Overview of Mechanical Design Nate Laverdure LCLS-II 2 K Cold Box FDR March 9, 2017

Design overview and interfaces Outline Design overview and interfaces Configurations and bayonet installation/removal Design details Thermal reliefs Cold compressor installation Bellows/straightener assembly Heater assembly Central support column Mechanical drawing package LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical design overview LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical design overview LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold box configurations High flow configuration (CC-1 through CC-5) From linac To 4KCB From LHe dewar LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold box configurations Low flow configuration (CC-2 through CC-6) From linac To 4KCB From LHe dewar LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold box configurations – u-tubes Size High flow CC-1 through CC-5 IBX-CC1I-2KPR-1 9-1/4” CC1O-CC2I-2KPR-1 CC5O-2KCB-CCR-1 5-3/16” 2KCB-4KCB-CCR-1 LHD-2KCB-4KVAP-1 3-1/8” Low flow CC-2 through CC-6 IBX-CC2I-2KPR-1 CC5O-CC6I-2KPR-1 Used in both configurations LCLS-II 2 K CBX FDR, Mar 9, 2017

Top plate and work platform Access requirements Around bayonets for system configuration changes Around control valves, relief valves, and feedthroughs for maintenance Sufficient aisle width for egress from work areas LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold box configuration control Bayonet installation/removal procedure LCLS-II 2 K CBX FDR, Mar 9, 2017

Bayonet installation/removal procedure LCLS-II 2 K CBX FDR, Mar 9, 2017

Thermal relief assembly All 2K Cold Box cryogenic reliefs are: Thermal reliefs ASME reliefs Protected against air contamination via guard vacuum enclosure Exhausted to header which is protected against moisture entry and vented outdoors LCLS-II 2 K CBX FDR, Mar 9, 2017

Thermal relief assembly LCLS-II 2 K CBX FDR, Mar 9, 2017

Thermal relief assembly Relief inspection/replacement process: Warm up 2K Cold Box and bring to 1 atm Backfill relief exhaust header with 3 atm He purge Break fittings around relief shroud and remove Disconnect relief flange and install blank while under purge Inspect/test relief on bench or replace Disconnect blank and install relief while under purge Re-install relief shroud Pump relief exhaust header to guard vacuum and backfill with 3 atm He purge LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – cold compressor installation LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – bellows/straightener assembly Used in CC-1 and CC-2 inlet piping spools LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – bellows/straightener assembly Cleanup of stagnant annular volume Recommendation: Large virtual leak exists between flex ID and process piping. Need to address this. Response: 12x 1/8” holes to facilitate pump and backfill of annular space LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – heater assembly Based on SNS and earlier heater designs LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – control valves LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – internal piping support Configurable support Pinned in 2 places for shipping Pinned in 1 place for normal operation LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – internal piping support LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – manway Based on 30” design used at JLab 4K Cold Box LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – central support column Maintains flatness of top plate during assembly Threaded rods and nuts for leveling during installation Shims inserted between flanges to carry large compression load And during operation Encased in passive copper conductor Insulated with MLI Thermal deflection limited to a few thousandths LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical details – vacuum pumping system LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical drawing package structure Final integration 79222-0020 top level assembly Assembled on SLAC site Includes all installation, outfitting of all external piping and external instrumentation Responsibility of final construction subcontractor Initial construction 79222-0027 top level assembly Shipped to SLAC Includes vacuum shell, internal piping, internal instrumentation Responsibility of initial construction subcontractor LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical drawing package LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical drawing package LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical drawing package LCLS-II 2 K CBX FDR, Mar 9, 2017

Mechanical drawing package LCLS-II 2 K CBX FDR, Mar 9, 2017

Documentation Document No. Title Author Status 79222-D6001 2K Cold Box Drawing List D. Rath Under review LCLS-II 2 K CBX FDR, Mar 9, 2017

2K Cold Box design documentation Summary 2K Cold Box design documentation P&ID released Mechanical drawings for initial construction of the 2K Cold Box primarily in checking or released Drawings to be complete by 10 Apr 2017 Access requirements are well defined Maturity of design is commensurate with FDR LCLS-II 2 K CBX FDR, Mar 9, 2017

Overview of Mechanical Design Nate Laverdure LCLS-II 2 K Cold Box FDR March 9, 2017

9-1/4” bayonet interference Background Used for subatm He connections at CC suction SNS experience with this component: seized during installation Outer male bayonet tube observed out-of-round Interference between OD of outer male bayonet tube and ID of lantern ring or valve flange body Not observed at JLab LCLS-II 2 K CBX FDR, Mar 9, 2017

9-1/4” bayonet interference Mitigation Purchase tube meeting ASTM A269 From this tubing, select and use only sections meeting additional imposed tolerance Verify clearance using purpose designed gauge or lantern ring Inspect ID of all lantern rings and valve flange bodies LCLS-II 2 K CBX FDR, Mar 9, 2017