QA/QC from the point-of-view of a "receiving" lab Marc Ross 15 October 2014 Customer’s Responsibilities Requirements for Conformance of SRF Cryomodules, Workshop held at ESS Lund, Sweden

Outline Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Introduction to LCLS-II CW X-ray FEL based on TESLA technology US multi-lab project management QA Management Guidance and Strategy Project QA Organization Data management  Product Life-cycle Management (PLM) Cryomodule Production Scheme Perspectives (See talks by Fermilab and Jlab)

In less than one year: Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) 1.Formed LCLS-II inter-lab partnership 2.Prepared a plan to be formally established as Project Baseline in Spring 2015 Includes multi-lab procurement and production scheme 3.Commissioned and executed High Q0 R&D culminating in treatment and testing of 20 nine-cell cavities 4.Adapted TESLA / XFEL cryomodule design for CW operation 5.Launched formal procurement process for ~280 cavities 6.Reviewed – successfully - by DoE SC / OPA twice

Outline Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Introduction to LCLS-II CW X-ray FEL based on TESLA technology US multi-lab project management QA Management Guidance and Strategy Project QA Organization Data management  Product Life-cycle Management (PLM) Cryomodule Production Scheme Perspectives (See talks by Fermilab and Jlab)

Remarkable Convergence: Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) 1.X-Ray FEL commissioned and operating at SLAC First light EU-XFEL Project Contracts / ILC Technical Design Report with industrial studies and costing EU-XFEL calls for tender ~ 2008 ILC TDR reviewed and released in High Q0 Development – Fermilab Potential to relieve CW SRF Linac cost-driver: Cryogenic system Established and published in 2012 BESAC review of construction projects (July 2013) provided new direction

Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Linac Coherent Light Source Facility Injector at 2-km point Existing Linac (1 km) (with modifications) First Light April 2009, CD-4 June 2010 New e  Transfer Line (340 m) X-ray Transport Line (200 m) UCLA Undulator (130 m) Near Experiment Hall Far Experiment Hall

Photons for Basic Energy Science (Material, Condensed Matter, Biology, Chemistry…)  Hard X-Ray Source:  1-5 keV w/ new 4 GeV SC linac  Up to 25 keV with LCLS Cu Linac  Soft X-Ray Source:  250 eV-1.2 keV w/ 4 GeV linac  Both linacs feed HXR undulator Cu Self Seeded High Rep Rate SASE Self Seeded (Grating) Cu SASE Photon Energy (keV) SC Linac High Rep Rate Cu Linac Legend 4.0 GeV Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

LCLS-II Concept Use 1 st km of SLAC linac for CW SCRF linac Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) SCRF Linac CuRF Linac Transport, Undulators & Experimental Stations

LCLS Layout in SLAC Linac Tunnel SXU HXU proposed FACET-II LCLS-ILCLS-II SC Linac bypass line  -wall A-line B-line Sector-10Sector-20Sector-30Sector-0 extension line L3L2L1 s (m) spreader New SCRF Linac (4 GeV) Proposed FACET-II and Bypass Line Existing LCLS-I Linac Undulators (LCLS-I & -II) (only approximately to scale) Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

LCLS-II Objectives: Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Build 4 GeV (up to 300 micro-Amp) CW superconducting linac based on TESLA / ILC / E-XFEL 1.3 GHz technology Develop cavity process for high-Q0 production Develop CW cryomodule design and operations scheme for 110 2K / CM (or better) based on high-Q0 cavity process Use industrial capability for 1) dressed-processed-cavity, 2) coupler, and 3) vacuum-vessel/cold-mass production Adapt JLab ‘CHL-2’ (12 GeV Upgrade) Cryoplant for SLAC

LCLS-II Linac Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Closely based on the European XFEL / ILC / TESLA Design Under development ~ 20 years with > 1000 cavities to be made and tested (inc. 800 for E-XFEL – completed 2016) Thirty-five 1.3 GHz 8-cavity cryomodules Two 3.9 GHz 8-cavity cryomodules Four cold segments (L0, L1, L2 and L3) which are separated by warm beamline sections GHz cavities GHz cavities

Fermilab-developed ‘gas-doping’ process  Fermilab has developed a cavity processing recipe that results in high quality factors (>3E10) at operating gradients between 10 and 20 MV/m. In 2014 Fermilab led a Q0 program in collaboration with Cornell and JLab. The primary goal is to develop a reliable and industrially compatible processing recipe to achieve an average Q0 of 2.7E10 at 16 MV/m in a practical cryomodule; minimum 1.5E10. To reach this goal, the collaborating institutions processed and tested single-cell and 9-cell 1.3 GHz cavities in a successive optimization cycle. The deliverable is industrial capability and cost-effective production yield. Supporting the cryoplant design choices 12 IBIC Monterey Sep 15, 2014 (M. Ross, SLAC)

13 IBIC Monterey Sep 15, 2014 (M. Ross, SLAC)

LCLS-II High Q0 R&D Program – Preliminary Nine-Cell VT Results High Q0 Program 9 cell results Q0E_acc (MV/m) Average3.4E Yield 100% (avg. 2.7e10)47% (18 MV/m)84%(16 MV/m) # below3 cavities < 2.7E+1010 < 18 MV/m3 < 16 MV/m Number of cavities tested; some multi-pass 19 (5 Cornell; 5 Jlab; 9 Fermilab) 14 High Q0 testing done at 3 labs: Fermilab (from 2012); JLab and Cornell (2014) LCLS-II DOE Status Review, Sept. 30 – Oct. 2, 2014 Initial results meet LCLS-II VTS High Q0 criteria Would make 2 cryomodules with: = 2.8e10, = 17.1MV/m, P d /CM = 86W

LCLS-II Cryomodule in 3-D 90 W (2K) nominal Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

CM, Feed Cap and Bypass and Vertical Transferline Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Horizontal Bypass Vertical Transferline Total transferline length is ~ 510 m

Cryomodule from the side: 12.6 m long; 1 m diameter (Similar to LHC dipole) 8 cavities w / superconducting quad magnet Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

Future view along linac – after LCLS-II SCRF linac installation: Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

Re-purposing the SLAC Tunnel Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) SLAC Linac Tunnel: 11 wide x 10 feet high It will be a tight fit! S. Boo, J. Chan Existing Copper Linac

LCLS-II Cavity Control Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) 10 to 100x lower current than ILC / XFEL (LCLS-II 60 micro Amp / EXFEL - ILC 6 mA)  Matched LCLS-II loaded Q L ~ 3e8; effective resonance width very narrow; BW few Hz Difficult with today’s state-of-the-art cavity controls LCLS-II: 6e6 < Q L < 1e8; nominal 4e7 BW 50 Hz ILC / XFEL: 1e6 < Q L < 1.4e7 Microphonics / cavity resonance control  key R&D topics for low current CW linacs Also useful for ILC

Project Collaboration: 50% of cryomodules: 1.3 GHz Cryomodules: 3.9 GHz Cryomodule engineering/design Helium distribution Processing for high Q (FNAL-invented gas doping) 50% of cryomodules: 1.3 GHz Cryoplant selection/design Processing for high Q Undulators e - gun & associated injector systems Undulator Vacuum Chamber Also supports FNAL w/ SCRF cleaning facility Undulator R&D: vertical polarization R&D planning, prototype support processing for high-Q (high Q gas doping) e - gun option Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

Summary Schedule Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) LCLS-II: one CM every 3 weeks (aggregate production of two labs) ILC: one CM every week (US)

Outline Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Introduction to LCLS-II CW X-ray FEL based on TESLA technology US multi-lab project management QA Management Guidance and Strategy Project QA Organization Data management  Product Life-cycle Management (PLM) Cryomodule Production Scheme Perspectives (See talks by Fermilab and Jlab)

A Model for Cavity and CM Production and Qualification Process Step hostedIndustryIndustry/Labo ratory Hub- laboratory ILC Host- laboratory Regional constraintnoyes or noyes Sub-comp/material - Production/Procurement Nb, Ti, specific comp. … Procurement 9-cell Cavity - Manufacturing 9-cell-cavity, Process, He-Jacketing Procurement 9-cell Cavity - Performance Test Cold, gradient test Cryomodule component - Manufacturing V. vessel, cold-mass... Procurement Cryomodule/Cavity - Assembly Cav-string/ CM-assembly SCRF Cryomodule - Perofrmance Test Cold, gradient test Accelerator integration, Commissioning Accelerator sys. Integ. 24 LCLS-II Vendor Outreach Hand-off Process: Partner Quality Assurance

EU-XFEL / LCLSII Comparison Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) EU-XFELLCLS-II GovernanceXFEL Company / Accelerator Consortium DoE SC/BES Program Manager BasisInter-lab MoA FundingIn-kind contributions and exchanges Centralized Technical ManagementDESY Accelerator Consortium Lead Multi-lab partnership: ‘managed as one lab’ QA toolsSiemens Team-CenterGeneral Guidance / Partner-lab home-built Project PlanningOracle Primavera ‘P6’ Cavity / CM TestingDESYPartial testing at partner- institutions Env. Safety HealthEU regulatedLab-by-lab compliance and consistency

LCLS II Approach to Multi-Lab Project Management Cost and Schedule Baseline – Single Source P6/COBRA primary tools – Trained staff following common protocols Funding transfers from SLAC to partner labs via MPO Baseline changes, contingency managed centrally w/ approval thresholds Documentation Management LCLS II Website, EDMS (Team Center) Procurements – Planned centrally Specific deliverables managed and executed by responsible lab ES&H – Work performed at partner labs mostly follow local rules QA & Systems Engineering – Flow-down from requirements Communications & Coordination – Clear R2A2s for labs and people Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

Lessons-Learned from SNS Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) 1.A clear mission need and program support are imperative. 2.Build a strong, effective project management organization early. 3.Multi-laboratory partnerships with clear responsibilities and centralized budget authority can be successfully used for new, big-scale projects 4.Many project management tools and processes are needed to manage project performance, but processes alone are not sufficient to effectively manage project performance. 5.Planning for commissioning and operations should take place early 6.Innovative HR programs are key for successful recruiting and retention of staff 7.Safety requires the unrelenting attention and commitment of management and labor. S. Herron, C. Strawbridge, ORNL, PAC2009

Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Contract Performance SLAC and DOE collaborate to develop annual performance measures for inclusion in the management and operations Contract (Prime Contract) between Stanford University Board of Trustees and the DOE. Each year, the most important goals are identified as Notable Outcomes in the Performance Evaluation and Measurement Plan (PEMP), and other focus areas for the management and operations goals are agreed to between SLAC, SU and SSO. These are reflected in the FY Lab Agenda, and are also connected to relevant employees' performance goals.

EDMS-PLM Applications DESY TeamCenter Meeting The goal of this meeting is to consider the application of EDMS to the development, production, and operation of LCLS-II equipment. We will: 1.Share experiences with the use of EDMS for project development, review, and production. 2.Discuss the systems in place that link DESY, DESY-XFEL partners, and XFEL industry in order to understand the technical (QC/QA), oversight (management), and safety (e.g. PED) functionality. 3.Evaluate possible application of parts of these systems to LCLS-II, including, possibly, application of the full-system in specific, specialized examples – such as cavity fabrication vendor oversight. This example is of direct, immediate interest as we consider cavity fabrication and processing. 4. Discuss paths forward, including EDMS development, licensing, use of alternate platforms and etc. Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) 31 March – 1 April 2014

LCLS-II Methodology for Interface Control Technical Requirements Management L. Plummer & D. Marsh Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Top – down Design Example

LCLS-II Project Controls Documents Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) describe: 1) elements of Project Management 2) overall machine requirements, basic parameters, design standards and guidelines, 3) main configuration of each system System Control Documents cover all specific design and interface requirements for each system Procurement/Fabrication Packages are drawings, specifications and plans that are passed on to the product realization processes. L. Plummer & D. Marsh

Cryogenic System Specifications LCLS-II DOE Status Review, Sept Oct. 2, Doc Type Doc NumberDocument TitleDraftedReleased Completion Date PRDLCLSII-2.4-PR-0041-R0Linac overview requirements ✔✔ 3/20/14 PRDLCLSII-2.4-PR-0041-R1Linac Requirements ✔✔ 6/23/14 PRDLCLSII-2.4-PR-0133-R0Parameters ✔✔ 4/8/14 PRDLCLSII-4.1-PR-0146-R0SCRF 1.3 GHz cryomodules ✔✔ 4/30/14 PRDLCLSII-4.1-PR-0098-R0RF power and LLRF requirements ✔✔ 7/21/14 PRDLCLSII-4.1-PR-0097-R03.9 GHz cryomodules ✔✔ 6/23/14 FRSLCLSII-4.5-FR-0053-R01.3 GHz Superconducting RF Cryomodule ✔✔ 6/23/14 FRSLCLSII-4.5-FR-0096-R03.9 GHz CM ✔ (2/15/15) FRSLCLSII-4.5-FR-0070-R0Cryogenic Systems Heat Loads ✔ (9/18/14) FRSLCLSII-4.8-FR-0244-R0Cryogenic Plant ✔ (10/01/14) FRSLCLSII-4.9-FR-0057-R0Cryogenic Distribution System ✔✔ 6/23/14 ICDLCLSII-2.5-IC-0056-R0Accelerator to Cryogenics ✔✔ 7/30/14 ICDLCLSII-5.4-IC-0235-R0Cryoplant to Infrastructure Systems ✔✔ 7/24/14 ICDLCLSII-4.9-IC-0058-R0Cryogenic Distribution System ✔✔ 8/4/14

LCLS-II Document / Configuration Control (Sharepoint) Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

Necessary LCLS-II Documentation Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Preliminary Project Execution Plan Acquisition Strategy Conceptual Design Report (w/external review) Preliminary Hazard Analysis Report Updated for cryogenics, ODH, MW beams and PL activities Integrated Safety Management Plan Quality Assurance Program Safeguards and Security National Environmental Policy Act Strategy Project Data Sheet (under review at DOE) Risk Management Plan (SLAC & LCLS II) Project Risk Registry

Outline Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Introduction to LCLS-II CW X-ray FEL based on TESLA technology US multi-lab project management QA Management Guidance and Strategy Project QA Organization Data management  Product Life-cycle Management (PLM) Cryomodule Production Scheme Perspectives (See talks by Fermilab and Jlab)

Cryomodule Collaboration Fermilab is leading the cryomodule design effort Extensive experience with TESLA-style cryomodule design and assembly Jefferson Lab and Cornell are partners in design review, costing, and production Jefferson Lab sharing half the 1.3 GHz production -Recent 12 GeV upgrade production experience -20+ years experience Argonne Lab is also participating in cryostat design Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC)

Perspective (1): The nature of SRF Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Many, many steps between System tests Intermediate QC steps to capture key procedures. Like 'build to print' cavity procurement Typical problem: too much data. See talks by LCLS partners Jlab and Fermilab. Establish hold points, exception handling, and sign off as a vendor relationship. This workshop is an ideal venue to discuss ‘gaps’ For example: For example screw tightening / screw locking. Technical design choices may help assurance in some cases.

Perspective (2): Inter-lab partnerships Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Hand-off between institutions Strengthened definition of core competence by DoE in 1990's to reduce redundancies Concentrates expertise, infrastructure Forces inter-lab partnerships apply new technology (APS-U, SNS, LCLS-I) Certified QA programs lab-by-lab a funding-agency requirement for Performance Evaluation and Measurement Plan (PEMP-scoring), Itself a QA process Top-down ranking with high-impact

Perspective(3): Scope of effort Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Formalize parameters, procedures, and steps toward compliance. 1.3 GHz cavity Standard facilitates step-by-step improvement Develop technical balance between labs (staff) with partnered contact persons for each hand off. Best customer is a competent one Arrange management partnerships Including well-established (highest) practical authority for judgment / appeal. Budget and plan for 'level of effort ' staffing using guidance. Typically 15% for complex systems; mostly QA e.g. One engineer / scientist at SLAC for every 6 at partner institute Summary documentation available

Perspectives (4): Procurement Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Partner involvement in procurement basics project-wide application of QA protocol for each (major) procurement Partners involved in tender selection process

Summary: toward SRF CM conformance  Requirements for Conformance of SRF CM, Oct 15, 2014 (M. Ross, SLAC) Define hold points to check progress between System tests: Define hand-off acceptance (between institutions) -Now in draft for LCLS-II Develop technical balance between labs (staff) Require partner involvement in procurement basics