Dana Arenius LCLS-II 4.5K Cold Box Director’s Review November 16, 2016 4.5K Cold Box Overview Dana Arenius LCLS-II 4.5K Cold Box Director’s Review November 16, 2016

Contractual Milestones Design Schedule Delays Outline 4.5K Cold Box Function Contractual Milestones Design Schedule Delays Schedule Recovery Actions Summary LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Cryoplant First Light & Normal Beam Operations 2 Cryomodule Strings U-Tube Connections 14 MV/m Gradient 2.0≤ Qo ≤3.0 Compressor System 4.5 K Coldbox LHe Dewar 2.0 K Normal Beam Operations 2 Cryoplants 2 Cryomodule Strings U-Tube Connections Removed Gradient - 16 MV/m 2.0≤ Qo ≤3.0 Compressor System He Gas Tanks 4.5 K Coldbox LHe Dewar LN 2 Dewar 2.0 K Coldbox U-TUBE JUMPER CONNECTIONS - IB IB Upstream Distribution Box Downstream Distribution Box Downstream Distribution Upstream String Box Downstream String LH BC 1 L L 1 L 2 L 3 FC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 IB Cryogenic Cryogenic Transfer 3 . 9 GHz Cryomodule 1 . 3 GHz Cryomodule End / Feed Cap Vacuum Barrier Bypass Line Cryoplant Gas Header Interface Box LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Cryoplant Layout Overview LN2 storage CP1 4.5K Cold Box GHe storage CP1 Oil Removal CP2 4.5K Cold Box CP2 Oil Removal CP2 Compressors CP1 Compressors Oil processor 2K CBX Guard Vacuum CDS Interface Boxes LHe Dewar LHe Dewar Instrument Air Motor Control Center 4 LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Single Plant Operation (CP-1) for First Light, 14 MV/m First Light Design Heat Loads with Qo=2.7x1010 Steady State CW Operation @ 14 MV/m Mode 1: Max Capacity of the Cryoplant Temp Level Heat Load [kW] High Temperature Thermal Shield, (35K) 15.3 Low Temperature Thermal Shield, (5K) 1.3 Primary Temperature 2K 4 Variation in the 2.0 K Heat Loads of First Light for the Selected First Light Gradient with Qo Source: Jlab Refrigerator Specification 79220-S001 One cryoplant is sufficient to support the First Light Operation (Ref: SLAC LCLSII-4.5-EN-0179-R2) LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Two Plant Operation (CP-1 & CP-2) For Design Heat Loads Design Heat Loads with Qo=2.7x1010 Steady State CW Operations @ 16 MV/m Mode 1: Max Capacity of the Cryoplant Temp Level Heat Load [kW] High Temperature Thermal Shield, (35K) 15.3 Low Temperature Thermal Shield, (5K) 1.3 Primary Temperature 2K 4 Variation in the 2K Design Heat Loads with Variable Gradient and Qo Source: Jlab 4.5K Cold Box Specification 79220-S001 (Ref: SLAC LCLSII-4.5-EN-0179-R2) Two cryoplant operation to support variation in gradient and Qo LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

4.5K Cold Box Design Challenges Included in plant performance analysis: Large variation of operational design parameters First Light single plant load (heavy load) vs. Normal two plant operation (~50% load for each plant) Unknown final Qo determination, design basis 2.7x1010 Required extensive heat exchanger/turbine performance analysis for wide possible load variation Level of Seismic design criteria for California Subcontract requirement for CA Seismic licensed PE LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

JLab/SLAC/Air Liquide Engineering Coordination Weekly status and issue resolution meetings Attended by AL/SLAC/JLab engineering, vendor PM JLab procurement Not attended by AL subcontractors PHPK (cold box assembly engineering and fabrication) Sumitomo (heat exchanger manufacturer) Hopper (Seismic PE, Subcontractor to PHPK) LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

4.5K Cold Box Contractual Milestone Schedule FDR Completion Plan: Nov 28th, Seismic Analysis Last Long Lead Item Ordered: 1-Nov-16 LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

4.5K Cold Boxes, 1.04.08.06/.16 Preliminary design review completed Heat exchanger sizing Absorber Beds Process cycle design verification Final Design Review 7-8th Sept ~90% of 92 required documents delivered 3-D modeling of internal piping completed Missing Piping Stress & Seismic Design Hold on top plate (upper cold box) and both cold box vacuum shells until analysis of piping stress and seismic analysis is complete (Note: Internal piping/vessel structure attached to vacuum shell) Missing analysis scheduled to be delivered ~28th November LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Schedule Recovery Action Items Implemented Notification of unsatisfactory schedule performance to vendor senior management Vendor schedule optimization study of remaining work to recover schedule implemented Continuation of weekly AL/Jlab/SLAC engineering coordination meetings Invitation by AL to JLab to attend weekly AL/Subcontractor coordination meeting for direct stakeholder communication PHPK Hopper LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Summary Heat exchanger analysis was longer than expected in completing PDR per contractual date and heat exchanger ordering Heat exchanger delay affected 3-D piping, piping stress and seismic analysis completion dates for FDR Lacking stress/seismic analysis, formal approval for cold box shell ordering (needed for CB fabrication) was delayed FDR Seismic analysis completion is scheduled for Nov 28th Schedule study implemented to recovery schedule slip Expanded JLab interaction with vendor subcontractors LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

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LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Cryoplant Modes of Operation (1) *Tables from 4.5K Cold Box Procurement Specification 79220-S001 Table 3.4(A) – Mode 1, Max. Capacity Table 3.4(C) – Mode 3, Max. Liquefaction Supply Return Load w p T q [g/s] [atm] [K] [kW] Warm Shield 146 Note 1 35 2.5 55 15.2 Cold Intercept 37 3.25 5.5 1.29 7.50 1.3 4-K Refrigeration 4-K Liquefaction 15 3.2 4.5 1.10 300.0 Sub-Atmospheric 200 1.20 30.0 Supply Return Load w p T q [g/s] [atm] [K] [kW] Warm Shield 155 Note 1 44 2.3 56.5 10.1  Cold Intercept 20 3.2 5.8 1.23 10.8 0.9 4-K Refrigeration 4-K Liquefaction 40 4.5 1.10 300.0 Sub-Atmospheric Table 3.4(B) – Mode 2, Nominal turn down Table 3.4(D) – Mode 4, Max. Refrigeration Supply Return Load w p T q   [g/s] [atm] [K] [kW] Warm Shield 96.7  Note 1  35 2.5 55 10.10 Cold Intercept 27 3.2 5.5 1.29 7.50 0.9 4-K Refrigeration 4-K Liquefaction Sub-Atmospheric 157 4.5 1.20 30.0 Supply Return Load w p T q   [g/s] [atm] [K] [kW] Warm Shield 146  Note 1 35 2.5 55 15.2 Cold Intercept 31 3.2 5.3 1.23 9.0 1.3 4-K Refrigeration 481 4.5 4.45 4-K Liquefaction Sub-Atmospheric The specification requires the cryoplant to support a wide operational variable domain while maintaining plant efficiency. LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Cryoplant Modes of Operation (2) Table 3.4(E) – Mode 5, Max. Fill Table 3.4(F) – Mode 6, Standby Supply Return Load w p T q   [g/s] [atm] [K] [kW] Warm Shield 146  Note 1 35 2.7 55 15.2 Cold Intercept 3.2 5.3 1.23 7.8 1.3 4-K Refrigeration 4-K Liquefaction 45  4.5 1.10 300.0 Sub-Atmospheric 157 1.20 30.0 Supply Return Load w p T q   [g/s] [atm] [K] [kW] Warm Shield 96.7   Note 1 35 2.7 55 10.1 Cold Intercept 25 3.2 5.3 1.23 7.5 0.9 4-K Refrigeration 27 4.5 0.5 Mode 7, 50% Turn Down Supply Return Load w p T q   [g/s] [atm] [K] [kW] Warm Shield [Note 2] 35.0 [±5] 2.5 55 [±5] 7.5 Cold Intercept 3.2 5.0 [±0.5] 1.29 8.0 0.7 4-K Liq. 4.5 1.1 300 Sub-Atm. 100 1.2 30 1.9  A seventh operating point was checked and validated by the vendor for operation at 50% of maximum single plant operation mode as an additional operating point within the domain *Tables from 4.5K Cold Box Procurement Specification 79220-S001 LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Process Model Validation- JLAB/SLAC Calculation (Example: Mode 1- Max Capacity), All 7 Modes completed LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Validation of Heat Exchanger UAs Heat Exchanger Cooling Curve For the heat exchanger sizing, the mode yielding the maximum UA value is considered (highlighted in yellow). Integrated UAs were calculated and compared with the vendor calculated values. Good agreement in the UA and the NTU values LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

Safety Margin on UAs “A uniformly applied UA safety margin of 15% is required for all heat exchangers for the operating mode requiring the highest UA”. The UA provided by the Vendor is in compliance with the requirement for the Heat Exchangers LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016

4.5K CB Pressure Drop in Heat Exchangers-Vendor Data Pressure Drops in HXs for Mode 1: Max Capacity (Example for each Mode) “The ratio of the core pressure drop to the distributor pressure drop > 3.” “The ratio of the sum of the core and distributor pressure drops to the sum of the header and nozzle pressure drop > 3.” The pressure drop values provided by the vendor satisfy the above requirements LCLS-II 4.5K Cold Box Director’s Review, November 16, 2016