LCLSII CMTFLERF For LCLSII Cryomodule Testing at JLab

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LCLS-II CMTF@LERF For LCLS-II Cryomodule Testing at JLab E. Daly / K. Jordan /

LCLS-II [email protected] For LCLS-II Cryomodule Testing at JLab E. Daly / K. Jordan / C. Hovater / M. Wiseman with help from Accel Ops and Engineering 03 -AUG-2017

Outline • Overview • Introduction • LERF Vault as Cryomodule Test Facility (CMTF) •

Outline • Overview • Introduction • LERF Vault as Cryomodule Test Facility (CMTF) • Phasing • Cost / Schedule / Staffing • Assumptions / Constraints • Impacts / Risks • Summary REV 3, 03 -AUG-2017 2

Using LERF as Cryomodule Test-Bed - Overview • A detailed scope, cost and schedule

Using LERF as Cryomodule Test-Bed - Overview • A detailed scope, cost and schedule estimate for installing and testing LCLS-II cryomodules (two-at-a-time) as an assembly in the LERF has been developed in response to possible LCLS-II project needs. • Estimate considers four phases of increasing scope - short term limited testing (microphonics & technical characterization) up to a full test bed (a possible mitigation for schedule recovery) to operate in parallel with the CMTF in the Test Lab. • Phase 1 – Set Up LERF for CM testing • Phase 2 – First pair of CMs - Initial Full Power Testing • Phase 3 – Three Production CM testing cycles - A typical test cycle is 5 -8 weeks • Phase 4 – Restore LERF REV 3, 03 -AUG-2017 3

Using LERF as Cryomodule Test-Bed - Opportunity • The LCLS-II project has discovered issues

Using LERF as Cryomodule Test-Bed - Opportunity • The LCLS-II project has discovered issues with microphonics during the prototype cryomodule testing phase at FNAL and JLab • Development on-gooing to demonstrate closed-loop RF control due to microphonics Need to achieve expected cryogenic conditions in testing facilities • • In the longer term, a place to conduct integrated RF/Cryo testing and an additional place to test cryomodules could be very useful for both LCLS-II and JLab LERF has existing utilities (water, electrical, cryogenic, waveguides, radiation shielding, personnel protection, etc. ) and is situated near a large-scale cryogenic plant Similarity to actual LCLS-II machine conditions – large Cryoplant located near operational cryomodules • Address microphonics and large-scale issues which cannot be assessed in smaller cryogenic testing facilities REV 3, 03 -AUG-2017 4

Approach • Phase I – Convert the FEL vault into a cryomodule testing facility

Approach • Phase I – Convert the FEL vault into a cryomodule testing facility to conduct integrated RF testing of CM/LLRF/HPRF (using Solid State Amplifiers) • Phase II / Phase III – Utilize facility to expand capability to test multiple cryomodules in order to mitigate possible schedule delays caused by late CM assembly activities. • Phase IV – Restore LERF REV 3, 03 -AUG-2017 5

LCLS-II CM Layout in LERF – Testing 2 CMs per Cycle CM Slot Storage

LCLS-II CM Layout in LERF – Testing 2 CMs per Cycle CM Slot Storage Access • • Current machine contains slots for 3 full CMs and 1 Injector CM Shielded vault Existing PSS including radiation and ODH monitoring Utilities include cryo, water, electrical • Propose 2 CMs installed in middle of FEL machine REV 2, 03 -AUG-2017 6

Preliminary Detailed P 6 Cost Estimate Set Up First Test Three Tests Restoration •

Preliminary Detailed P 6 Cost Estimate Set Up First Test Three Tests Restoration • Full cost recovery Including operating cost estimates for LERF • Operating costs - $10. 8 K/week while CM is cold • Path forward assuming JLab approval • Proposal brought into the LCLS-II project baseline via baseline change request – expect some minor cost adjustments • Subsequently managed using EVMS to monitor and report on progress REV 3, 03 -AUG-2017 7

P 6 Schedule (1/2) REV 3, 03 -AUG-2017 8

P 6 Schedule (1/2) REV 3, 03 -AUG-2017 8

P 6 Schedule (2/2) REV 3, 03 -AUG-2017 9

P 6 Schedule (2/2) REV 3, 03 -AUG-2017 9

CEBAF Operations – Constraints on LERF Ops • CEBAF Operation Plan - FY 18

CEBAF Operations – Constraints on LERF Ops • CEBAF Operation Plan - FY 18 Q 1 – 10 wks (Oct/Nov/Dec) – Highly Likely - FY 18 Q 2 – 6 wks (Feb/Mar) – Highly Likely - FY 18 Q 3 – 8 wks at 6 Ge. V - TBC • CHL Configurations - FY 18 Q 1/Q 2 – 2 x (CHL + Cold Boxes) • Transition by May 6 th to 1 CHL - FY 18 Q 3/Q 4 – 1 x (CHL + Cold Box) – Two week transition at 4 K (cold down opportunity) • Transition by Sep 10 th to 2 CHLs • Cryogenics - U-tube ops required at 4 K - Integrate with maintenance plans on SC 1 (Ops on SC 2 – FY 18 Q 3) • Power Consumption - Off-peak running will save on power bill - Mitigates the demand charge for the next year REV 3, 03 -AUG-2017 10

Schedule Integrated with CEBAF Operations • Testing cycles could occur three times per FY

Schedule Integrated with CEBAF Operations • Testing cycles could occur three times per FY at the conclusion of planned CEBAF runs • First testing cycle most likely in Jul-2018 contingent upon actual FY 2018 run schedule and staffing availability REV 3, 03 -AUG-2017 11

P 6 Labor Profile (1/2) – Incremental Labor Required Incremental labor required to convert

P 6 Labor Profile (1/2) – Incremental Labor Required Incremental labor required to convert LERF and support testing (doesn’t include actual testing labor) CM Tests REV 3, 03 -AUG-2017 12

P 6 Labor Profile (2/2) – Incremental + Testing Labor Total labor required to

P 6 Labor Profile (2/2) – Incremental + Testing Labor Total labor required to convert LERF and support testing (includes actual testing labor time-phased) CM Tests REV 3, 03 -AUG-2017 13

Assumptions • Priority for JLab is 12 Ge. V Operations - Schedule for testing

Assumptions • Priority for JLab is 12 Ge. V Operations - Schedule for testing CMs will be coordinated with FY 2018 & FY 2019 run schedules - CM testing windows will be adjusted to minimize impact on NP program • Full cost recovery from LERF operations is required - Defined boundaries between laboratory program and WFO - Cost includes specific LERF facility charges • Draft cost and schedule presented in parallel to LCLS-II and JLab management. - Updates and revisions based on discussions are included • Staffing requirements will be considered as part of overall FY 2018/2019 laboratory planning. Priority consistent with WFO vs. CEBAF operations. Recommend meeting with LCLS-II Project Director, Lab Director and Chief Planning Officer to review and discuss overall plan REV 3, 03 -AUG-2017 14

Impacts & Risks • Cryogenics: present 2 K issues complicate near term scheduling. Contamination

Impacts & Risks • Cryogenics: present 2 K issues complicate near term scheduling. Contamination is a concern that could affect availability. - Can’t stab U-tubes during CEBAF ops (need CEBAF @ 4 K for 1 week) - Repeated stabbing adds potential contamination problems - Cooldown and warm-up : overall cryo load must be handled properly with controls. • CEBAF Operations: - Phase I no impact. - Phase II & III requires PSS Control and interface. Cannot keep two of the FEL CMs cold as CEBAF spares. Coordination is required with other cryo activities. - Phase II & III need coordination with CEBAF 12 Ge. V operations. • LERF Operations: Phase II and Phase III would eliminate all other LERF operations. • Staffing: Initial plan utilizes combination of in-house staff and possibly term hires. Higher priority work might limit available staff. • Schedule: Working towards July test cycle (April if all goes very well. ) REV 3, 03 -AUG-2017 15

Summary • LERF Vault as Cryomodule Test Facility - Full Cost Recovery - ~

Summary • LERF Vault as Cryomodule Test Facility - Full Cost Recovery - ~ $4 M over 18 to 24 months - Provide parallel testing facility to reduce testing bottleneck (12 to 15 CMs may need to be tested in FY 2018/FY 2019) and mitigate schedule delays due to cavity supply and CM design issues • Seeking decision from LCLS-II management regarding proposal for LERF facility REV 3, 03 -AUG-2017 16

Back Up REV 3, 03 -AUG-2017 17

Back Up REV 3, 03 -AUG-2017 17

JLab Proposed Layout for LCLS-II CM Production CM Testing Phase II CM Assembly (2

JLab Proposed Layout for LCLS-II CM Production CM Testing Phase II CM Assembly (2 X) Clean Room String Assembly Phase I CM Assembly (2 X) Final Assembly / Prep for Testing Vacuum Vessel Installation REV 3, 03 -AUG-2017 18

JLab Facilities Improvements : Testing in CMTF Draft FRS for CMTF in Progress (LCLSII-4.

JLab Facilities Improvements : Testing in CMTF Draft FRS for CMTF in Progress (LCLSII-4. 6 -FR-0285); Similar to FNAL CMTS 1 FRS • Ability to run 8 cavities simultaneously End Cans (2 sets to support CM production rate) • Engineering Specification JL 0012682 S in Review/Approval Process • Connects CM to CTF valve box via u-tubes • Interfaces for valves, LL and diodes to monitor and control helium flow/inventory • Provides reliefs for primary circuit, shield circuit and insulating vacuum space HPRF • Receive 1. 3 GHz 3. 8 k. W Solid-State Amplifiers (SSAs) • Procure Circulators • Modify Waveguide and Interlocks • Run line power to SSA/Circulators • Provide controls in CMTF Control Room LLRF • RF Instrumentation (arc detectors, IR sensors, etc. ) • Provide digital controls in CMTF Control Room • Software development Cryogenic Test Facility (CTF) • Improve return side piping to reduce overall pressure drop from CMTF • Ensure recovery system (pumping, compression) provides base pressure of 0. 031 atm (23 torr) in the CM helium bath • Improve/replace aging instrumentation such as arc cells, flow meters and temperature sensors REV 3, 03 -AUG-2017 19

JLab CMTF • HPRF system suitable for individual cavity testing or 8 cavities in

JLab CMTF • HPRF system suitable for individual cavity testing or 8 cavities in short duration steady state • TBD system for testing SC magnet – need PS & leads info • Magnetic shielding encloses testing volume reducing external fields to less than 50 m. G • Cryogenic capacity for testing up to 8 cavities in CW mode • End Caps – specific for LCLS-II CM testing • Interface to CM piping and existing junction box using u-tubes REV 3, 03 -AUG-2017 20

JLab CMTF Conceptual Layout JUNCTION BOX * = New Hardware END CAP* BAYONET BOX*

JLab CMTF Conceptual Layout JUNCTION BOX * = New Hardware END CAP* BAYONET BOX* BAYONET U-TUBE* CAVE DOOR (CLOSED) HEAT EXCHANGER End view of CM with bayonets connecting JB, HX and BB REV 3, 03 -AUG-2017 21

Approval Process THE PROCESS INVOLVES FOUR STAGES: STAGE 1 – INITIAL EXPLORATION WITH POTENTIAL

Approval Process THE PROCESS INVOLVES FOUR STAGES: STAGE 1 – INITIAL EXPLORATION WITH POTENTIAL PARTNERS STAGE 2 – EVALUATION BY PRIMARY DIVISION MANAGER STAGE 3 – DECISION BRIEFING TO LABORATORY LEADERSHIP STAGE 4 – APPROVAL BY DOE REV 3, 03 -AUG-2017 22

STAGE 3 –DECISION BRIEFING TO LABORATORY LEADERSHIP* Prepare a decision briefing, using the information

STAGE 3 –DECISION BRIEFING TO LABORATORY LEADERSHIP* Prepare a decision briefing, using the information from the Proposal Information Form (PIF), to obtain lab approval. The briefing must include the following elements: a. Outside Work Opportunity Title and Partner b. Overview of opportunity: description of work with deliverables and milestones c. Details of the opportunity: duration; resources needed, key skills, infrastructure needs, partner contribution d. Complete Budget Estimate form through the Budget Office (By FY, FTEs by skill, and non-labor) e. Benefit to Lab (how does opportunity supports JLab’s mission and scientific goals, core competencies, etc. ) f. Proposed method for receiving funds (FOA, Grants, proposals, CRADAs in support of SBIR/STTR proposals, Work for Others, IAA, CRADAs, IWOs, etc. ) Lab Leadership recommends that the Laboratory Director approves the initiative. Some initiatives may need DOE approval. The preparation of relevant documents is described under Stage 4, below. If approved, the PI has an actual commitment from the Lab to continue to Stage 4. If the proposal does not include new funds into the Lab then it can be approved without moving to Stage 4. *Taken directly from Lab Approval Process REV 3, 03 -AUG-2017 23

Phase I – Configure LERF for Testing • Removal of 20’ of back leg

Phase I – Configure LERF for Testing • Removal of 20’ of back leg of existing machine to install/position CMs • Removal of u-tubes from two existing CMs in FEL vault • • • - Can remove two high performing CMs to augment CEBAF Requires a set of u tubes to connect CMs to existing cryogenic transfer line bayonet connections - Review design; procure cryogenic hardware Requires one set of CM testing end caps (same design as CMTF) - Review design; procure cryogenic hardware Requires two sets of stands (same design as CMTF) Requires one set of interconnect hardware including HOM BLA, bellows Install cryogenic controls (Cryocon temp readbacks, heaters, JT and cooldown valves, etc. ) Pull cabling Install SLAC-provided SSAs and HPRF hardware Install SLAC-provided LLRF controls Review and approve any updates to OSP for FEL vault operations - Decarad and Faraday cups for radiation monitoring REV 3, 03 -AUG-2017 24

Phase II – Initial Full Power RF/Cryo Testing • Assumes all hardware from Phase

Phase II – Initial Full Power RF/Cryo Testing • Assumes all hardware from Phase I available • Schedule allows for more time and resources for initial testing cycle • • • Install pair of CMs in LERF Connect RF, instrumentation and cryo controls Coordinate cooldown with CEBAF operations Evaluate procedures for cooldown, RF testing and warm up Coordinate warm up with CEBAF operations Remove pair of CMs from LERF REV 3, 03 -AUG-2017 25

Phase III – CM Acceptance Testing • Assumes Phase II completed • Schedule considers

Phase III – CM Acceptance Testing • Assumes Phase II completed • Schedule considers logistics for installing multiple CMs in LERF vault • Staffing estimate will be based on current project baseline - Assumes one test cycle in CMTF / 5 wks - Potential impact - CMTF & LERF testing is conducted in parallel REV 3, 03 -AUG-2017 26

Phase IV – Restore LERF • Assumes Phase III completed • Remove any LCLS-II

Phase IV – Restore LERF • Assumes Phase III completed • Remove any LCLS-II specific hardware from vault • Replace LERF specific hardware REV 3, 03 -AUG-2017 27