta FDR, Jan. 29 -30 2019 16

Documentation: Physics & Gen’l CM Requirements Copied from 3. 9 GHz CM technical specification LCLSII-4. 5 -ES-0879 Document Reference Number Document Title LCLSII-1. 1 -PR-0133 LCLSII-4. 1 -PR-0146 Physics requirements LCLS-II Parameters 1. 3 GHz Cryomodule LCLSII-4. 1 -PR-0097 LCLSII-2. 4 -PR-0136 LCLSII-1. 1 -IC-0657 SCRF 3. 9 GHz Cryomodule Beam Position Monitor MAD Model for LCLS-II Cryomodules LCLSII-4. 1 -FR-0096 General cryomodule requirements Functional Requirements, “ 3. 9 GHz Superconducting RF Cryomodule” LCLSII-4. 5 -ES-0356 Engineering Specifications Document, “ 1. 3 GHz Cryomodule Technical Description” LCLSII-4. 5 -EN-0179 Engineering Note, “Cryomodule Heat Load” LCLS-II-4. 5 -EN-0186 Engineering Note, “Cryogenic System – Cryomodule Design Methodology” LCLSII-2. 5 -IC-0056 LCLSII-4. 5 -IC-0661 Interface Control Document, “Accelerator Systems to Cryogenic Systems” 1. 3 GHz Cryomodule Physical Interfaces SLAC-I-720 -0 A 24 E-001 Seismic Design Specification for Buildings, Structures, Equipment and Systems: 2014 LCLSII-4. 5 -EN-0226 LCLSII-4. 9 -IC-0058 LCLSII-4. 5 -EN-0214 Engineering Note, “Cryomodule Seismic Design Criteria” Interface Control Document, "Cryogenic Distribution System" Cryomodule Design Heat Flux for Vacuum Failures 3. 9 GHz Cryomodule Final Design Review, January 30 -31, 2017, Yun He 17

Documentation: CM Details, Analyses, Compliance Document Reference Number F 10014857 LCLSII-4. 5 -EN-0711 (ED 0004081) LCLSII-4. 5 -EN-0566 (ED 0004361) LCLSII-4. 5 -ES-0414 LCLSII-4. 5 -ES-0415 LCLSII-4. 5 -ES-0416 LCLSII-4. 5 -ES-0417 LCLSII-4. 5 -ES-0419 LCLSII-4. 5 -EN-0418 LCLSII-4. 5 -ES-0403 F 10023160 ED 0001995 ED 0002396 ED 0004908 ED 0002638 LCLSII-4. 5 -EN-0710 (ED 0002593) ED 0002453 ED 0002406 ED 0002405 ED 0002404 LCLSII-4. 9 -EN-0253 LCLSII-4. 9 -EN-0255 ED 0005767 Fermilab Document Draft LCLSII-4. 5 -EN-0918 Document Title Cryomodule engineering details, analyses, and compliance documents Assembly, 3. 9 GHz cryomodule drawing LCLS-II 3. 9 GHz cryomodule mechanical design LCLS-II 1. 3 GHz cryomodule mechanical design CM Coaxial Cable and Connectors Specification (Same as 1. 3 GHz CM) Cryomodule Instrumentation Specification (Same as 1. 3 GHz CM) Cryomodule Multi-pin Connectors Specification (Same as 1. 3 GHz Cryomodule) Cryomodule Wire Specification (Same as 1. 3 GHz Cryomodule) LCLS-II 1. 3 GHz Cryomodule Transport System (Same as 1. 3 GHz Cryomodule) LCLS-II Cryomodule Stand Analysis Cold Button Beam Position Monitor (Same as 1. 3 GHz Cryomodule) LCLS-II Cold BPM Assembly Drawing (Same as 1. 3 GHz Cryomodule) LCLS-II CDS Relief System Analysis Cryomodule vacuum vessel venting calculation Structural analysis of 3. 9 GHz cryomodule vacuum vessel A subset of 1. 3 GHz P&ID (instrumentation) tag name list Cryomodule interconnect design and installation (Same as 1. 3 GHz CM) JT valve sizing and flow calculation (Same as 1. 3 GHz CM) Cool-down valve sizing and flow calculation (Same as 1. 3 GHz CM) Cryomodule two phase pipe pressure, vapor velocity, and venting calculation (Same as 1. 3 GHz CM) Cryomodule cooldown line pressure, flow, and venting calculation (Same as 1. 3 GHz CM) CDS/Cryomodule What-If Analysis, (Same as 1. 3 GHz CM) CDS/Cryomodule Failure Mode and Effects Analysis (Same as 1. 3 GHz CM) 3. 9 GHz Fundamental Power Coupler 3. 9 GHz Cryomodule Coaxial Cable and Connectors Specification 3. 9 GHz CM Instrumentation List 3. 9 GHz Cryomodule Final Design Review, January 30 -31, 2017, Yun He 18