Baseline Change Request BCR Title: 1.04.06.15 LERF as CM Testing Facility (LERF = Low Energy Recirculation Facility) Presenter’s Name: Ed Daly CCB Presentation Date: 08-21-2017

BCR Summary Documents the work scope increase for an additional CM testing facility at JLab Update the cost and schedule to include: Set up of the LERF as a CM testing facility Include additional labor to support facility Net Impact: Cost: Increase of $3,690K Technical: Using LCLS-II HPRF/LLRF provides early feedback on RF/SRF system integrated performance Schedule: Enables acceleration of CM testing by increasing testing through-put CCB Presentation – 08-21-2017

Using LERF as Cryomodule Test-Bed - Opportunity The LCLS-II project has discovered issues with CM performance (microphonics, achieving high Qo, Field Emission) during the prototype cryomodule testing phase at FNAL and JLab Resulting in some re-work of CMs Need to demonstrate closed-loop RF control due to microphonics Need to achieve expected cryogenic conditions in testing facilities In the longer term, a place to conduct integrated RF/Cryo testing and an additional place to test cryomodules could be very useful for both LCLS-II and JLab LERF has existing utilities (water, electrical, cryogenic, waveguides, radiation shielding, personnel protection, etc.) and is situated near a large-scale cryogenic plant Similarity to actual LCLS-II machine conditions – large Cryoplant located near operational cryomodules CCB Presentation – 08-21-2017

Using LERF as Cryomodule Test-Bed - Overview A detailed scope, cost and schedule estimate for installing and testing LCLS-II cryomodules (two-at-a-time) as an assembly in the LERF has been developed. Estimate considers four phases – to achieve a full test bed (a possible mitigation for schedule recovery) to operate in parallel with the CMTF in the Test Lab. Phase 1 – Set Up LERF for CM testing Phase 2 – First pair of CMs - Initial Full Power Testing Phase 3 – Three Production CM testing cycles A typical test cycle is 5-8 weeks Phase 4 – Restore LERF CCB Presentation – 08-21-2017

Approach Phase I – Convert the FEL vault into a cryomodule testing facility to conduct integrated RF testing of CM/LLRF/HPRF (using Solid State Amplifiers, Isolators and other equipment loan) Phase II / Phase III – Utilize facility to expand capability to test multiple cryomodules in order to mitigate possible schedule delays caused by late CM assembly activities. Phase IV – Restore LERF CCB Presentation – 08-21-2017

LCLS-II CM Layout in LERF – Testing 2 CMs per Cycle CM Slot CM Slot CM Slot Access Storage Current machine contains slots for 3 full CMs and 1 Injector CM Shielded vault Existing PSS including radiation and ODH monitoring Utilities include cryo, water, electrical Propose 2 CMs installed in middle of FEL machine CCB Presentation – 08-21-2017

BCR Form CCB Presentation – 08-21-2017

Cost Estimate Baseline Proposed Delta Description M&S Hours Burdened Costs 1.04.06.15 Infrastructure $1,985,710 5,093 $8,602,787 $3,241,660 22,219 $12,292,894 $1,255,950 17,126 $3,690,107 Total Full cost recovery Including operating cost estimates for LERF Operating costs - $10.8K/week while CM is cold Path forward Proposal brought into the LCLS-II project baseline via baseline change request – expect some minor cost adjustments Subsequently managed using EVMS to monitor and report on progress CCB Presentation – 08-21-2017

Coordination of Project Supplied Equipment RF High Power (Dian Yeremian) 16 Solid State Amplifiers, Isolators and Dual directional couplers Low Level RF (Matt Boyes) Four complete LLRF Racks (fully dressed with chassis and internal cables) RF EPICS Software LO Distribution and Reference Distribution* Cryo Controls (Kevin Mattison) Two complete cryo controls racks (fully dressed with equipment) Cryo EPICS Software Vacuum Controls (Sung Kwon)* Beam line, coupler and insulating vacuum control racks (fully dressed with equipment). Note: Pumps are supplied by JLAB. Vacuum EPICS Software *Budgeted in the BCR, but could be supplied by project if available. CCB Presentation – 08-21-2017

P6 Schedule (1/2) CCB Presentation – 08-21-2017

P6 Schedule (2/2) CCB Presentation – 08-21-2017

CEBAF Operations – Constraints on LERF Ops CEBAF Operation Plan FY18 Q1 – 10 wks (Oct/Nov/Dec) – Highly Likely FY18 Q2 – 6 wks (Feb/Mar) – Highly Likely FY18Q3 – 8 wks at 6 GeV - TBC CHL Configurations FY18 Q1/Q2 – 2 x (CHL + Cold Boxes) Transition by May 6th to 1 CHL FY18 Q3/Q4 – 1 x (CHL + Cold Box) – Two week transition at 4K (cold down opportunity) Transition by Sep 10th to 2 CHLs Cryogenics U-tube ops required at 4K Integrate with maintenance plans on SC1 (Ops on SC2 – FY18Q3) Power Consumption Off-peak running will save on power bill Mitigates the demand charge for the next year CCB Presentation – 08-21-2017

Schedule Integrated with CEBAF Operations Testing cycles could occur three times per FY at the conclusion of planned CEBAF runs First testing cycle most likely in Jul-2018 contingent upon actual FY2018 run schedule and staffing availability Can test at least 6 CMs by mid-2019 CCB Presentation – 08-21-2017

CM Testing Schedule Considerations Project needs 35 1.3 GHz successful tests out of 40 CMs built Assume that all CMs require at least one test JLab pCM will be re-tested at FNAL in Sep-2017 One additional test cycle added in Schedule Re-alignment BCR Doesn’t consider 3.9 GHz CM testing needs Expect acceptable results from test with sixth CM at FNAL and sixth CM at JLab that includes all design improvements to mitigate microphonics Current project plan includes testing 1 CM per month per partner lab 5 CMs have been tested as of end of July (2 pCMs + 2 FNAL CMs and 1 JLab CMs) Estimate 20 CMs tested between Aug-2017 and May-2018 (10 months) without interruptions due to supply chain or cryogenics availability Up to 15 more required by March 2019 CCB Presentation – 08-21-2017

P6 Labor Profile (1/2) – Incremental Labor Required Incremental labor required to convert LERF and support testing (doesn’t include actual testing labor) CM Tests Phase 1 Phase 2 Phase 3 Phase 4 CCB Presentation – 08-21-2017

Key Staff Have Been Identified that report to CM CAM Kevin Jordan leads Removal / Installation / Restoration activities that occur until CMs are ready to test Technical lead for coordination of installation and removal activities planned to convert the LERF to a CM testing facility Responsible for planning the work, reviewing it with stakeholders, and coordinating activities with groups providing resources. Ensures that the full scope of work is completed in accordance with best and safe work practices through the use of the ATLis work planning system Curt Hovater coordinates SLAC-provided hardware, supports installation activities and leads integration of RF/SRF systems Jim Henry (Cryo Hardware, Overall Layout) leads design efforts with support from Joe Gubeli (RF system layout, Waveguides) Supporting Staff Groups within Engineering, Facilities and Accelerator Divisions that provided cost estimates will provide staff to perform activities Operations committed to provide staff to conduct CM testing during CEBAF down-times CCB Presentation – 08-21-2017

Assumptions Priority for JLab is 12 GeV Operations Schedule for testing CMs will be coordinated with FY2018 & FY2019 run schedules CM testing windows will be adjusted to minimize impact on NP program Full cost recovery from LERF operations is required Defined boundaries between laboratory program and WFO Cost includes specific LERF facility charges Draft cost and schedule presented in parallel to LCLS-II and JLab management. Updates and revisions based on discussions are included Staffing requirements will be considered as part of overall FY2018/2019 laboratory planning. Priority consistent with WFO vs. CEBAF operations. CCB Presentation – 08-21-2017

Impacts & Risks Cryogenics: present 2K issues complicate near term scheduling. Contamination is a concern that could affect availability. U-tubes operations add potential contamination problems Cooldown and warm-up: overall cryo load must be handled properly with controls. CEBAF Operations: Phase I no impact. Phase II & III requires PSS Control and interface. Cannot keep two of the FEL CMs cold as CEBAF spares. Coordination is required with other cryo activities. Phase II & III need coordination with CEBAF 12 GeV operations. LERF Operations: Phase II and Phase III would eliminate all other LERF operations. Staffing: Initial plan utilizes combination of in-house staff and possibly term hires. Higher priority work might limit available staff. Schedule: Working towards July test cycle (April if all goes very well.) CCB Presentation – 08-21-2017

Stakeholder Input Received JLab Cryomodule CAM and STL PMCS group Stakeholder Review Stakeholder Input Received JLab Cryomodule CAM and STL PMCS group Cryogenic System Manager, SRF Group Leader and CM Chief Engineer Accelerator System Manager and AS Group Leads LCLS-II Project Manager LCLS-II Project Director JLab Laboratory Director, Chief Planning Officer and ADs JLab SMEs, Technical Review Team and Division Heads CCB Presentation – 08-21-2017

Review Agenda https://www.jlab.org/indico/event/233/ Reviewers Tom Peterson (SLAC, chair and report) George Biallas (JLab) Andrew Burrill (SLAC) Chris Cuevas (JLab) Harry Fanning (JLab) Bob May (Jlab) Attendees SLAC: J. Galayda, M. Ross, A. Burrill (at Jefferson Lab), J. Chan, G. Hays M. Reichenadter (remote) JLAB: E. Daly, K. Jordan, C. Hovater, J. Preble, J. Leung, J. Henry, G. Neil, J. Fitzpatrick, K. Macha, D. Hamlette FNAL: R. Stanek, C. Ginsburg (remote) CCB Presentation – 08-21-2017

Strongly recommend of LERF as additional CMTF Summary Strongly recommend of LERF as additional CMTF Additional in-parallel testing station adds test cycles that can be used for re-testing reworked CMs and other unplanned tests Mitigates schedule slippage caused by unscheduled down-time of existing cryogenic testing facilities at Partner Lab Schedule has been integrated with CEBAF Operations Funding enables starting design and removal/installation activities in August CCB Presentation – 08-21-2017

Back Up CCB Presentation – 08-21-2017

Phase I – Configure LERF for Testing Removal of 20’ of back leg of existing machine to install/position CMs Removal of u-tubes from two existing CMs in FEL vault Can remove two high performing CMs to augment CEBAF Requires a set of u tubes to connect CMs to existing cryogenic transfer line bayonet connections Review design; procure cryogenic hardware Requires one set of CM testing end caps (same design as CMTF) Requires two sets of stands (same design as CMTF) Requires one set of interconnect hardware including HOM BLA, bellows Install cryogenic controls (Cryocon temp readbacks, heaters, JT and cooldown valves, etc.) Pull cabling Install SLAC-provided SSAs and HPRF hardware Install SLAC-provided LLRF controls Review and approve any updates to OSP for FEL vault operations Decarad and Faraday cups for radiation monitoring CCB Presentation – 08-21-2017

Phase II – Initial Full Power RF/Cryo Testing Assumes all hardware from Phase I available Schedule allows for more time and resources for initial testing cycle Install pair of CMs in LERF Connect RF, instrumentation and cryo controls Coordinate cooldown with CEBAF operations Evaluate procedures for cooldown, RF testing and warm up Coordinate warm up with CEBAF operations Remove pair of CMs from LERF CCB Presentation – 08-21-2017

Phase III – CM Acceptance Testing Assumes Phase II completed Schedule considers logistics for installing multiple CMs in LERF vault Staffing estimate will be based on current project baseline Assumes one test cycle in CMTF / 5 wks Potential impact - CMTF & LERF testing is conducted in parallel CCB Presentation – 08-21-2017

Assumes Phase III completed Phase IV – Restore LERF Assumes Phase III completed Remove any LCLS-II specific hardware from vault Replace LERF specific hardware CCB Presentation – 08-21-2017