LCLS-II Cryogenic Distribution System CDS Surface Components PDR Jerry Makara December 16, 2014

2 Function J.Makara, CDS DB PDR, 12/16/2014 Provides cryogenic flow control, including controlled cooldown/warmup of three primary CM circuits -High Temperature Thermal Shield (HTTS) (Lines E & F) -Low Temperature Thermal Intercept (LTTI) (Lines C & D) - SRF Cavity Circuit (Subcooled Supply and Gas Return Pipe) (Lines A and B) Provides independent cryogenic operations of West (Upstream) and East (Downstream) Linac Cryomodule strings Isolates from Cryoplant through removable u-tubes, set of six for each Linac string Provides paths for CM circuit pressure relieving as necessary for various failure modes CDS Functional Requirement Specification Document LCLSII-4.9-FR-0057 CDS DB Functional Analysis LCLSII-4.9-EN-0288

3 Interface Process Lines J.Makara, CDS DB PDR, 12/16/2014 CP Cryo Connections (JLab u-tubes): HTTS ~3” female bayonet (JLab designs for DB) supply and return ~2” (flow) male bayonet (JLab designs and provides) LTTI~2” female bayonet (JLab designs for DB) supply and return ~1” (flow) male bayonet (JLab designs and provides) 4K Supply~3” female bayonet (JLab designs for DB) ~2” (flow) male bayonet (JLab designs and provides) GRP~9”female bayonet (JLab designs for DB) ~8” (flow) male bayonet (JLab designs and provides) CP Warm GHe HP Supply (Purification and Main Compr System) DN25 LP Return (Purification and Main Compr System) DN150 Sub-atm Seal Guard (helium purge) DN15 TL Connections (with Vacuum Break): HTTS DN50 (2” NPS) supply and return LTTIDN50 (2” NPS) supply and return 2K SupplyDN50 (2” NPS) GRPDN250 (10” NPS) VacuumDN600 (24” NPS)

4 Mixing Chamber CM Cooldown Rate Control J.Makara, CDS DB PDR, 12/16/2014 CDS DB Mixing Chamber Cooldown Rate Control documented in LCLSII-4.9-EN-0291

5 J.Makara, CDS DB PDR, 12/16/2014 CP/MCS Operation Modes – Cooldown Controlled Cooldown/Warmup: Purification Cooldown  Uses 35K HTTS supply line either at 80 K (CP LN2 cooled) or 35 K (CP expanders 1&2)  Mixes warm helium from CP MCS with cold helium from CP for cooldown temperature control  CM cooldown constraints (HTTS and SRFC): o 10 K/hour max o 15 K max differential top/bottom of 300 mm GRP o 50 K max differential across each CM inlet/outlet GRP Fill Warmup CP/HTTS Supply CP/MCS Documented in LCLSII-4.9-EN-0290 and -0291

6 CM Thermal Mass J.Makara, CDS DB PDR, 12/16/2014

7 CM Thermal Mass

8 CM SCRF Cooldown Flows J.Makara, CDS DB PDR, 12/16/2014

9 CM SRFC Cooldown J.Makara, CDS DB PDR, 12/16/2014

10 Process Nominal Conditions J.Makara, CDS DB PDR, 12/16/2014 Cryogenic Circuit MAWP (bara) MDMT (K) Nominal Operating Pressure (bara) CP-DB Nominal Operating Temperature (K) CP-DB Nominal Operating Flow (Max Load) (g/s) US / DS HTTS Supply (Line-E)2030~3.7~3561 / 52 HTTS Return (Line-F)2030>2.7~55 LTTI Supply (Line-C)204.5~3~529 / 27 LTTI Return (Line-D)204.5>1.2 ~6 4K Supply (Line-A)201.8~3~4.590 / 98 Gas Return Pipe (Line-B)41.8>0.027 (budget)>3.0 CDS Functional Requirement Specification LCLSII-4.9-FR-0057 LCLS-II Cryogenic Heat Load LCLSII-4.5-EN-0179 LCLS-II CDS HT Shield, LT Intercept and 2K Supply dP Analysis LCLSII-EN-0295 LCLS-II CDS Gas Return Pipe Pressure Drop Analysis LCLSII-EN-0292 Nominal used for various calculations, estimates with uncertainty factors. (LTTI flows noted above at 6 K return but are 16/15 g/s US/DS for 8 K return)

11 J.Makara, CDS DB PDR, 12/16/2014 Control Valves International Electrotechnical Commission IEC (ISA ) is used for valve sizing equations and HePak for helium fluid properties. CDS Valve Sizing is documented in LCLSII-4.9-EN-0338

12 J.Makara, CDS DB PDR, 12/16/2014 Control Valves Control ValveReq’d CvValve Size (Cv) Table 1. HTTS Supply Valve PV-90040DN50 (82) Table 2. HTTS Return Valve PV-903 and Cooldown Valve PV-90555DN50 (82) Table 3. DB thermal Shield Supply Valve PV-9027DN20 (13) Table 4. LTTI Supply Valve PV-95012DN25 (17) Table 5. LTTI Return Valve PV-955 and cooldown PV-9548DN25 (17) Table 6. 4K Supply Valve PV-923 and PV-92620DN32 (27) Table 7. 4K Supply Valve 2KHX Bypass PV-92438DN40 (38) Table 8. GRP Valve PV DN250 (1856) or two DN150 (1276) Table 9. GRP 2KHX Bypass Valve PV DN150 (696) Table 10. GRP 2KHX Outlet Valve PV DN250 (1856) or two DN150 (1392) Table 11. GRP Cooldown Valve PV DN80 (186) Table 12. Warm GHe Supply for Mixing Temperature control PV-901, PV-925, PV-95213DN25 (20)

13 CM HTTS, LTTI, and 2K Supply Primary Reliefs J.Makara, CDS DB PDR, 12/16/2014 HTTS LTTI 2K Supply DISTR BOX COMPR SUCTION Relief system requirements are documented in LCLSII-4.9-EN-0297 and LCLSII-4.9-EN-0300 FRS 1.3 GHz SRF CM LCLSII-2.5-FR-0053

14 J.Makara, CDS DB PDR, 12/16/2014 DISTR BOX HRS COMPR SUCTION GRP CM GRP Primary Reliefs Relief system to protect CM SRF cavities which have dual pressure rating based on SRF cavity temperature – 4 bara below 80 K 2 bara above 80 K. <1.5 bara operational pressure control Non-reclosing relief device for <80 K operation w/ helium guard Reclosing relief device for >80 K operation FRS 1.3 GHz SRF CM LCLSII-2.5-FR-0053 Non-reclosing relief device for contamination control helium guard

HTTS691 Watts LTTI 81 Watts 4K/2K 46 Watts DBs Heat Load (total): Thermo-acoustic oscillation prevention/mitigation Fabrication QA (cleanliness, leak tightness, superinsulation, etc.) 2K circuit cryogenic valves are very large with heat load and vendor uncertainties; double thermal intercept contacts (40K, 5K) proposed though large part of heat load is due to the inner valve stem of conduction heat load from 300K to 2K. GRP bayonets will also have 5K thermal intercept contact. 2KHX with 5K thermal shield proposed due to large surface area. 15 Heat Load Estimate J.Makara, CDS DB PDR, 12/16/ K 40 K CDS DB Heat Loads are summarized in LCLSII-4.9-EN-0294 Heat Load Risks

16 J.Makara, CDS DB PDR, 12/16/2014 Layout CDS DB Site Layout LCLSII-4.9-EN-0293

17 Layout J.Makara, CDS DB PDR, 12/16/2014 ~37’ West (US) DB East (DS) DB To/from Linac tunnel To/from CP CP Interface Box CP Interface Box CP U-tubes

18 Procurement Strategy J.Makara, CDS DB PDR, 12/16/2014 DB Engineering Technical Specification Vendor provides engineering and performance assurance o Moves risk to vendor o Allows use of vendor expertise and best practices o Possible two vendor procurement process FNAL/CMTF Superfluid Cryogenic Plant and DESY/XFEL XLVB 2KHX highest risk of performance o Pre-installation testing consideration o Double-independent verification of design o Possible two vendor procurement process

19 Installation Plan J.Makara, CDS DB PDR, 12/16/2014 DISTRIBUTION BOX INSTALLATION Delivery/Placement Delivery/Acceptance Testing Control System Operations tune/verification DB Operations Readiness Clearance received (FESHM 5032) Performance Acceptance Testing (DB with LN2 but no CMs, or CP) Connection to TLs and CP DB is connected Visual Inspection of DB, internal and external Remove any internal supports beams inside DBs Connect valve pneumatics Test actuator functionality Instrumentation electrical integrity checkout per ESD Connect insulating vacuum pumping system per ESD Pump down insulating vacuum for mass-spec leak check Mass-spec leak check all circuits per ESD System Description Flow Schematics (P&ID) Engineering Notes (PVEN, PSEN, VVEN) What-if FMEA VIE Controls Documentation (I/O, loops, interlocks, FSM) Standard operating procedures Maintenance and operations continuity procedures (e.g. relief testing) Safety Review Panel ORC issued Connection of LN2 Supply (tanker) LN2 Cooldown/instrumentation checkout Shutdown/helium leak check/warmup

20 Summary J.Makara, CDS DB PDR, 12/16/2014 CDS FRS (LCLSII-4.9-FR-0057) Independent Linac string cooldown/warmup - Dual Distribution Boxes - Vacuum break isolation to TL feeding CMs Capture/return helium inventory to Cryoplant Cryoplant isolation via removable u-tubes - Set of six u-tubes for each DB Operating modes supported (Cooldown/Warmup, 4.5K Standby, 2K standby, 2K CW Max & Nom loads) Controlled cooldown/warmup of individual circuits - Warm helium/cold helium mixing for the three circuits (HTTS, LTTI, 4K Supply_ GRP) CDS ICD (LCLSII-4.9-IC-0058) SRF CM FRS (LCLSII-2.5-FR-0053) CDS DB Control Loop Functions (LCLSII-4.9-EN-0289) CDS DB Functional Analysis (LCLSII-4.9-EN-0288) CDS Cryomodule Cooldown Method (LCLSII-4.9-EN-0290) CDS DB Mixing Chamber CD Rate Control (LCLSII-4.9-EN-0291) CDS DB Flow Schematic (LCLSII-4.9-EN-0303) CDS Valve List (LCLSII-4.9-EN-0254) CDS Instrument List (LCLSII-4.9-EN-0256) CDS FMEA (LCLSII-4.9-EN-0255) CDS What-If Analysis (LCLSII-4.9-EN-0253) CDS DB Site Layout (LCLSII-4.9-EN-0293) CDS DB Procurement CDS DB Installation CDS DB dP Analysis/Valve Sizing (LCLSII-4.9-EN-0338) CDS DB Pressure Reliefs (LCLSII-4.9-EN-0297) CDS CM Cooldown Rate Control (LCLSII-4.9-EN-0291) Mixing Chamber CM Thermal Mass Cooldown Flows CDS DB Heat Load (LCLSII-4.9-EN-0294) CDS DB Technical Specification