Production Cryomodule Design Status LCLSII 1 3 GHz

Production Cryomodule Design Status LCLS-II 1. 3 GHz Cryomodule Production Readiness Review Joshua Kaluzny, Yuriy Orlov 13 -14 September 2016

Outline • Introduction • Design specifications, requirements, interface documents • Top level drawings for 1. 3 GHz Production CM • Production drawings status • Changes since FDR • FDR review recommendations and status • Summary Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 2

Introduction 1. 3 GHz Production Cryomodule, F 10041183, 3 D model Production Cryomodule FDR indico site: https: //indico. fnal. gov/conference. Display. py? conf. Id=9874 Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 3

LCLS-II Cryomodule Documentation, page 1 Reference Number Document Title Physics requirements LCLSII-1. 1 -PR-0133 -R 3 LCLS-II Parameters LCLSII-4. 1 -PR-0146 -R 1 1. 3 GHz Cryomodule LCLSII-2. 4 -PR-0136 -R 3 Beam Position Monitor General cryomodule requirements (in draft and/or under review) (Documentation of Analysis) LCLSII-2. 5 -FR-0053 -R 1 Functional Requirements Specification, "1. 3 GHz Cryomodule" LCLSII-4. 5 -ES-0356 -R 0 Engineering Specifications Document, “ 1. 3 GHz Cryomodule Technical Description” LCLSII-4. 5 -EN-0179 -R 2 Engineering Note, “Cryomodule Heat Load” LCLSII-4. 5 -EN-0186 -R 0 Engineering Note, “Cryogenic System – Cryomodule Design Methodology” LCLSII-2. 5 -IC-0056 -R 4 Interface Control Document, “Accelerator Systems to Cryogenic Systems” LCLSII-4. 5 -IC-0372 -R 0 Interface Control Document, "LCLS-II Cryomodule External Interfaces" (ED-0002307) SLAC-I-720 -0 A 24 E-001 Seismic Design Specification for Buildings, Structures, Equipment and Systems: 2014 Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 4

LCLS-II Cryomodule Documentation, page 2 Reference Number`` Document Title LCLSII-4. 5 -EN-0226 -R 0 Engineering Note, “Cryomodule Seismic Design Criteria” LCLSII-4. 9 -IC-0058 -R 3 Interface Control Document, "Cryogenic Distribution System" About cryomodule components LCLSII-4. 5 -ES-0411 Fermilab Engineering Specification, "LCLS-II Cryomodule Vacuum Vessel" LCLSII-4. 5 -ES-0412 Fermilab Engineering Specification, "LCLS-II Cryomodule HGRP" LCLSII-4. 5 -ES-0055 -R 1 Engineering Specifications Document, “Fundamental Power Coupler" LCLSII-4. 5 -IC-0237 -R 0 Interface Control Document, “Fundamental Power Coupler” LCLSII-4. 5 -EN-0221 -R 0 Engineering Note, “Tuner electro-mechanical design” LCLSII-4. 5 -ES-0385 -R 1 Cryomodule SRF Cavity Tuner LCLSII-4. 5 -EN-0222 -R 0 Magnetic Shielding: Requirements and Possible Solutions LCLS-II-4. 5 -EN-0310 -R 0 Engineering Note, “A Study of Magnetic Shielding Performance of a Fermilab International Linear Collider Superconducting RF Cavity Cryomodule” Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 5

LCLS-II Cryomodule Documentation, page 3 Reference Number Document Title LCLSII-4. 5 -ES-0413 Fermilab Engineering Specification, "LCLS-II Prototype Cavity Magnetic Shield Specification" LCLSII-4. 5 -ES-0355 -R 0 Engineering Specifications Document, "Cryomodule Magnet" LCLSII-1. 1 -EN-0286 -R 0 Engineering Note, “Vacuum System Safety Plan” LCLSII-4. 5 -ES-0414 -R 0 Engineering Specifications Document, “CM Coaxial Cable and Connectors Specification" LCLSII-4. 5 -ES-0415 -R 0 Engineering Specifications Document, “Prototype Cryomodule Sensors Specification" LCLSII-4. 5 -ES-0416 -R 0 Engineering Specifications Document, “Multi-pin Connectors" LCLSII-4. 5 -ES-0417 -R 0 Engineering Specifications Document, “Prototype Cryomodule Sensor Wiring" LCLSII-4. 5 -ES-0418 LCLS-II 1. 3 GHz Cryomodule Stand Design LCLSII-4. 5 -ES-0419 -R 0 LCLS-II 1. 3 GHz Cryomodule Transport System LCLSII-4. 5 -EN-0612 -R 0 Test Results of LCLS-II Cryomodule Prototype Magnets LCLSII-4. 5 -ES-0403 -R 0 Cold Button Beam Position Monitor F 10023160 -A LCLS-II Cold BPM Assembly Drawing Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 6

LCLS-II Cryomodule Documentation, page 4 Reference Number Document Title Cryomodule engineering details, analyses, and compliance documents F 10041183 -A ASSEMBLY, 1. 3 GHz PRODUCTION CM LCLS-II (DWG) F 10022915 -D LCLS-II Prototype Cryomodule P&ID (drawing) F 10040796 -A LCLS-II Production Cryomodule P&ID (drawing) ED 0001152 Master Spreadsheet 1. 3 GHz CM-LCLS-II (cryomodule dimensional details) ED 0001995 LCLS-II CDS Relief System Analysis EN 02076 Fermilab Engineering Note, LCLS-II Cryomodule Vacuum Vessel (FESHM conformance) ED 0002337 Fermilab Engineering Note LCLS-II Vacuum Vessel FEA Structural Analysis ED 0002396 Cryomodule vacuum vessel venting analysis ED 0002383 Procedure for Support Post Traction Test ED 0002112 -C Fermilab Engineering Specification, LCLS-II Cryomodule Beam Pipe Copper Plating ED 0002026 Assembly Procedure for LCLS-II Support Post (Draft) ED 0002454 LCLS-II 1. 3 GHz Prototype Cryomodule Instrumentation List ED 0002638 P&ID (instrumentation) tag name list Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 7

LCLS-II Cryomodule Documentation, page 5 Reference Number Document Title ED 0002593 Inter-connect assembly procedures ED 0002453 JT valve sizing and flow calculation ED 0002406 Cool-down valve sizing and flow calculation ED 0002405 Cryomodule two phase pipe pressure, vapor velocity, and venting calculation ED 0002404 Cryomodule cooldown line pressure, flow, and venting calculation ED 0002962 Cryomodule cavity helium circuits 5500 -ES-371043 Fermilab Specification: 1. 3 GHz Cryomodule (Type IV) Interconnect Bellows Assembly Engineering Note EN 02057 Prototype Cryomodule piping engineering note (FESHM piping standard) Fermilab draft document Electric heater sizing, design, implementation engineering note NE-EO-2015 -004 LCLS-II 1. 3 GHz Cryomodule Cold Mass Thermal Intercept Analysis (ANL effort) LCLSII-4. 5 -EN-0430 -R 0 Stress Analysis of LCLS II Cryomodule for Seismic Load LCLSII-4. 9 -EN-0253 -R 0 CDS/Cryomodule What-If Analysis LCLSII-4. 9 -EN-0255 -R 0 CDS/Cryomodule Failure Mode and Effects Analysis LCLSII-4. 5 -EN-0567/EN 01774 Dressed cavity helium vessel engineering note (cavity AES 035, FESHM conformance) Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 8

F 10041166 -B, Assembly Cavity String Production 1. 3 GHz-CM As assembled in cleanroom String after twophase pipe and magnet are added Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 9

F 10041120 -A, Assembly Coldmass Production Cryomodule 1. 3 GHz Coldmass shown with and without 50 K shield Cross section views Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 10

F 10041183 -A, Assembly 1. 3 GHz Production Cryomodule LCLS-II Final assembly Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 11

Drawings status for F 10041183 -A According TC Structure Manager: • Total: 1028 DWG’s • including 87 F 0* drawings from ILC and DESY • 1011 DWG’s are released • 17 DWG’s are not released • MLI on valve port • GRP end connections for testing • Cryomodule stands • Coupler intercept assembly (all subcomponents released, pre-released) Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 12

Changes after FDR • Using Loctite Type 242 for threaded connections on Cold Mass Upper (DWG F 10009954 -H) • Locking mechanism (such as Belleville washers) and indium foil for thermal intercept connections • Change in configuration for thermal connection from power couplers to 50 K • 5 K coupler intercept modified to hold vacuum forces 50 K thermal intercept Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 5 K thermal Intercept 13

Changes after FDR (continued) • • Invar rod clamp - changed during prototype assembly Magnetic shield - ease of assembly, solve interference issues (tuner) Valve thermal intercepts Instrumentation flanges (reduced connectors, reduced size of guard helium flange) • Magnet current lead flange cover Guard helium flange Current lead cover Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 14

FDR Review Committee recommendation, FNAL May 12 -14, 2015 (Page 1) II. Recommendations The FDR Committee recommends that the LCLSII team: 1. Specify the fast cool down procedure for cryomodules in terms of cooling rate, start-stop temperatures, time and helium mass flow. Identify cool-down procedure stakeholders and define all input parameters, then write a draft document. It is recognized that at some level the finalization of this document will require hardware to be in place and constant monitoring of cool -down parameters, but at the very least step by step processes should be identified. (Closed) 2. Prove an active demagnetization scheme for various cryomodule locations and at all eight shielding locations in cryomodule. Test the complete cryomodule for demagnetization once available to ensure results remain consistent. (Closed) 3. The effect of string end caps on the magnetic performance of the cryomodule should be investigated. (Closed) 4. Define the specification of the relative permeability of components and the test procedure. (Closed) Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 15

FDR Review Committee recommendation, FNAL May 12 -14, 2015 (Page 2) 5. Resolve remaining seismic issues for the cryomodule design. The insulating vacuum vessel and the internal cryomodule components and their supports meet seismic design requirements. The supports attaching the cryomodule to the floor of the accelerator tunnel do not meet seismic design requirements. Resolving the deficiencies in the supports should not be difficult and should not impact the design of other cryomodule components. (Cryomodule seismic design approved, Support stands still under review) 6. Perform further modeling and tests of the fundamental power coupler cooling with more thermal connections to 70 K intercept and come up with a final design that meets a specified maximum temperature. Case studies with additional heating should be conducted to establish a safety overhead. A separate coupler review is strongly suggested. (Closed) 7. Investigate the capacity of the cryo-plant at TJNAF and propose, if needed, modifications to reach fast the cool down rate for cryomodules assembled and tested at TJNAF. (Closed) 8. Define pipe size and helium supply requirements in tunnel for instrumentation ports. (See Engineering Note - LCLSII-4. 5 -EN-0617 -R 0) Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 16

FDR Review Committee recommendation, FNAL May 12 -14, 2015 (Page 3) 9. Create a unified and consistent mechanism to ensure lessons learned from prototype development and testing are documented and communicated between partner labs (TJNAF, FNAL and SLAC) in a timely manner. This means that all issues need to be tracked. (Cumulative small changes can lead to greater issues. ) (Closed) 10. Establish traveler requirements that are agreed upon by partner labs, i. e. what needs to be tracked/recorded, deviations, tests, quality etc. that will aide production and operation. Define individuals at each of the three labs who can sign off NCRs. (Closed) 11. Establish how travelers will be communicated to SLAC; format, timing etc. (Closed) 12. Define requirements for both location and type of fail-safe components, and update design to reflect these. (Closed) 13. Integrate installation and commissioning tasks into the schedule to reflect pre-op and accelerator readiness reviews. (Closed) Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 17

FDR Review Committee recommendation, FNAL May 12 -14, 2015 (Page 4) 14. Define how much time is required to commission the integrated cryo-system and ensure the schedule reflects necessary readiness reviews. (Closed) 15. Schedule time during assembly and installation to include EEIP (Electrical Equipment Inspection Program) performed by SLAC qualified staff. (Closed) 16. Transport a cryomodule that has been assembled and tested at TJNAF to FNAL for retesting on FNAL equipment. This affords the opportunity to confirm test results produced at the two laboratories as well as to observe changes in cryomodule performance following transportation. After shipment of a cryomodule from TJNAF to FNAL, the demagnetization should be re-measured. (Closed) 17. The Project has recently shifted to a cryogenic system with two cryo-plants. This decision does not impact the design of individual cryomodules; however configuration of the system as a whole requires development to take advantage of opportunities to enhance reliability by taking advantage of the redundancy present with two cryo-plants. (Closed) 18. The performance of thermal grease in the radiation environment expected within the cryomodule insulating vacuum should be investigated. (Closed) Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 18

Summary • Design is complete • FDR passed, recommendations addressed • Drawings 98% released, outstanding drawings will not effect production • Prototype cryomodule assemblies show the design is viable for fabrication • Prototype cryomodule cold, including fast cooldown performed Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 19

Backup slides Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 20

FNAL Team Center numbers for important components of 1. 3 GHz CM (Prototype & Production) LCLS-II, 1. 3 GHz p. CM LCLS-II, 1. 3 GHz Production CM Cryomodule Assembly F 10009945 F 10041183 Vacuum Vessel F 10026609 Cold Mass Assembly F 10009950 F 10041120 Assembly Cold Mass Upper F 10009954 Assembly cavity String F 10009887 F 10041166 Assembly 1. 3 GHz dressed Cavity F 10027807 (short-short) F 10041087 (short-long) Assembly magnet package F 10009375 Assembly lever tuner (FNAL) F 10008766 Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 21

Cryomodule Labels Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 22

Drawings status for F 10041183 -A Fermilab/JLab 1. 3 GHz Cryomodule Production Readiness Review, 13 -14 Sep 2016 23

Production Cryomodule Final Design Review, 12 May 2015 24

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